TENDER NO - HPCLtenders.hpcl.co.in/tenders/tender_prog/tenderfiles/6326/Tender... · HINDUSTAN PETROLEUM CORPORATION LIMITED TERMINAL AUTOMATION PROJECT 3 | 359 SPECIAL CONDITIONS

HINDUSTAN PETROLEUM CORPORATION

LIMITED TERMINAL AUTOMATION PROJECT

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HINDUSTAN PETROLEUM CORPORATION LIMITED

ENGINEERING & PROJECTS

GRESHAM HOUSE (2 ND FLOOR),

SIR P. M. ROAD, FORT,

MUMBAI -400 001.

TENDER NO:

TENDER DOCUMENT

FOR

TERMINAL AUTOMATION SYSTEM PROJECT

AT

AONLA DEPOT , BAREILY UP



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SPECIAL CONDITIONS

OF

CONTRACT

(SCC)



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SPECIAL CONDITIONS OF CONTRACT

1. Completion period: 7 months from the date of issue of LOI / Work order.

This excludes the stabilization period.

2. Water required for construction purposes, if any, would be made available if

possible, by HPCL within the Installation at one source, free of cost, the

vendor shall be responsible for taking the same to the place of work as

required. In case of interruption in availability of construction water, vendor

shall make his own arrangements for progressing with the works and no

claim for additional work/time can be made on this account.

3. Power required for the project works shall be arranged by the Vendor.

4. The contract shall be executed on a unit rate basis. The unit rates shall

remain firm except otherwise if stated specifically in the General Terms &

Conditions of the tender.

5. The Contractor shall provide and maintain at his own expenses all lights,

guards, fencing and watching when and wherever deemed necessary by

the site-in-charge for protection of the work, equipments, instruments,

accessories or for safety and convenience of those employed on the works

or public.

6. The Contractor shall provide and maintain proper temporary sheds of

adequate capacity for storage of all materials and his own store in good

and water tight conditions at site. Any damage / loss of materials in the

contractor’s custody will be to his account and will be recovered from his

running bills.

7. TERMS OF PAYMENT :

Subject to the provisions under the General Terms & Conditions of the

Contract for deduction of taxes at source, retention money, Liquidated

Damages etc. the following payment terms shall prevail;

7.1 For Supply item (Except TAS Software)



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7.1.1 10% of the quoted rates shall be paid after data sheet approval & placement

of Order by the Vendor along with submission of the following document

a) Approved Data Sheet & QAP

b) Copy of firm PO place on OEM

c) Equivalent amount Bank Guarantee valid till completion period of

respective Phase. The Validity of the BG may be extended based

on the discretion of HPCL.

7.1.2 70% of the quoted rates shall be paid on receipt of the material at site based

on the certification of HPCL/PMC along with submission of the following

documents;

a) Copies of invoices showing goods description, quantity, unit

price and total amount.

b) Railway receipt / Lorry Receipt / delivery challan duly

acknowledged by the Consignee.

c) Vendor’s Warrantee Certificate

d) Inspection Certificate and dispatch clearance issued by the

nominated Inspection Agency and supplier’s factory

inspection report.

7.1.3 10% of the quoted rates shall be paid on completion of erection and

successful commissioning (SITE ACCEPTANCE TEST). In case SAT is not

completed within 3 months from the schedule due to reason not

attributable to the Vendor then amount will be payable against cold SAT

on submission of equivalent amount of Bank Guarantee valid till 12

months which may be further extended based on the discretion of HPCL

Successful commissioning is defined as compliance of all SAT punch points

by the Vendor and accepted by HPCL

7.1.4 Balance 10% of the quoted rates shall be on completion of the

stabilization Period.



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In case Stabilization period is not completed within 3 months from the

schedule due to reason not attributable to the Vendor then amount will be

payable against submission of equivalent amount of Bank Guarantee valid

till 12 months which may be further extended based on the discretion of

HPCL

Completion of stabilization period will be defined by the successful

completion of User Acceptance Test. At the completion of User Acceptance

Test the System will be taken over by HPCL.

7.2 For Erection Items

7.2.1 80% of the quoted rates shall be paid basis on physical progress of work

certified by Site Engineer of HPCL / PMC as per the approved billing

schedule and upon submission of the following documents.

a) Copies of invoices

b) Copy of certified progress of work

c) Proof of payment of ESI and deposition of EPF etc.

d) Wage Sheet

e) Certified time sheet

7.2.2 10% of the quoted rates shall be paid on completion of erection and

successful commissioning (SITE ACCEPTANCE TEST). In case SAT is not

completed within 3 months from the schedule due to reason not

attributable to the Vendor then amount will be payable against submission

of equivalent amount of Bank Guarantee valid till 12 months which may be

further extended based on the discretion of HPCL

Successful commissioning is defined as compliance of all SAT punch points

by bidder and accepted by HPCL



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7.2.3 Balance 10% of the quoted rates shall be on completion of the

Stabilization Period

In case Stabilization period is not completed within 3 months from the

schedule due to reason not attributable to the Vendor then amount will be

payable against submission of equivalent amount of Bank Guarantee valid

till 12 months which may be further extended based on the discretion of

HPCL

Completion of stabilization period will be defined by the successful

completion of User Acceptance Test. At the completion of User Acceptance

Test the System will be taken over by HPCL.

7.3 For TAS Software

7.3.1 20% of the quoted rates shall be paid after successful FAT.

7.3.2 60% of the quoted rates shall be paid after successful SAT.

7.3.3. Balance 20% of the quoted rates shall be paid after successful integration

of future equipment or on submission of equivalent amount of Bank

Guarantee after SAT which shall be valid till completion of job.

8 For Testing and commissioning Items : 100 % of the quoted rates shall be

paid on completion of erection and successful commissioning (SITE

ACCEPTANCE TEST)

In case SAT is not completed within 3 months from the schedule due to

reason not attributable to the Vendor then amount will be payable against

submission of equivalent amount of Bank Guarantee valid till 12 months

which may be further extended based on the discretion of HPCL

Successful commissioning is defined as compliance of all SAT punch points by

bidder and accepted by HPCL

8.3 For Training Items : 100 % of the quoted rates shall be paid on completion

of Training. Vendor to complete training as per the approved training

module.

8.4 For Comprehensive Annual Maintenance Contract ( 5 years)



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The CAMC charges shall be quoted in absolute amount (not in %). The

composite rate quoted by vendor for 5 years CAMC period shall be

split year wise in the following percentage for payment purpose

Year 1 : 10% of CAMC cost of 5 years





Quarterly Payments will be made as per the detailed terms & conditions

for AMC contracts as mentioned in the Technical Specifications of this

tender.

9 Bidders are required to accept the payment terms given above without any

deviations. In case of deviations, Bidders will be given one opportunity to

withdraw the same without any revision in prices failing which the offer is liable

to be rejected.

10 Receipt of unconditional acceptance of order and security deposit as per GTC

is a pre-condition for release of any payments.

11 The final payment will be made on completion of all the work and on

fulfillment by the contractor of all his liabilities under the contract duly

backed up by a completion & no claim certificate.

12 “Site “/ “Location” shall mean the Aonla Depot, Bareilly.

13 Form C/D, Road Permits, Entry Permits etc. will not be issued by HPCL during

execution, warranty & CAMC period.

14 DEFECT LIABILITY PERIOD/Warranty Period

In addition to clause No.11 & 5n of GTC, the entire system including all

supplied materials shall be warranted for another 12 months. Thus the

total period of warranty/guarantee will be for 24 months starting from

date of acceptance of the system (i.e. date of compliance of punch points



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of SITE ACCEPTANCE OF THE SYSTEM by HPCL). During warranty period

the contractor shall be liable to replace / rectify any item/ equipment

found defective. All spares and consumables required during the warranty

period shall be under the scope of the contractor. However printer

cartridge and stationery will be outside the scope of warranty

replenishment.

15 Bids will be evaluated taking into account the charges towards CAMC for 5

years. However HPCL reserves the right to award the CAMC contract

subsequently at the end of the warranty period or earlier.

16 The rates quoted should be inclusive of all taxes & duties etc delivered at

site. In case of deviations, Bidders will be given one opportunity to withdraw

the same without any revision in prices, failing which offer shall be liable to be

rejected.

17 The above Special conditions shall be read in conjunction with General

Conditions of Contract and Instructions to bidders. If any provision in these

special conditions is at variance with that of the aforesaid documents, the

Special Conditions shall be deemed to take precedence there over.

18 No conditions should be mentioned in the price bid. Conditional price bid

shall be liable for rejection.

19. CONFIDENTIALITY:

The Bidders are requested to handle/respond the tender in utmost

confidentiality and shall not copy documents/information of the

Corporation and shall not divulge/distribute/share any

documents/information or knowledge of things or process which Bidder

comes to know or acquires during the tendering/execution process. HPCL

also reserves the right to initiate appropriate legal action against Bidder

for breach of this condition or any copy right or infringement of

intellectual property of HPCL disclosed to Bidder during the

tendering/execution process.

18 General :



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• No idle time charges shall be payable by HPCL, in any case what so ever.

• In the absence of any specifications covering any material, design of work

(s) the same shall be performed / supplies / executed in accordance with

Standard Engineering Practice as per the instructions / directions of the

Engineer-in-Charge, which will be binding on the bidder. These have to be

completed at no extra cost to HPCL.

• It is the clear understanding of the bidder that the complete scope as

defined or as may be required for the intended objective of this tender is

included in the quoted price. No extra payment apart from the quoted

price will be made in order to achieve the intended objectives. Reasons

like, bidder having not envisaged / considered a particular activity or

element of cost required to be carried out for achieving the intended

objective or some activity not specifically mentioned in the tender

enquiry/tender but required to be carried out for achieving the intended

objective, will not form basis for considering extra payments.

• No extra payments will be made for working on extended hours /

Saturdays / Sundays / Holidays to meet the committed/required time

schedules.

19.0 SOLE RIGHTS TO TEMPLATES / DOCUMENTATION / PROCESSES

• HPCL will have the sole rights to the templates / documentation /

processes / solution model etc. developed in the course of implementation

and the Successful Bidder and/or their partners will not be allowed to use

them without the explicit prior permission of HPCL in writing.

20 SUCCESSFUL BIDDER’S RESPONSIBILITY



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• Successful Bidder will be wholly and solely responsible and liable for all the

jobs carried out by them / services provided by them. HPCL acceptance

having signed off a particular milestone will not exonerate the Successful

Bidder from his prime responsibilities to have done a correct job as per the

requirement of the job/contract and as per international practices in the

first instance itself. If required, Successful Bidder will be required to revisit

those milestones which are already signed off and will be required to

make suitable corrections at no extra cost to HPCL.

21. PATENT /COPYRIGHT PROTECTION

• If any third party claims that a Product/Service(s) supplied by the bidder in

connection with this contract here under infringes a patent or copyright,

the bidder will defend HPCL against that claim at Bidder’s expense and pay

all costs, damages, and attorney’s fees etc. and it would be the sole

responsibility of the successful bidder to comply with all instructions that a

Court finally awards.

• If such a claim is made or is likely to be made, Bidder to enable HPCL to

continue to use, or to modify or replace the Product. If none of these

alternatives is acceptable to HPCL, the Bidder will give HPCL a credit for

such Product. as well as for all resultant consequential losses, resulting out

of the non-availability of the product for HPCL’s use.

22. COMPLIANCE TO TENDER ENQUIRY DOCUMENT

• Tender quoted should be in compliance to the tender enquiry conditions.

All Annexure duly filled up along with necessary documentation as

requested in the tender enquiry and / or required to support Successful

Bidder’s claim must be enclosed with the tender in the first instance itself.

• Any willful attempts by the Successful Bidder to camouflage the deviations



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by not mentioning them in the prescribed format may render the bid itself

non responsive. Only the deviations which are mentioned on the format

attached in tender or in the datasheets will be taken during evaluation and

remaining offer shall be considered as exact compliance to tender enquiry.

23.0 Limitation of Liability :

1) In no event shall either Party to the contract be responsible for or

obligated in any manner to pay any special , exemplary, punitive,

consequential or other indirect damages( whether under tort, negligence

or strict liability ) in respect of any loss, damage, claim or demand asserted

by the other Party hereunder, even if the first mentioned Party was

informed or made aware of the possibility of such damages

2) The maximum liability of each Party arising from any circumstances

including negligence, errors & omissions shall be limited to the total

contract value.

24.0 Bidders are required to quote the Unit rates in R only.



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SPECIFICATIONS



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INTENT OF SPECIFICATIONS

Hindustan Petroleum Corporation Limited (HPCL) intents to automate new 8+6

Bay Gantries & allied facilities which are being constructed at Aonla Depot. The

Depot receives, stores and dispatch MS, SKO, HSD, Ethanol etc. Presently Aonla

Depot is operational & has automated operation for existing 4 Bay Gantry Tank

Truck Filling, Tank Farm, Product Pump operation, Fire water pump operation

interface including module for Management Information System & Reporting

and interface with our ERP. M/s Advanced Systek Pvt Ltd, Vadodara has done

Terminal Automation & provided its software for automated operation of

aforesaid facilities. It is proposed to provide new software along with the

equipment required & interface the existing TAS equipment, modules with the

new software. However the existing 4 Bay Gantry is not required to be interfaced.

Complete new Software shall be provided for new & existing facility in such a

manner that ongoing operations are not impacted. All functions defined in this

tender document shall be performed in an integrated cohesive manner. The new

system shall be seamlessly integrated with the existing TAS equipment to control

and monitor the entire Depot.

Before submitting techno commercial bids, bidders are required to visit and study

the existing scheme of Automation & other aspects of Plant operations for the

terminal. Any job, material, equipment, instrument etc. not explicitly mentioned in

the Schedule of quantity but required to be provided to meet the functional &

technical requirement as mentioned in this tender shall be in the scope of

Vendor.

M/s HPCL may appoint Project Management Consultant (PMC) on their behalf for

execution & implementation of the entire TAS including Data Sheets approval,

Site Supervision, Bills Certification, Project monitoring etc. & all related activities

of automation as covered under this tender. However, inspection of equipment &

materials are excluded from the scope of the PMC. Vendor shall get the

inspection done of the equipment & materials from the approved Third Party

Inspection agency as stipulated in the scope of Inspection of this document.

It may be noted that the quantities given in the BOQ are indicative and

quantities can be revised during execution of the P.O. Change order, if required

will be issued. Completion period is 7 months excluding stabilization period of



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min. 90 days. The following are the major milestones included in the Completion

Period

• Datasheet Approval

• Functional Design Specification & Hardware Design Manual which shall

include all philosophy for integration with the existing TAS

• Batch Accuracy Test

• FAT

• Site Execution

• Commissioning & Trial Runs

• Site Acceptance Test including compliance

Stabilization & User Acceptance Test is excluded from the completion period.

Layout of Location is attached.

Bidders shall visit the site to understand the process, operation, scope of work

including integration with the existing Automation System. Any further site visits

required by the Vendor after placement of Purchase Order for understanding the

process, study the facilities, detail design engineering etc. shall be part of the

completion period.



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GENERAL

The major operational areas identified for automation are

a) Tank truck loading operation for New 8 & 6 Bay Gantries

b) Product pump operation including supply & interface with VFDs &

Starters

c) Complete New Software with all modules incorporating new, proposed

(Phase-II) & existing facilities.

d) Integration of existing equipment & modules excluding the existing 4

bay Gantry which will be discontinued to use after commissioning of New

8+6 bay Gantries.

e) Management Information System & Reporting

All these operations shall be logically integrated through New Servers &

Programmable Logic Controller, UPS and other field & control room equipment

to ensure accurate, seamless & secured operation and data exchange. The spares

available in the existing hardware may be used, if suitable. All existing equipment

& instruments will be handed over in working condition. Any existing hardware

etc. required to be replaced to suit the Integrated System shall be in the Vendor’s

scope.

Successful Bidder hereafter referred as Vendor shall make sure that

commissioning of all the instruments / equipment and Site Acceptance Test (SAT)

shall be completed as per the completion schedule mentioned in Special Terms &

Condition.

As Aonla Depot is an operating Terminal, the Vendor shall carry out day to day

activity after taking necessary hot/ cold work permits. Vendor shall appoint a

Safety supervisor, apart from the Work Supervisor, who shall be available

throughout the working time and shall be responsible for taking permits and

observing safety and security regulation of the terminal. Vendor shall deploy at

least one qualified and experienced (1 to 2 yrs)

instrumentation/electrical/mechanical engineer exclusively at the site during the

entire execution period as the work supervisor.

It shall be the endeavor of HPCL to provide work permit beyond normal



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operating hour to the extent possible. However all the work shall be preferably

planned for completion by the Vendor within the normal working hour. Vendor

shall be provided suitable area to construct the fabrication yard in the de-

licensed area within the depot premises to carry out prefabrication job. For works

which may require total/ part shut down of the Gantry operation or which may

hamper the normal loading operation, the automation vendor is required to work

during night hours/ holidays and during such times when it does not hamper the

operation of the terminal. Prior planning & permission from the Terminal

manager shall be obtained. All hot work shall be planned in advance and

discussed with the Terminal manager and shall be carried out on Sundays /

holidays to cause minimum impact on the regular operation on working days. All

Work shall be planned without interruption to terminal normal working. No extra

claim shall be admissible for night working, holiday working or extra hours

working if permission for the same is given by HPCL.

The Vendor shall ensure all the safety procedures are followed during the above

activity. The safety procedures to be followed are as listed elsewhere in the

specification & as per the Oil Industry norms. Vendor shall submit the fortnightly

safety report along with the work progress report.

The vendor shall train operating personnel from the location in the following

areas so as to make them fully familiar with the system and its day to day

operation:-

• General design & system Engineering.

• All related MMI & logics

• Design criterion, specification, testing, functional aspects & installation

of equipment.

• Operational & preventive maintenance of individual equipment

• Trouble shooting for all the individual equipment. Operational &

preventive maintenance of individual equipment & overall

system(excluding the existing System)

• Trouble shooting for all the supplied equipment/instruments under this

tender.



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The above training shall be conducted at the site during handing over of the

system & during the Warranty period. Two such trainings shall be held every year

in the Warranty Period. Each training module shall be of minimum 2 days.

The TT crews are also required to be familiarized with the operation of the TLF

equipment for which HPCL shall organize the program and the vendor shall

demonstrate the T/T operation.



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SCOPE OF WORK

This document serves as detailed specification for the Vendor as minimum

requirement for automating the specified operations at the Terminal. Vendor

shall execute the work on turnkey basis & shall design, supply, install, commission

& stabilize the system as per the deliverables listed in this document.

Notwithstanding the sub divisions of the tender document into several sections

and volumes, every part of each shall be deemed to be supplementary of every

other part and shall be read with and into the contract.

Vendor’s scope of work is divided into three Major categories viz. Overall Scope

of Work, Scope of work for the New 8 +6 Bay Gantries & allied facilities and

Scope of work required for Integration with the existing System.

A. Overall Scope of Work shall include but not limited to the following:

• Complete design and System engineering required for the sub-system &

its interfacing with the existing Terminal Automation equipment to ensure

the deliverables are achieved in line with technical & functional

requirement laid down in this tender document.

• Design of complete integrated software which shall include all modules of

the existing TAS ( excluding existing 4 bay Gantry), New 8 +6 Bay Gantry,

Product pump module with VFD & Starter interface, TFMS, Fire Engine

Automation, MIS, Overnight Registration Module, ERP interface etc., all

logics as per approved FDS/FAT/SAT and proposed Phase –II facilities like

Proposed A/G product & Water Tanks, Hi-Hi Level switch for proposed &

existing A/G Tanks, ROSOV & MOVs & their interlocks, Safety System & its

interface with Process System, logic & interface with pressurized Fire

Hydrant System. The Software & logics shall be complete to include all the

proposed facilities, the integration of which is not part of the completion

period & but the same shall be done during the execution/warranty

period/ CAMC period at no extra cost. Hardware for the proposed facilities

will be provided by HPCL in the next phase. All required protocol interface

details for integration of proposed hardware in the next Phase including visit

of OEM, if required will be provided by HPCL.



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• Supply, laying, testing & termination of all Power, Control, Signal cables &

all other type of special/ regular, required cables for all new Automation

Equipment & instruments. It shall also include all cables required for

interface with existing free issue items which are being integrated as per

the scope of this document. Also additional cables required for re-routing

of existing equipment shall also be included. OFC cables shall be laid if the

distance between buildings are more than 100 mtrs.

• Supply, installation, testing & commissioning of all equipment/

instruments, material etc. complete as stipulated in the schedule of

quantities. Any allied hardware/ items which are not explicitly spelt out in

the Schedule of quantities or in specification but are required for the

completeness of the work as per the framework defined in this tender like

structural steels, foundation work & other civil works, fittings, gaskets, stud

bolts, any other hardware required, consumables etc. shall also be deemed

to be included under the respective items. No separate payment shall be

made for such items.

• Third party inspection of the bought out item, Trial run of the system, Site

acceptance test, system stabilization and User Acceptance Test of the

complete system.

• Packing, forwarding, transportation, custom clearance, insurance, storage

etc.

• Supply, fabrication, welding, stud bolt, erection, painting of any steel

structural required for installation of equipment, panels, junction boxes,

instruments, etc. including any other free issue items, as required & as per

site engineer’s instructions.

• Supply, fabrication, welding, nut bolting, erection, painting of any

structural steel required for installation of Cable Trays.

• Supply & installation of all Erection materials including consumables &

non consumables as galvanized and perforated cable trays with cover,

cable racks, conduits, junction boxes, pull boxes, clamps, compression

fitting, cable glands, all instrument supports, electrodes and other

materials for completeness of erection. The erection materials shall also be

suitable to the hazardous area classification.



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• Supply of Bends, reducer, expander, flanges, matching/companion

Flanges, Gaskets, jumper clip, other pipe fittings etc. as required for direct

mounting of the instruments & equipment All these pipes & fittings shall

be part of the respective instruments, equipment and shall not be paid

separately.

• Construction of Cable trench in soft soil, hard soil, rocky strata, RCC etc

including supply & laying of NP 2 Hume pipes below all road crossing, GI

conduit inside tank farm, as required

• The spare available in the existing cables, JBs & other hardware can be

used. Any additional cable, JBs & hardware required for the new

equipment shall be supplied by the Vendor

• Supply, Fabrication and installation of sunshields 18 gauge GI Sheet/

aluminum canopy for field mounted equipment, instruments such as

pressure transmitters, density meters, earthing relays, Card Readers at the

Gate Barriers/Parking Area, IR sensor etc. Dimension of such canopy shall

be such on all sides of the equipment adequately.

• Submission of all data sheets along with OEM’s confirmation on Product

life cycle, his support for Backup engineering & spares

• Cable entry to the Control room shall be cables / tube entries into the

control room through MCT block after laying and testing of all tubes,

cables etc.,

• Preparation & submission of all the required Documents including as-

built drawings, documents as per the execution of work at site and

submission to HPCL

• Providing training to HPCL operation team and T/T Crew member as per

the scope defined in the tender,

• Supply of mandatory spares before completion of SAT.

• Execution of Warranty, Comprehensive Annual Maintenance Contract, etc.



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• Supply of special tools, test equipment, consumables required for

installation, testing, calibration and commissioning of the system. All

commissioning and start-up spares required up to commissioning, system

acceptance and handing over of the system to the HPCL shall be in the

vendor’s scope.

• Certification from the OEM for correct installation & its terminations, if

applicable, of the following equipment, instruments

o Meters & Pulsar assembly

o DCV

o Radar Gauge

o Densitometer

o BAE

o Batch Controllers

• Proper installation and alignment of line / vessels / equipment mounted

instruments like valve, PD meters, etc.

• Drilling holes on all panels, power distribution panel, control panels, etc.

for cables / glands.

• The functional & operational requirements as specified in this tender

might undergo revisions as per the location requirement during detail

design engineering, functional design specification or during execution.

The vendor must ensure that all these changes are incorporated &

demonstrated during Site Acceptance Test.

• All Civil works required for execution of TAS including supply of all materials

required like foundation for mounting of instruments and equipment

supplied by Vendor and those given as free issue items, Road cutting , laying

of Hume pipes, re-asphalting the roads, wherever required etc.

• All mechanical, electrical jobs required for TAS shall be in Vendor’s scope.



22 | 3 5 9

• Calibration & Verification of all new equipment & instruments

• Calibration and W&M Stamping of the New Electronic metering system. Any

other instruments, equipment which may require stamping as per statutory

law shall also be in the Vendor’s scope.

• All documentations, drawings & test procedure

• Construction of temporary Storage Shed for storing the all the equipment,

material, instruments etc. & dismantling the same after completion of work.

• Third Party Inspection of the instruments, equipment & materials as per the

approved QAP.

• Mandatory Spares shall be supplied before SAT

• All road permits from Sales Tax authorities for importing/movement of all

these equipment, instruments, material.

• The vendor shall be fully responsible for proper selection of equipment’s,

engineering, performance and successful operation of the complete

system including all bought out equipment, subsystems supplied by them

when integrated with the overall Automation System meeting the

functional requirements.

• Vendor shall offer the services of the competent installation team which

would install the equipment / instruments, lay the interconnecting cabling,

check out, testing and commissioning the system.

• All technical personnel assigned to the site by the Vendor shall be fully

conversant with the supplied system and software package, and shall have

both hardware and software capability to bring the system on line quickly

and efficiently with a minimum interference with other concurrent

construction and commissioning activities.

• Strict adherence to HPCL’s Safety, Health & Environment policy



23 | 3 5 9

B. Scope of Work in the New 8 +6 Bay Gantries & allied facilities shall include

but not limited to the following:

• Supply, installation, testing & commissioning of the Electronic Metering

System, RIT, Card Reader, earthing relay, RTD, JBs, Cables, all allied

hardware, instruments equipment etc. complete required for Gantry

Automation

• The additive blocks in the existing Gantry need to be dismantled & re-

installed & commissioned in the New Gantry at the designated points as

given in the Bay Configuration. The SS pipes, tubings etc. required for the

same shall be in TAS Vendors scope

• New delivery line of size HSD-16”, MS-16”, SKO-10”, Ethanol-6” is being

laid by HPCL. Each product pipeline entering into TLF shall be provided by

TAS Vendor with Bulk Air Eliminator for removing the entrapped air.

Foundation for all Header line equipment as per the requirement shall be

in the scope of Vendor. Modification of the header line to suit the BAE

requirement will be in Vendor’s scope including all tapping’s required PT,

DT, orifice plate etc. Also any gasket, stud bolts etc. required for

installation of these equipment shall be in Vendors scope. TRV shall be

provided on the BAE & on the downstream of NRV. TRVs shall be

connected to the unloading line along with supply of NRV.

• Similarly, each product pipeline entering into TLF shall be provided with

densitometer with Orifice plate arrangement for measuring ambient &

standard density of product & Pressure Transmitter. Complete new

tubing/ piping for the densitometer, PT along with required isolation

valves, stud bolts gaskets etc shall be in Vendor’s scope. New Orifice plate

shall be provided for each product line. Orifice plate shall be designed to

ensure that the product flow through the densitometer all the time during

loading of that particular product. In case the product is not flowing

through densitometers during loading of that particular product then

“Error” message shall be displayed instead of last healthy reading

• Each header line shall be provided with new NRV & Electrically actuated

Triple offset Butter fly valve (TOBV), both of same size as header line.



24 | 3 5 9

• Earthing of all the equipment, instruments by Cu wire/ GI Strip (min 50 x 6)

to the existing earth pit.

• ESD & One No MCP shall be provided at the New Gantry, New gate Cabin,

Control Room & New Pump House.

• Supply of Radar Gauges, Density Probe, Single spot temperature sensor

with WLS/ w/o WLS for U/G tanks

• Supply of gaskets, stud bolts & all allied hardware etc. shall be included in

the scope of Vendor’s job.

C. Integration of the existing Terminal Automation equipment with new TAS

Software: The existing System is supplied & maintained by M/s AST, Vadodara.

Vendor shall get the access authority, if required, from M/s AST, Vadodara for

modification/ up-gradation, logic changes & integration of the existing TAS

equipment with new software before carrying out any such modification. Scope

of Work for integration with the existing TAS equipment/instrument &

hardware shall include but not limited to the following:

o Replacement of existing TAS software with the complete new TAS

Software including new as well as existing TAS module as complete

integrated System. The new TAS software shall have complete logics

graphics, interlocks etc. for the complete integrated System including the

proposed facilities

o Supply & installation of new LRC servers, client Machines & process PLC.

S&D Room will be provided in the Main Gate Security office ( Block No 21)

of layout & accordingly TTES & allied facilities shall be provided.

o Any Modification/ up-gradation of the existing equipment/ instruments,

material or any hardware including all supplies as required for seamlessly

interfacing to meet the specified technical & functional requirement.

o The new integrated TAS shall have complete provision to include new

additional tanks, ROSOV/MOV module, Safety System & interface, Hi-Hi

level switch for new as well as existing tanks, pressurized hydrant system

which shall be provided by HPCL in next Phase. All logics, graphics

required for integration shall be included in the TAS software, PLC logics,

graphics etc. Only the hardware like TFMS equipment, ROSOV/MOV,



25 | 3 5 9

Safety PLC & allied hardware like cabling, JBs, CIU, FCU etc. shall be

provided by HPCL in next Phase. Also the required protocol will be

provided by HPCL. Integration of these equipment will be in the scope of

Vendor during the project execution/Warranty Period/CAMC period at no

extra cost to HPCL

o Complete MIS module, Overnight registration module, Maintenance

Module, Alarm & Event Module shall be part of TAS software

o Preparation of integrated Functional design specification in consultation

with HPCL. Any change/ modification/up-gradation in the existing

hardware/instrument. Modules for incorporating any logics shall be in the

Vendor’s scope.

o The Spares available in the existing hardware can be used by the Vendor.

Any additional hardware, instrument, equipment etc. required shall be

supplied along with its allied hardware.

o Supply, Installation & Commissioning of New MCB panel, Networking

Panel for New Instrument/equipment. Individual MCB shall be provided for

each parent equipment & instrument so that the same can be powered off

as & when required for maintenance purpose.

o Supply, laying, testing & termination of all additional Power, Control,

Signal cables & all other type of special/ regular, cables required for

modification & integration with the existing TAS.

o The Product pumps are proposed to be controlled either through Starters

or through Variable Frequency Drive (VFD) or combination of Starter &

VFD. The VFD System shall be supplied by the Vendor. The Starters will be

provided in the MCC which shall be interfaced by the TAS Vendor. All

Cabling from Control room to VFD System shall be in Vendor’s scope. Only

Power cabling from Pumps to VFD/MCC will be in HPCL scope. The

existing TWD Product pump shall be stopped in case of ESD or Hi-Hi Level

activation

o Modification in the existing Control Room Cable Trench, if required.



26 | 3 5 9

o All items required for integration, though not specifically mentioned

above, of the new equipment/ instruments are deemed to be included

under integration item only unless otherwise specified.

o Any existing component which is not suitable for modification/ up-

gradation to include the new facilities proposed in the tender, shall be

replaced at no extra cost.

o Complete integration with the existing TAS equipment (excluding 4 Bay

Gantry) with the new Software shall be quoted in relevant line item of the

BOQ



27 | 3 5 9

HPCL’s SCOPE OF WORKS.

HPCL shall provide the following to the successful vendor:

o Gantry Structure & pipeline up to the 3”/2” isolation valve for installation

of metering system. Tapping for RTD shall be in TAS Vendor scope

o Spare Manhole on the U/G Tanks for mounting of TAS equipment

o Existing Terminal Automation equipment/instruments in proper working

condition.

o All power cabling for Pumps from VFD System.

o New TFMS equipment, ROSOV/MOV, Safety PLC, Hi-Hi Level Switch,

Jockey Pumps & Fire Pumps including allied hardware like cabling, JBs

cable trays, CIU etc. in the next Phase

o All free issue items in standalone working condition.

o Spare Hume pipes wherever available.

o Anti-Virus for TAS Machine

o Warranty/CAMC of free issue items & Systems through existing Vendor



28 | 3 5 9

INTRODUCTION

A computerized automation system is envisaged for the HPCL –Aonla Depot. The

basic operation of the Depot is to receive, store & dispatch various types and

grades of petroleum products. The petroleum products are received through

pipeline

The details of Aonla Depot & the present layout drawings are enclosed.

The following activities shall be controlled by the terminal automation system.

a) Tank Truck Loading (8 Bay + 6 Bay Gantry)

b) Tank Farm Operation & Valve Operation (Existing & Future. For Future Tank

Farm & valve operation only Software graphic, logics are required )

c) Tank Truck Entry & Access Control including the registration System

d) Product Pump Automation (for existing, proposed & future requirement)

e) Fire Engine Operation for both MCP (existing) & pressurized

System(Proposed)

f) Management Information System (for existing, proposed & future

requirement)

g) ERP interface (for existing, proposed & future requirement)

h) ESD system ( For Future requirement)



29 | 3 5 9

DESIGN CRITERIA

Vendor shall note the following minimum requirement for designing the facilities.

These shall be read in conjunction with the function & technical requirements as

specified elsewhere in this document

The system is required to be designed for following broad parameters:

Maximum temperature : 55 Degree centigrade.

Minimum temperature :

0 Degree centigrade

Maximum Relative humidity :

95 %.

Petroleum products to be

loaded

: MS, HSD & SKO. Ethanol blending &

Additive dosing is also required

Products Characteristics : As given below

Flow rate :

Flow rate of 150 to 1500 LPM at each

Loading point. Maximum Header Flow Rate

will be when all the pumps for that particular

product are operating & minimum Header

flow rate when the smallest capacity pump

for that particular product is operating.

Working pressure :

1 Kg/ Sq cm to 10 Kg/ Sq Cm

Design pressure :

15 Kg./Sq.Cm

PRODUCT CHARACTERSTICS

PARAMETERS MS SKO HSD

Specific Gravity 0.7-0.75 0.75-0.8 0.8-0.9

Viscosity @38Deg C 1.1CST 1.2CST 2.54-4.0 CST



30 | 3 5 9

SYSTEM RESPONSE TIME: Vendor shall design the System so as to have the

following minimum response time.

ACTIVITY MAX. RESPONSE

TIME

Time for transferring of change of status of equipment

and alarms of the entire terminal

: 5 Sec

Time taken to call a particular screen from any other

screen with all the contents.

: 2 Sec

Time for updating of any hardware analogue variable : 2 sec

Remote command from Operator station to action has

taken place via hardware I/O

: 2 Sec

Card Reader and Data entry terminal : 3 Sec

Time for complete update of real time database : 8 Sec

Scanning rate in TFM for field instruments : 2 Sec

Scanning of all digital signals connected to interlock

logic application

2 sec

Scan time for Open loop analog signals : 300 m Sec

Scan time for Closed loop analog signals : 300 m Sec

For BATCH Controller, Tank Farm serial device and RIT

communication with LRC

: 2 Sec

Time taken between card flashing & barrier gate

opening

: 5 Sec

Time taken between card flashing & corresponding

batch controller message appearance

: 4 Sec

Time taken for Valve status that has changed in the

field to get updated on display.

: 5 Sec

Other system responses required for driver interaction

such as card validation, RIT lamp sequences, down

loading of data etc.

: 4 Sec

Time Taken for a particular screen from any other

screen with all contents

: 2 Sec



31 | 3 5 9

APPLICAPABLE CODES & STANDARDS

• The components of instrumentation and control system shall be designed,

manufactured, assembled and tested in accordance with the latest standards of

the Standards Institution, Instrument Society of America, Institute of Electrical

Engineers and Manufacturer's association of the country where they are

manufactured / country of principals. They shall also confirm to the relevant

latest standards of the Bureau of Indian Standards (BIS) wherever available, so

that specific aspects under Indian conditions are taken care of.

• The equipment shall also conform to the latest Indian Electricity Rules, OISD,

PESO & petroleum rules as regards safety, earthing and other essential

provisions specified there in for the installation and operation of electrical plants.

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

shall have BIS approval.

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

Painting.

• All equipment shall comply with the statutory requirements of the Government

of India and the State Government of respective states.

• The Vendor shall execute the job to comply with the requirements of the

relevant regulations or acts in force in the area together with design

specifications with respect to:

Indian Electricity rule

Indian Factories act

Regulations laid down by chief electrical inspector

Regulations laid down by Factory Inspector of state Indian Standard

Specifications



32 | 3 5 9

Oil Industries safety directorate norms.

International Organization of Legal Metrology.

Regulations relevant to explosion hazardous areas

Petroleum & Explosive Safety Organisation norms & regulations

The equipment supplied shall be designed in accordance with the requirement of

all internationally &locally applicable standards/specifications listed below.

American National Standards Institute (ANSI)

American Society for Testing and Materials (ASTM)

National Electrical Manufacturers Association (NEMA)

American Society of Mechanical Engineers (ASME)

American Petroleum Institute (API)

Institute of Electrical electronic Engineers (IEEE)

National Fire Protection Agency (NFPA)

International Electro-technical Commission (IEC)

International Standard Organisation (ISO)

Open Software Foundation (OSF)

Bureau of Indian Standards (BIS)

The following codes as a minimum shall be applicable in designing the system.

These codes (Latest edition) shall be produced as & when required by HPCL/

PMC for checking the system

Code / Standard Description

ANSI/ISA 575-01

Control valve sizing , capacity test procedures, face to

face dimensions, leakage

RP 520 Fire sizing of safety and control valve

RP 598 Control valve leakage

IS 2341:1963 Calibration vessel



33 | 3 5 9

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

ISA RP SS-1

S 62-01, S82-02

S8-03, S18.1

Instrument Society of America standard and codes

IEC 61131 PARTS 1-4 Programmable controller

DIN V VDE 0801 Principles for computers in safety related systems

DIN V 19250-1994 Safety consideration for fail safe control for control and

instrumentation equipment

IEC 61508 Functional safety programmable electronic system

IEC 801/EN 50081/82 Electromagnetic compatibility

IEC 79.10/BS 4683/

IS 2148

Hazardous area classification

IEC-529/IS 2147/

NEMA

For execution of Inst. Enclosures

IEC-85 Thermal Evaluation and classification of electrical

insulation

IS 1271 Specification for thermal evaluation and classification

of electrical insulation.

OSID

recommendations

For storage, handling and safety systems and

transportation

CENELEC

EN 50014-50039

European norms for Hazardous area equipment and

accessories

EN 60950-1992 Power supply

DIN 43760 Resistance temperature detectors

IS 3624 Specification for pressure and vacuum gauges

IS 1554/ IS 5831 PVC insulated cables

TIA/EIA 568A

ISO/IEC 11801

Telecommunication cable standard

ASTM 1086 Tank instrument system

API MP MS Ch 21 Flow measurement using Electronic Metering System

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

ISO 4266 Petroleum and liquid petroleum products –

Measurement of level and temperature in storage

tanks by automatic methods.

OIML R85 Automatic level gauges for measuring the level of



34 | 3 5 9

liquid in fixed storage tanks.

IS 2801 PD meter Accuracy

BASEEFA/PTB/KEMA/F

M/ATEX/ TUV/

PESO/CMRS/ IBR/

RDSO/W&M

Statutory standards

BS 5308 Part-I Instrumentation Cable

IS 2148 Flame proof , enclosure for electrical apparatus

IS 3624 Specification for Pressure & Vacuum Gauges

IS 3043 Code of Practice for Earthing



35 | 3 5 9

DESIGN CRITERIA FOR TANK TRUCK LOADING FACILITIES

• Tank Trucks are loaded on a volumetric basis in the filling Gantry.

• New (8+6) Bay Gantries are constructed to load MS, HSD, SKO at the

designated bays which shall be filled simultaneously depending on the Bay

configuration & the product mix, as required, through two different loading

arms. Each loading Point shall be capable of filling multiple variant of the

same product depending on the infrastructure /equipment provided.

• Existing 4 Bay Gantry shall be used till the time the new Gantries are

commissioned. The same is not required to be integrated with the new

software. However, it is preferable to run the existing Gantry to the extent

possible through old software till the new Gantries are commissioned.

• Each loading point shall be provided with a 3” Positive displacement meter,

dedicated strainer cum air eliminator and digital control valve. In case of MS,

additional 1½”/ 2” Positive displacement meter, dedicated strainer cum air

eliminator and digital control valve shall be provided for Ethanol blending. All

variants of particular product shall be handled by same loading arm. Same

Tank truck may have different variant of the same product loaded into

different compartment. The variants of the particular products could be any of

the following:

o Base product

o Base product with blending.

o Base product with one additive.



36 | 3 5 9

o Base product with Two additives

o Base product with blending and one additive

o Base product with blending and two additives.

• Vendor is required to specify the total pressure drop across complete

metering assembly. Maximum allowable pressure drop shall be limited to 1.3

kg/cm2 across metering; strainer, air separator cum eliminator, PD Meter &

DCV.

• Each loading points shall be provided the Batch Controller as per the technical

specification. This Batch Controller shall control the digital control valves of

the base products, secondary product being used for blending and the

additives. These loading points shall be operated through batch controller as

per the batch downloaded from LRCS. The Batch Controller shall send the

Pump demand to the existing PLC to start/ stop the pumps ( Main Product,

Secondary Product, Additive) as per the requirement

• RTD shall be provided at each loading point. RTD temperature of the

respective loading point shall be send in the post load packet

• Each loading point shall be provided with a Remote interaction terminal (RIT).

Each RIT will have emergency stop push button to shut down filling operation

in case of emergency.

• Existing Push buttons provided for Pumps in both the Gantry shall be able to

stop the pump even if the Pumps are in Remote mode

• Intrinsically safe proximity card reader shall be provided at each bay.

• Each bay shall be provided with Earthing device which shall be interlocked

with the manual earthing, apart from other suitable interlocks as defined in

the technical specifications.

• Density for the blended product shall be calculated by the application

software based on the density input of individual product as the blending is

done at point. The existing software shall monitor & record density for each

truck compartment and communicate it to ERP for printing on the invoice. In

case the product is not flowing through densitometers during loading of that



37 | 3 5 9

particular product then “Error” message shall be displayed instead of last

healthy reading

• The pressures in the header lines are to be transmitted to PLC / LRC. If

pressure in the delivery pipeline header exceeds specified value or reduced

below specified value, alarm should be transmitted to PLC panel from

pressure transmitter for stopping the Batch Controller or starting/ stopping

the pump.



38 | 3 5 9

DESIGN REQUIREMENT IN CONTROL ROOM, S&D ROOM & TM ROOM:

o Control Room shall be provided with the following:

Loading Rack Control Servers shall be provided in Hot Standby

configuration

New Tank Farm Management System, Client PC’s , Communication

networks, Engineering Station, Printers, Networking Panel, Power

distribution Panel along with associated hardware and software shall be

provided

Existing Gateway Servers. Any up-gradation/ replacement required to meet

complete functional & technical specifications shall be in the scope of

Vendor.

Supply of new Terminal Servers for the new as well as existing

components/instrument/hardware

New Process PLC to meet the complete requirement specified in the

Tender.

New local area network (LAN) for the connecting Servers and Client PCs

may be used. Any additional requirement to meet functional & technical

requirement shall be in the scope of the Vendor.

Complete TAS System shall be provided on HPCL IP Schema.

Anti-Virus ( Trend Micro) shall be provided by HPCL

o Tank Truck Entry System with overnight registration System including all

additional associated hardware & software to meet complete functional

specifications. Card Readers shall be provided at the Parking/ Security cabin,

Entry Exit Gate Barrier while existing Card Reader in the Planning room & Gate

Barrier shall be issued as free issue.

o ERP computer shall be in the scope of HPCL & shall be provided in the

S&D/Planning Room/Admin building. The JDE software installed by HPCL



39 | 3 5 9

performs the pre-loading operations. The interface between the Host system

and LRC system is in the scope of the Vendor

JDE computer shall be connected with Load Rack Computer (LRC) through

Gateway Sever. LRC will act as central repository for all databases and

information, used by various sub systems. JDE computer is provided with

features that facilitate all pre-loading operations to be performed outside the

licensed area in the Marketing room. The following functions are performed

by the Host Computer:

• Register tank trucks which report for filling

• Commercial verification of tank truck based on its databank

• Recall & modify data corresponding to a truck registered earlier.

• Transfer truck data to LRC server through GWS based on the interface

developed by the Vendor.

o System should have redundancy for all critical communication links like Batch

Controllers to LRC interface; LRC to ERP, PLC to LRC interface; Terminal Server

to Ethernet switch, VFD to PLC interface & PLC processor to PLC I/O racks etc.

as specified in the functional requirement to ensure full operational capacity

at all times as per detailed specifications specified in the tender.

o Marshalling racks, DC supply units, power supply distribution cabinets/ boxes,

power pack units, intrinsic safe barriers/isolators, other auxiliary cabinets, etc.

as per specifications.

o Two Nos. electronic anti rodent to be installed in Control room



40 | 3 5 9

SOFTWARE REQUIREMENT

General

The capacity of offered software should be min. 100 % extra with respect to nos. of

data base points/ SCADA points/ tags after calculating requirements of the total

system. License offered shall be with 50% spare SCADA points/ Data base

points/tags after calculating requirements of the total system & additional 4 tanks,

4 Loading points & 4 products. These additional Tanks, loading points & products

are over & above the facilities considered in Next Phase. The offered software

should have in-built capability/provision to take care for future expansion (no. of

instruments/equipments added and software capability to handle those additional

instrument/equipment) without any limitation. System should be flexible from the

point of view of up-gradation. These shall be verified during FAT. Detailed sheet of

SCADA points/ Data base points/tags shall be available showing total available &

used SCADA points/ Data base points/tags in the TAS software- “System

Diagnostic”

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

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

The original copy of the license certificate for the operating system, RDBMS 6 user

license – 2 No. for redundant LRC/ TAS server and LRC / TAS server software each

needs to be provided to HPCL from the principal collaborator from the country of

origin clearly mentioning the details like project name, end user name, name &

version of the offered software for each of above, data base sizing as a minimum.

The original copy of the license certificate in name of HPCL location supported with

un-priced shipping import documents shall be provided to HPCL for effecting

payment to the vendor. The prime bidder/ system integrator with collaborator

backup shall confirm availability of the source code for the custom code

programmed Tank Truck Filling Operation application software with them. The

prime bidder/ system integrator shall confirm technical support for the offered

application software for the next 10 years as a minimum.

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

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



41 | 3 5 9

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

origin declaring qualified technical support for the offered application software for

the next 10 years as a minimum.

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

the resellers/ distributor/franchisee until unless principal software manufacturer

issues a letter to the TAS vendor stating distribution of licenses from the resellers/

distributor/franchisee as a policy.

For each server (LRC), running memory resident applications like Operating system,

RDBMS + code programmed application for truck filling operations, development

(engineering) + runtime + network license, if applicable, is to be provided from

principal supplier.



42 | 3 5 9

Confirmation on the following shall be furnished by the vendor on the technical

bid for evaluation of the offered software:

SR

.N

O

TAS FEATURES HPCL REQUIREMENTS VENDOR’S

CONFIRMATI

ON.

A. REDUNDANCY

1. Server failover alarm

announced Audibly & Visually

& logged in alarm

management.

YES, For both primary &

secondary server.

2. Ethernet failover alarm


& logged in alarm

management.

YES, For both primary &

secondary LAN.

3. LRC Server failover time. Maximum 30 seconds that

includes real time

Database, graphics, alarm,

events.

4. Operator / Client station

connection to Redundant

Server.

Operator / Client station

should always connect to

Primary Server.

5. Time taken by operator

stations / client stations to

connect/ upload all data, GUI

from active primary server.

Maximum 30 seconds for

all operator/client stations.

6. RAID MIRRORING

DIAGNOSTICS with built in

RAID for each LRC.

Yes, required.

7. Hard disk failure should be

annunciated Audibly &

Visually & logged in alarm

Yes, required.



43 | 3 5 9

management.

8 Electronic preset

communication channel

failover.

Communication channel

failure should be Visually

annunciated & logged in

alarm management.

9 PLC CPU Failover alarm


& logged in alarm

management..

YES; For both primary &

secondary PLC.

10 Terminal Server Failover alarm


& logged in alarm

management

Yes. Required

11 All Batch Controller one

channel communication

failure

Yes. Required. alarm shall

be announced both

Audibly & Visually &

logged in alarm

management

12 PLC to I/O Rack

communication failover

Active / Backup

communication link status

should be displayed on a

standard display & failover

shall be annunciated both

audibly & visually.

13 PLC Power Supply Redundant Power Supply

Required from

independent sources

14 Each PLC Processor Rack to

Host System Communication

Redundancy

Redundancy Required by

use of two dedicated

communication processor

modules in each PLC CPU

Rack

15 PLC DO Module DO Module to be provided

with in-built fuse blow

protection, maximum I/O



44 | 3 5 9

module density 8/16

points.

16 PLC I/O Modules Connection All I/O modules to be

connected with field

signals through use of

intermediate Remote

Termination Panel / field

Termination Assembly

17 Interconnection of Field

Devices to Terminal Server

Surge arrestor to be used

for interfacing Field devices

to Terminal Server

18 RDBMS redundancy Yes; auto change over is

desired.

19. PLC I/O Racks Bus Topology All I/O Racks to be multi-

dropped on dual

redundant bus

20 Retrieval of data from LRC Tool to be provided as a

part of system diagnostic/

repair to retrieve all the

data including all programs

in TAS Folder

21 Back up of data from LRC Tool to be provided as a

part of system to take back

up of all the data including

all programs in TAS Folder

22 Safety PLC Processor failure Alarm must be announced

audibly and visually and

must be logged in alarm

Management system.

B ALARM MANAGEMENT



45 | 3 5 9

1 User assignable different

alarm priorities for point in

alarm

Minimum Three required;

EMERGENCY / HIGH / LOW.

2 Present Value in alarm state

should be flashing / change

color on all displays

displaying the point.

User configurable required for

both features.

3 Alarm banner / display of

alarm.

Dedicated alarm line on all

displays required; Most current

emergency alarm should POP

UP on screen as a X-WINDOW;

User configurable.

4 Acknowledge alarm by

selecting any point in the

display & press a dedicated

Acknowledge Button.

Required.

6 Multiple alarm entries in the

alarm summary for a point

that is fluctuating between

alarms.

Yes ; Required.

7 Associated display for points

when clicked OR Double

clicked when in alarm.

Yes ; Required ; Associated

display should provide details

of alarm Dead band ; Alarm

limits as minimum.

C. Trends

1 Trend types available. Minimum multi plot ;

X – Y Plot ; Numeric plot

required.

2. Vertical axis readings. Engineering units & percentage

readings required.

3. Comparison between Real

Time; Historical & Archived

Data.

Trend comparison availability

required.

4. Copy of currently selected

trend data on to Clipboard for

pasting into spreadsheet.

Yes; Required.



46 | 3 5 9

5. Automatic displaying of

archived history if trend is

scrolled past current history

limits.

Yes; Required.

6. Trending of archived history

files.

Yes; Required.

7 Export of trends, graphs to

spread sheet software like MS

office/ Viewer, Open Office

Yes; Required.

D. HISTORICAL DATA ARCHIVING.

1. Activation of archiving. Operator demand; Periodic

Scheduling OR event initiated

as minimum for entire

database.

2. Back-up & Restore Operator demand.

E. REPORTING.

1. Activation reports. Operator demand ; Periodic

Scheduling OR Event initiated

facility required.

2. Configurable custom reports. Yes ; Required ; Either inbuilt

OR third party Ex. SEAGATE

CRYSTAL REPORTS TOOL.

3. Results from reports stored in

user database.

Yes ; Required.

4 Export of reports to spread

sheet software like MS office/

Viewer, Open Office

Yes; Required.

F. SECURITY.

1. Automatic logout of user

interface after pre-configured

time of inactivity.

Yes ; Required.

2. Control level Functionality. Min. 5 level control



47 | 3 5 9

functionality user assignable to

each point required.

3 Multiple login of same user at

different machine at same

time

Not required

4 TAS file system protection All files shall be bundled up in

one single folder & with a two

layer password protection

facility

G. APPLICATION PROGRAMMING INTERFACE.

1. Programming languages. Any open licensed standard

software is acceptable. The

software should handle Real

time data acquisition Data

point management with

settings for alarms etc.

supports links to its own GUI

and also API for generic

languages, Interface with

external database for History

etc

H. DATA EXCHANGE.

1. A tool to export desired data,

reports directly from the

database into Excel

spreadsheet/ Word/ ODBC/

Star office.

Yes ; Required.

2. Retrieve real time / historical

data from primary Server in

Microsoft Excel format.

Yes ; Required

I. DATA BASE CONFIGURATION.



48 | 3 5 9

1. Nos. of utilities required to

configure parameter value

points, printers ; stations ;

controllers.

The offered software shall

employ standard control

builder (development) package

that offers standard/ easy to

use tools to define system

database comprising of analog/

digital/ pulse inputs/ outputs,

database configuration like

linking dynamic parameter

values on graphic screens shall

not require individual code

programming / compiling

/linking (like VB scripting) & it

should be possible to modify

database online without re-

start of the system.

An easy configuration

should be provided to

easily Add/Update the

following

Product (Stock holder,

Stock, Blends-Additives)

Facilities (Bays, Gates,

Tanks, Pumps, Valves, pipeline

ESD, Interfaces, Device setting-

PLC) Operation (Cards, Truck,

Driver, Customer, Contractor)

Users (Users group, Password,

Menu-Screen restriction)

Parameters (Different modes of

software switch selection ,

Report selection,) programming

/ compiling Linking (like VB

scripting) & it should be

possible to modify database

online without re-start of the



49 | 3 5 9

system

2. Changes to common fields of

points, controllers, and station

should be globally applicable.

The utility shall be a standard

feature of development pack &

code programming /script

based tools/utility shall not be

acceptable.

3. User fields for each point for

tagging information like

cabinet Nos. / wire Nos.

Yes ; Required , this shall be a

standard tool of the

development package. code

programmed /script based

utility shall not be acceptable.

J OPERATOR INTERFACE

1. Predefined area on screen for

operator messaging.

Yes ; Required; pop-up window

on emergency conditions

2. Function keys. User configurable ; Frequently

used tasks can be accomplished

using dedicated function keys

(F1 to F12).

3. Zooming facility for trend

display.

Yes ; Required. The Trend chart

shall be min 50% of the total

display area

4. Standard Windowing

conventions employed.

Yes ; Required ;

5. Configurable Toolbar Icons &

Pull Down Menus.

Desired. However submenu

shall be available immediately



50 | 3 5 9

after activation of main menu.

6. Time Zone Availability. Time Zone should be displayed

on each station. LRC, Client &

all other equipment having

time stamping shall have time

synchronization. LRC time shall

be changed only through

“Administrator”

7. Standard display for

displaying unacknowledged

Alarms & Alarms which have

been Acknowledged but still

in Alarm.

Alarm summary display

Required. Alarm summary

should show / differentiate

Alarm status by flashing/color

change ; User configurable.

8. Summary pages for reports,

Trends, Displays & Groups.

Yes ; Required for SCADA based

system

9. Point detail display. Yes ; Required for SCADA based

system

10. Group detail display. Yes ; Required. for SCADA

based system

K. UPDATE / RESPONSE TIMES. Max. Response Time.

1. Time for transferring of

change of status of

equipment and alarms of the

entire terminal

5 Sec

2. Time taken to call a particular

screen from any other screen

with all the contents.

2 Sec

3. Time for updating of any

hardware analogue variable

2 sec

4. Remote command from

Operator station to action has

taken place via hardware I/O

2 Sec



51 | 3 5 9

5. Card Reader and Data entry

terminal

3 Sec

6. Time for complete update of

real time database

8 Sec

7. Scanning of all digital signals

connected to interlock logic

application

2 sec

8. Scan time for Open loop

analog signals

300 m Sec

9. Scan time for Closed loop

analog signals

300 m Sec

10. For BATCH Controller and RIT

communication with LRC

2 Sec

11 Time taken between card

flashing & barrier gate

opening

5 Sec

12 Time taken between card

flashing & corresponding

batch controller message

appearance

4 Sec

13 Other system responses

required for driver interaction

such as card validation, RIT

lamp sequences, down

loading of data etc.

4 Sec

14. Presence of “ Help” functions

built into the Operator station

software for operator

guidance in all screen/

toolbar menu.

Required. For entire

system/operational commands

15 Presence of “ System

Diagnostic ” mimic to quickly

locate a faulty hardware.

Yes Required.



52 | 3 5 9

16. System stability and system

response when TLF is working

at full load (i.e. when all bays

are loading)

No freezing, hanging, crash or

slow down.

17. Rational allocation of bays

( scheduling function) i.e.

there is no long queue on one

bay while some other bay

capable of loading the same

product is free. “ Preferred

bay” concept shall be made

available

Yes. Configurable

18. Is the system capable of

manual filling through Batch

controller (i.e. driver/bay

officer keys in pre-set

quantity at BC and carries out

filling operation)

Yes. Facility to upload the load

details of manual mode

operation to LRC automatically

as soon as manual batch

controller comes back to

remote operation. All manual

uploaded data shall be made

available as a separate report

19. After recovery how does a

failed LRC equalize its status

for the data updated during

the time it was down.

All data from the primary server

shall be copied automatically

once the failed LRC comes

within the system as a

secondary server without any

loss or degradation of data.

20 LRC data Synchronization Automatic Synchronization is

required. System screen shall

display.

L ACCESSABILITY:

No of users can access one

application at a time

6 Minimum

M MAINTENANCE REQUIREMENTS



53 | 3 5 9

Time to reach the site to carry

out emergency maintenance

on software problems

24 Hours

N LICENSES.

1. Name / Version of TAS

software offered.

Original paper license from

PRINCIPAL MANUFACTURER

to be offered with mention of

project name ; Database size ;

Version/Name of offered

software along with un-priced

copy of IMPORT SHIPPING

documents if applicable

2. Name / Version of RDBMS

offered.


PRINCIPAL Supplier to be

provided for REDUNDANT

RDBMS Version/Name of

offered software along with

unpriced copy of IMPORT

SHIPPING documents if

applicable .

3. Name / Version of Operating

System.

Original license from


provided for OPERATING

SYSTEM.

4 Name/ Version of Safety PLC

Software



provided for SAFETY PLC

SYSTEM.(for both configuration

& MMI)

5 Name/ Version of Process PLC

Software



provided for PROCESS PLC

SYSTEM.(for both configuration

& MMI)



54 | 3 5 9

6. Details on custody transfer

system (LRC Application)

Availability of source code for

LRC application with prime

bidder/Manufacturer required

7. Name / Version of TFMS

software offered


PRINCIPAL to be offered with

mention of project name ;


software Version/Name of

offered software along with un-

priced copy of IMPORT

SHIPPING documents if

applicable

8. SCADA point License Original paper license from

PRINCIPAL MANUFACTURER

to be offered with mention of

project name ; Database size ;


software along with unpriced


documents if applicable.


software along with unpriced


documents if applicable

The TAS Vendor should confirm the following - Any component not owned by him but being provided as a part of the solution offered. - Confirm that vendor is authorised to distribute / license the above component to HPCL. - Whether HPCL needs to sign any document prior to commissioning/execution of the project relating to any software component as a part of the solution by the vendor.

Note: Original copy of all Licenses shall be submitted in the name of HPCL

mentioning details like project name, Location name, end user name, name &

version of the offered software along with terms & condition, if any. The original



55 | 3 5 9

copy of the license certificate supported with un-priced shipping import

documents shall be provided to HPCL for effecting payment to the vendor.

Minimum 6 user licenses (on each LRC machine) to be provided for operating

system and RDBMS (i.e 2 sets of user licenses for RDBMS and OS shall be

provided)

If any component not owned by the vendor but being provided as a part of the

solution is offered, The vendor must be authorised to distribute / license the

above component to HPCL. HPCL must be notified if it needs to sign any

document prior to commissioning/execution of the project relating to any

software component as a part of the solution by the vendor.

Security Guidelines for Terminal Automation System (TAS) :

Following security guidelines for a secure operation of the Terminal automation

system shall become a part of the system being offered by the successful

tenderer.

Batch controller should keep the operational data for the day and the same will

be compared with the LRCS database for generating exception reports.

The automation vendor has to provide security for the total operations with a

view to have an audit trial of each and every operation at the automated location.

All files pertaining to TAS shall be bundled in one common folder named as TAS

folder. The folder shall be with password protection and shall be accessible to

administrator with due security.

The security and authorizations should be implemented at the following areas:

a) Operating system level

b) Database level

c) Application software level

a) Operating system:

TAS MMI on client should also operate on non-administrator login.



56 | 3 5 9

Each and every user should be provided a User-ID with proper

authorizations for logging into the operating system.

The System shall display the User-ID in the tool bar through which the User

logs in the system.

“Administrator” User-ID should be only be used for installation of software

and any maintenance purposes. It should not be used for day-to-day

operations.

Users should not be allowed to login to the system with “Administrator”

user for day-to-day operation.

Administrator User-ID and other user-IDs and passwords should be allowed

to be changed. It should not be hard coded in the software or linked to

machine address.

b) Database:

TAS Users should not be allowed to open and update the database directly.

Only the Administrator should be allowed for any maintenance work to

make changes to the database and all the changes made to the database

should be logged. Administrator shall have separate login password &

transaction password. Any changes in the System shall be allowed only after

successful validation of these passwords. System shall have in-built check

for having separate password

Database should be allowed to be updated only through the application

with proper authorizations and should not be allowed to be updated

directly unless otherwise specified in the tender.

Security and authorizations should be implemented on a role based

authorization system.

Referential integrity checks should be built into the database to maintain



57 | 3 5 9

the integrity of the database.

For all completed physical operations, the data recorded in the database

should not be allowed to be updated / changed.

All the changes to the database should be logged by the system and the

same should be made available for any audit trial at a later date with time,

date & Unique ID stamping

Database logs should be backed up onto to tape and the same to be

preserved for later use.

c) Application software:

Security and authorizations should be implemented on a role based

authorization system.

Application software should provide creation of various User Group with

specific authorizations for the Group. Different User Group like Manager,

Supervisor, Engineer, Operator etc. should be created and define Menu/

Screens and Add/ update / modify restriction for each group.

Application software should provide creation and maintenance of User IDs

and attaching the various roles defined above to each and every individual

at the location.

Broadly there shall be min. five levels of security.

Level I – This group shall have no restrictions and is reserved for personnel

providing the technical support to the terminal. Typically, no one at the terminal

shall have Level I access.



58 | 3 5 9

Level II - Terminal Manager - This Group shall have no data restrictions except to

critical hardware & facility configuration data. Level II shall be for the most highly

privileged terminal operators.

Level III - Terminal Operators - This Group shall view only access to facility

configuration data and shall the capability to access operational data

Level IV - Sales Clerk - This security group shall have no access to Facility

Configuration data, but shall have the capability to edit data items strictly

pertaining to his job profile.

Level V - View only - This security shall have no access to Facility Configuration

data. All other screens shall be “View only”. No action shall be allowed by this

group.

Application Software shall provide exceptions report consisting of changes /

cancellations and manual creation of data at the end of the day.

Report should be provided listing the trucks filled from the TAS / LRCS database

and also the same from the Batch controller information from the bays. The same

has to be reconciled at the end of the day operations.

Automation Vendor shall also provide reputed anti-virus solution (latest) for the

servers being provided based on the type of the operating system used.

SERVER OPERATING SYSTEM

LRC SERVER

The Vendor shall design, supply, install and commission Windows operating

system (Windows 2008 server edition or latest) based machine with proper



59 | 3 5 9

licensing on both the server with redundancy. One of the servers shall be Master

(Primary) and other shall be Slave (Secondary) with Hot Standby. It is mandatory

that TAS software & other software shall communicate to primary server only.

The servers shall have OS Mirroring and the operating system shall be capable of

achieving redundancy at server level by use of suitable Asymmetric Hi-

Availability Software.

The Hi-Availability Software shall have at least the following features:

Failure Detection with Heartbeat or Similar Mechanism

Login Consistency

Rebooting

Avoid False Triggering

Service Modules

Administration

Configuration Flexibility

Expandability and Scalability

Gateway server operating system

The Vendor shall design, supply, install and commission suitable Windows

operating system based machine with proper licensing.

The Vendor shall supply, install, and commission suitable preloaded Windows

2008 Standard Server with any latest SP, if available, and media (CD) with paper

license and recovery media.

All necessary drivers for all components for Windows 2008 should be supplied

with the server(s).



60 | 3 5 9

CLIENT OPERATING SYSTEM

The Vendor shall supply, install and commission Microsoft Windows 2007 or

latest Operating System with Microsoft genuine certified licensing on all the

clients and suitably tune them for running the application.

RELATIONAL DATABASE MANAGEMENT SYSTEM (RDBMS)

The Vendor shall supply, install and commission ORACLE 11g or latest or MS SQL

Server. The server component of the RDBMS shall be suitably loaded onto both

the servers to achieve fault tolerance and redundancy and proper tuning shall be

made in Database to interact suitably with HA Software. The application package

shall be developed on this platform. The RDBMS server shall be tuned for

performing the necessary tasks (i.e. Data Replications etc.) to maintain the fault

tolerance and redundancy of the entire TAS package. The necessary client

components shall be installed on the client PCs and tuned to run in tandem with

the server component. Both server shall show last synchronized time & loss of

synchronization at time. The synchronization shall be automatic & the status

whether “Synchronized” or “Not Synchronized” shall be displayed on the screen.

GUI BASED RAPID APPLICATION DEVELOPMENT TOOLS

The Vendor shall use suitable GUI based rapid application development tools (viz.

Microsoft Visual Studio) for the development of the TAS application package.

NOTE : For all Windows OS & other Microsoft product, the security/ functionality

patches which are mandatory in nature shall be upgraded /installed in all

machines during project execution, system stabilization, warranty & CAMC.

Vendor shall bring the required patches in CD & submit the reports of such

installation to the concerned officer.

SNMP BASED NETWORK MANAGEMENT SOFTWARE

The Vendor shall supply, install and commission SNMP based network

management Software for Microsoft Windows based Network to manage the

inter-building wide networking from the control room.



61 | 3 5 9

TAILOR-MADE APPLICATION SOFTWARE

A modular GUI based Application package shall be designed, developed,

implemented and commissioned to meet the whole depot operation

requirement.

The software should have excellent features in regard to real time data

acquisition, data & alarm processing (real time), database downloading, Terminal

security, access etc. The software should also meet our desired operational

criterion in regard to T/T loading, scheduling, stock recording, monitoring &

control of product movement, TFMS, Fire Water module, Access Control, Pump

automation module, MOV automation module.

The Application package shall be of Client - Server Architecture with RDBMS

running at backend. The entire Application Package for these terminal

automation systems shall be essentially:

Scalable: The capacity of offered software should be with 100 % extra with

respect to nos. of SCADA points/data base points/ tags after calculating

requirements of the total system. The offered software should have in-built

capability / provision to take care for future expansion to the extent of minimum

four additional loading points; up to four new product tanks & Four new

products as a minimum. System should be flexible from the point of view of up-

gradation. These shall be verified during FAT. In case of tag based system,

unlimited tags should be offered.

Up-gradable: The system architecture shall provide a logical planned

implementation of evolving technologies and provision for up-gradation of

existing equipment. The system design shall permit the online addition of new

sub-systems with no disruption to either the operation or system

communications, for future expansion.

Flexible: The offered systems shall be flexible enough to accommodate minor

changes required by user during the operations. The features related to this shall

be clearly described in the FDS & FAT

User Friendly: The entire application shall be developed to incorporate



62 | 3 5 9

maximum user friendliness.

Latest Technology: The offered systems shall be of latest technology with all

state-of-the art features.

The tailor-made application software shall be continuously uploading and

downloading DATA / Commands with the instrumentation systems. The

application software shall in turn store the filtered data in related databases for

various purposes like Displays, Trending, and Reports etc.

While developing this tailor made application software the developer shall

consider the following points.

All modules of application packages shall be developed on and around RDBMS

(viz. ORACLE, SQL server).

The front-end of the application package shall be developed using any popular

Visual RAD Tools (viz. Visual Basic 6.0, Visual C ++ etc.) or shall be SCADA based

HMI software

The various modules shall be developed to work in tandem with each other as

well as in standalone mode if required.

In case of failure of link between Server and Client, server component of

application shall be able to update and synchronize the data when link comes up.

System health screen shall be dynamic for all the links

Reporting modules shall be able to generate business graphics.

Apart from above the Vendor shall also develop suitable TTES module for entry

of authorized trucks in the loading area with the help of TDM & LRC computers.

TTES operator shall assign a proximity type card & FAN shall be generated with

the help of LRC and shall be handed over to the T/T driver for authorized access

in the predefined bay inside the loading gantry. TTES shall also generate the

invoice reports after the trucks are filled.



63 | 3 5 9

The terminal shall be provided with automatic security system between licensed

loading area and non-licensed area for tank truck movement in and out of these

areas. This is done through the computer controlled Card reader and automatic

barrier gates. Exit barrier gate is also automatic and is controlled from exit card

reader. After passing of each truck, the barrier gate shall close automatically

based on feedback from suitable IR sensors provided by vendor. The IR sensors

provided shall have suitable protection/ canopy against the sun rays so that the

reflection does not hinder in its operation

The tank truck driver shall show the card at the entry card reader. LRC shall read

the card label code and check to see whether it matches with that of any of the

tank trucks for which FAN slips have already been issued.

If the code matches with that of any of the tank trucks (TT) currently under

loading or waiting for loading , then the RED lamp on the Card reader lights up

to indicate, that the card is not a valid one and the entry barrier gate remains

closed.

The TTES shall also restrict entry to the tank truck (TT) under the following

situations:

• The card label code corresponds to a tank truck (TT) which has already been

loaded and the card is not surrendered by the driver or if a tank truck (TT)

with the same card code is already in the licensed area.

• The card code has been invalidated by the operator.

• The Card corresponds to the non-filling card/ supervisory card

A Card issued to a tank truck shall be valid only for the date of issue and

specified time duration from the time of issue. If the tank truck does not report at

the entry barrier gate within the specified duration, then the card shall be

automatically invalidated by the TAS and bay shall be released automatically.



64 | 3 5 9

The acceptance/ Rejection of the card shall be indicated in the card reader at the

entry barrier gate. A manual over ride control for opening and closing of gate

shall also be built into the system and the operation shall be possible at the gate.

All entry / exit operation with TAS system including manual over ride operation

period shall be logged.

The TAS software or any of the modules GUI shall not be offered on webpage. In

case any of the module is offered on webpage schematics, Say software opening

in internet explorer, the system shall give user facility to reinstall internet Explorer

in the Help Tab of the TAS software index.

Functional requirements

The TTES shall cater to all pre-loading operational interaction and operator

interaction for all post loading documentation. The following operation shall be

possible from TTES Terminal, as a minimum.

Registration of Truck which have reported for taking load at dispatch office

Facility to create load details via suitable entry / editing screen

Facility to cancel or modify the data corresponding to Truck registered earlier

Facility to communicate with LRC to exchange load details and thus enabling

access control mechanism.

To list all the pending orders registered.

Preparation and issue of Filling Advise Note (FAN)

Facility to manually over ride Loading Bay assigned by LRC

Manual completion / adjustment of Load in the event of Bay or Truck

becoming sick and reauthorization of Trucks in order to move to another

loading bay, to complete filling.



65 | 3 5 9

Facility to view current status of Loading Bays and Trucks under Queue or

loading.

Facility to generate invoices / Delivery challans

Issue of access control cards.

Single FAN is prepared for a tank truck. The FAN shall contain broadly the

following details:

• Tank Truck registration number

• Product Name

• Compartment wise capacity

• Bay number

• Customer Name& Code

• FAN Number

• Abloy Lock Number

• Time of FAN generation

All data, graphic screens as available in other server & client machine shall also

be available in the TTES

TTES shall also have bay assignment/ queuing system.LRC shall monitor the

operational status of all the bays and their loading points at the terminal. The Bay

allocation logic ( user configurable) shall ensure that no more than 3 tank trucks

are queued up for loading at a loading bay at any point of time. A maximum of 2

tank trucks can be waiting when a tank truck is already being loaded at the

loading bay.

In case of all desired bays already having one tank truck waiting in queue, the

second tank truck is allocated to that bay, which is likely to complete loading first.



66 | 3 5 9

Preferred bay allocation (User Configurable) for each product shall be available in

the TTES

Truck Preference logic (User Configurable) shall be available in the TTES

The following status information about each of the loading bays at the terminal

shall be available with the LRC.

• Number of loading bays available for filling each of the products.

• Number of loading bays declared healthy for use.

• Number of Tank Trucks already queued for each of the loading bays.

• Current status of each of the loading bays.

The Bay allocation logic shall identify compartments for filling various products

according to the following guidelines:

• Every compartment selected for filling must be completely loaded. No

compartment can be empty or partially filled.

• Sum of the capacities of all compartments selected for filling a product

must be equal to the total quantity of the product requested.

• Optimum utilization of all the healthy loading bays at the terminal. Bay

allocation logic must decide the loading bays such that the Tank truck will

be filled within the shortest possible duration with minimal movement of

Tank trucks within the licensed area.

• Bay allocation logic shall attempt to assign a single loading bay so that all

compartments of the tank truck can be filled in the same bay. In case the

combination of products is such that filling cannot be completed in a

single loading bay, then the Bay allocation logic will assign appropriate

Bays for filling the Products. To the extent possible allocation of T/T



67 | 3 5 9

requiring to be positioned at two different bays for mixed loads shall be

avoided.

• TAS Software shall have provision for both “Day Open” & “Day end”

OVERNIGHT REGISTRATION Functionality

a. Overnight Registration module shall be part of TAS application software

b. TAS System shall be time sync with ERP/IMS

c. Card Reader shall be provided in the Parking area/ security cabin.

d. Proximity Card will be issued to individual TT.

e. T/T Driver will arrive at the Parking area & show the card at the card

reader. Red and Green lamps shall be provided along with card reader. The Green lamp shall glow when the card is accepted by the

system and Red lamp will glow when the card is not accepted by the

system. The time & date will be transferred to IMS for planning purpose. Necessary interface with IMS/ERP required to be developed

at the TAS end will be in Vendor’s scope & at the IMS/ERP end will be

in the HPCL scope. Required document/ protocol will be provided by HPCL. In case the Card reader is having any problem, the same shall

be functionally bypassed. Registration of the T/T will be done

manually in the IMS in such case

f. In case the driver shows card multiple time, only first authorized one

shall be reckoned as the valid one & recorded in the database. Next swipe from the same card will be accepted only the complete cycle

i.e. the T/T is exited from the Terminal plus configurable time delay of

say 2 Hrs.

g. If the T/T is invalid like CCOE license is expired or calibration is not valid then the same will be rejected by IMS.



68 | 3 5 9

h. If because of some reason the T/T cycle is not completed, option for

manually closing the card cycle will be available with the authorized user.

i. Time out option for the Reported T/T shall be available

j. The Entry Gate barrier shall not open without showing the card at the

Parking area/ security cabin Card reader unless the same is

functionally bypassed.

k. The exit gate will open after the T/T is “loaded &

sealed”/”Sick”/”aborted”. In case the exit gate card reader is not working, the same will be functionally bypassed & in such case exit

gate time is taken as time at which the T/T becomes loaded & sealed.

l. The entry & exit card reader time & date shall also be transferred to

IMS/ERP.

m. Any SMS/e-mails to be send based on above action shall be done at the IMS/ERP end

n. Customized reports shall be generated by the System as per the format given by HPCL.

o. Location-wise TT database in the vendor’s module shall be dynamically updated from the HPCL TT database in IMS. Frequency &

access protocol of such updation will be as per HPCL advice.



69 | 3 5 9

DESIGN CRITERIA FOR HYBRID TANK FARM SYSTEM AND VALVE CONTROL

SYSTEM

• Supply, installation, testing & commissioning of Tank Farm equipment for the

New U/G Tanks

• Integration of the existing Tank Farm equipment with the new TAS/TFMS

software

• Interface of the header line Valves with the Process PLC & TAS software. The

header line Valves shall be provided with the actuator & FCU. The header line

Valve shall open at the Day open & shall close at day end or after configured

idle time. The header line valve shall also close at the day end & upon

activation of ESD.

• The TFMS software shall have complete inbuilt provisions for logics, graphics

etc. for 4 A/G Tanks (4 Product Tanks & 1 Water Tank) and 3 Nos. U/G tanks

which will be constructed by HPCL in the second phase. All Tank Farm

equipment & allied hardware will be provided by HPCL. However integration

of the same will be done by the Vendor at no extra cost during the

execution/warranty/CAMC period.

• Valve Sub-System shall have complete inbuilt provisions for logics, graphics

etc. ROSOVs, MOVs, their push buttons which HPCL will be providing in the

next phase for all existing & proposed Tanks.

• Software shall have also provision complete inbuilt provisions for logics,

graphics etc. for independent Hi-Hi level switch shall be provided by HPCL

• Tank Farm Software shall be interfaced with Loading Rack Computer System

in order to receive online/ real time information from all tanks & shall be

relayed to the ERP System at “ End of Day” operation

• The TFMS shall provide individual spot temperature as well as average

product temperature and same to be displayed on screen.

• The TAS Software & TFMS software shall be OPC compliant. Any other tool

required for establishing communication between these two software’s shall

be provided by the Vendor.



70 | 3 5 9

• Tank Farm Management Software (TFMS) shall reside in Hot Standby

configured LRCs either as a part of application software or as a separate Hot

Standby software. All data shall be available with LRC & graphics shall be

available in all clients Machine Alternatively, it may be also installed in two

different Client Machines. If the TFMS is loaded on the client machine then the

software shall be hot standby and these Tank farm machines shall be

connected to other client machines through LAN. Graphics of tank farm shall

be available on the entire client Machines. LRC shall take the data from the

Tank Farm machine designated as “Primary” until unless there is failure either

communication or hardware in which case it should take data from secondary

TFMS client Machine. All data of Tank farm shall be available with LRC & no

data shall be lost in the event of failure of any or both the Tank Farm machine.

The offered Tank Farm software shall have the required approval & meet all

the functional & technical requirements as stipulated in the respective

sections of this document.

• The TFMS data shall be available in the history for a minimum period of 1

year. Provision of Data backup & restore facility shall also be available. ERP-

TFMS interface shall be available in those machines for relaying the data to

ERP at the day end operation. All details & functionality related to tank farm

as stipulated in this document including trending shall be available.

• The tank farm management software shall take the data directly from the tank

farm and process in such a fashion that the process control overview of the

tanks are possible simultaneously from single operator interface. All Volume

calculations by the Software shall be as per latest API Standard & ASTM

tables. The following data shall be available on real time basis on all the

machines.

a) Tank no., Product, Tank capacity

b) Product level and Gross & Net quantity. Also H, HH, L, LL levels

c) Average Product temperature & spot temperature at different

levels inside the tank

d) Ambient & Standard Density of the product of the tank.



71 | 3 5 9

e) Level of water in the tank & its volume.

f) Inventory of each product.

• Separate screen shall be available for Pipeline Transfer (both receipt &

dispatch) with the following details

o Tank No.

o Safe Filling Height

o Tank Gross Volume ( Before PLT Start; in KL)

o Ullage Available ( Dynamic; in KL)

o PLT quantity ( Location to put this figure in KL; Ullage >PLT qty else

alarm)

o Tank Level ( Dynamic)

o Tank Vol ( Dynamic)

o Tank Level ( Expected at the end of PLT)

o Tank Vol (Expected at the end of PLT)

o Expected Time of PLT completion( Dynamic)

o Alert @ 90% PLT Qty ( Configurable)

o Alert @ 15 mins before Completion( Configurable)

Tank farm management system

(Functional Requirement)

• Tank farm management system shall give values of oil/ product level, water

level, all temperature spots reading, average product temperature, total

observed volume, net observed volume, water volume, density of product,

corrected volumes at 15 degree centigrade, corrected density at 15 degree

centigrade, pumpable volume of the each type of product , ullage for each

product on real time basis in data form in tank summary sheet as well as in

graphics.



72 | 3 5 9

• In case of particular tank communication is not happening the system shall

highlight the entire readings of that tank in red colour (blinking) and all

readings shall show error instead of last reading recorded by system. Similarly

in the graphics of that particular tank all data shall show error and all text shall

be in red color blinking. A footnote in all tank screen shall indicate user about

the colour and flashing . The same shall be recorded in alarm summary.

• In case of entire tank farm not communicating to the server then entire tank

summary sheet shall be in red colour with flashing display . A message shall

appear on the top of data summary screen displaying Tank farm

communication Failed. Such alarm shall also be logged under emergency

alarms and audio announced.

• In the event of any spot or all spots of temperature sensor exceeds a set

value then alarm shall be logged in indicating temperature spot number and

tank number. All entries pertaining to that tank wherein temperature is used

including temperature data shall show error in red colour blinking . The set

value shall be configurable in the tank parameters sheet.

• In the event of any density displayed is outside the normally defined ranges of

the product , then alarm shall be logged and all entries pertaining to that

density shall show error in red colour blinking instead of last healthy reading.

The set value shall be configurable in the tank parameters sheet with two

fields namely minimum density and maximum density. User shall have choice

of density units for feeding the parameters .the units in which density

(minimum and maximum) are fed in target parmeters shall be used for display

also.

Tank HI, HI HI, LO,LO LO alarms : The alarm shall be user configurable.



73 | 3 5 9

DESIGN CRITERIA FOR PRODUCT PUMP AUTOMATION

• All the TLF Pumps including Ethanol & additives shall be started & stopped by

the TAS based on the pump demand.

• Variable Frequency Drives (VFDs) with soft starters shall be provided for the

Main products pumps (Centrifugal) & Ethanol Pump (Submersible Pump) and

Star delta Starter for other submersible pumps as per the details given. No

PLC is envisaged at the VFD end. Vendor is required to put the PID loop in the

TAS PLC & all logic for the same shall be incorporate in the TAS PLC. All other

pumps (Submersible pumps) will be operated through Motor Control Center

(MCC). It shall be possible to operate the pump in standalone mode through

VFD in case of PLC failure. It shall be possible to operate the pump through

PLC in case of VFD failure directly through soft starter. The application

software shall have provision for operating the pumps with or without VFD.

• Any additional hardware required for Pump control through TAS is deemed to

be included in the scope of the Vendor.

• It shall be possible to operate the pump in standalone mode through VFD in

case of PLC failure. It shall be possible to operate the pump through PLC/Soft

starters in case of VFD failure. The application software shall have provision

for operating the pumps with or without VFD.

• All required I/Os, cables and other hardware as required for pump control

through Automation System shall be considered.

• Product pumps may be operated with various combinations as given below

o Pumps on VFD & Soft Starter

o Pumps on Star Delta Starter

o Pumps directly through Soft starter in case of VFD failure

o All the pumps shall be possible to operate in standalone mode

• All Pumps shall be operated in the following modes.

o Auto from control room

o Manual from control room

o Local from local control station (LCS)

o In addition maintenance mode shall be provided in the Automation

System. This mode can be selected only after putting the selector



74 | 3 5 9

switching OFF mode. On selecting this mode, power to the selected motor

shall not be available from the MCC. Any modification required in the MCC

shall be done by the Vendor. Once the maintenance mode is selected than

it shall not be possible to start the operation even from local till

permission is available from the system by the authorized user.

• Each pump motor shall be provided with 3 positions Selector switch for

Remote (interlock), local (De-interlock), OFF mode of operation.

• It shall be possible to stop the pump even in remote mode from the LCS

provided in the Gantry/Pump house

• Pump control shall be achieved through the PLC. Selector Switch shall be

provided at the Pump house/ MCC Room to select the pump in Remote/

Local/OFF Mode. Local mode shall be allowed only after permissive is given

from the Control room.

• The priority (Main 1, Main 2 or standby) of the pump shall be pre-defined in

the system which can be changed by the operator as & when required. It shall

not be possible to change the mode when the pumps are in operation. The

Standby pump shall be started automatically on failure of main pump. In case

of failure of all the pumps of that particular group, loading shall stop.

• Additive & Ethanol pump shall be started & stopped as based on the Pump

demand by the Batch Controller. In case both the redundant additive or

ethanol pump stops then also loading at particular point filling dosed

product or blended product shall stop

• Operations of pumps shall be interlocked with the product level in the tank &

with other logics.

• The following information shall be available at the Control Room

o Pump Status i.e. Run, Trip

o Pump fail to Start

o Pump Local/Remote/OFF

o Pump sequencing status

o Pumps run time & last reset time



75 | 3 5 9

o VFD Healthy Status.

o Pump on VFD or DOL,

• Run hour of each pump shall be recorded & shall be available in the History.

• TWD Pumps status to be taken & also TWD pumps shall stop from Control

Room, on Hi –Hi level activation & on ESD. Also the TWD Pump shall stop in

case none of the receipt Valve of that particular product is in Open status.



76 | 3 5 9

• DESIGN CRITERIA FOR FIRE WATER PUMP AUTOMATION

o Firewater pump automation shall be achieved through process PLC which will

be connected to the Safety PLC by HPCL in the next phase.

o Currently the Fire Engine Pumps are automated through Manual call points

which shall be interfaced with the New TAS software.

o Additional ESD & MCP shall be provided at the both the new Gantries,

Security cabin, Control Room & Pump House.

o The software shall have both the logic to operate the Fire Engine with drop in

pressure or on MCP activation. The pressure drop logic will be executed once

the Jockey pumps are provided by HPCL in the next phase to keep the

hydrant line pressurized. TAS software shall have complete inbuilt logic,

graphics etc. to switch over to the pressurized System logic as given below

o The Jockey Pump shall keep the fire hydrant network pressurized at

8.5 Kg/cm2. In case the pressure drop below 8.0 Kg/ Sq cm, one

jockey pump shall automatically start & build the network pressure

up to 8.5 Kg/Sq cm. Jockey pump shall not start, if any of the Fire

engine is running.

o In case the First jockey pump fail to start, second jockey pump shall

start within configurable time. Idle state pump run time will be 10

sec (configurable)

o In case the pressure drop below 7.0 Kg/ Sq cm, Main 1 Fire Engine

shall start. Jockey pump shall stop automatically whenever the Fire

Engine starts. In case, the pressure does not reach 7.0 Kg/ Sq cm on

the hydraulically farthest point with some configurable time, second

main pump shall start & so on. However, Standby pump shall start

only in the event when either of Main-1 or Main -2 does not start.

The start of Stand-by pump should not be related to the line

pressure. Discretion of Operating this standby pump shall be with

Depot manager who can start the same by putting in local mode.



77 | 3 5 9

o Pumps shall be stopped manually.

o Whenever Fire Engine is activated the following action shall take place

• All the process (Loading at Bay, Pump operation, all MOVs in sequence

etc.) shall stop immediately.

• The Power to all the Automation Equipment, except to those required

for firefighting operations, shall cutoff after time configurable delay in

case the MCP is not becoming healthy or stop feedback of all the

Pumps are available

• Power shall be tripped off except the emergency Panel.

o Resumption of process & power to these equipment shall happen only after

healthy input from the field & authorization from the system by the

authorized user.

o All Valves shall be closed in a sequence. The logic for closure of MOV shall be

finalized in the FDS

o It shall be possible to start the Fire Engine from the Control Room. However,

Stop shall not be available.

o Selector switch shall be provided for Local/Remote/Maintenance operation.

o Software shall have also have provision for Test Mode. In Test Mode, the User

shall be able to start the Fire Engine. No other operation shall get affected in

test mode. Also Loading shall not be permitted if any of the Pumps except

those in maintenance/standby mode is in Local mode

o The Start, Stop & run time of the Fire engine shall be logged in the System

o Fire zone chart shall pop up irrespective of user screen indicating blinking

MCP and arrow indicator.



78 | 3 5 9

o The System shall generate an alarm & the event shall be logged in the system

whenever the Fire Engines are put in local mode. In case all the operating

engines are put in local mode or the Water volume in the water tanks are less

than the statutory requirement, then the loading operation shall stop. This

operation can only be resumed after authorization by the User.

o Soft MCP shall also be provided in all the screens of OIC which shall be

transaction password protected.

o Apart from Fire Engine activation, Product pump shall be stopped & DCVs

shall also be closed on activation of Manual Call points.

o Resumption of Loading on the bay shall be done only after showing the

Supervisory Card



79 | 3 5 9

SHUT DOWN FEATURES:

• Apart from Fire emergency, there may be other emergency situations.

Emergency shutdown (ESD) switches are provided to counter such emergency

situations.

• Whenever ESD is activated, all actions shall be as per MCP activation except

starting of Fire Engine. All logics as per detailed ESD cause and effect (min

actions) are specified elsewhere shall be part of the Process PLC logic.

• In addition to the above hard ESD, soft ESD shall be provided in all the client

machine for activating ESD from the computer. Soft ESD shall be transaction

password protected.

• Resumption of Loading on the bay shall be done only after showing the

Supervisory Card.

• Separate Screen for ESD giving dynamic display of actions executed shall

come on all the screen instantaneously irrespective of the module user is

working on. In case any action is not completed by the system, High priority

alarm shall be raised.

• Dynamic Cause & effect screen shall be developed giving real time status.



80 | 3 5 9

DESIGN CRITERIA FOR MANAGEMENT INFORMATION SYSTEM (MIS)

All the reports shall be as per HPCL’s format & will be decided during functional

design specification. Broadly, the MIS shall capture each & every operations

carried out through automation. The reports shall be user selectable in both

detailed as well as summary format. The Scope of report shall extend from the

current data to the archived data. The report generation shall be both periodic

like End of Day (EOD), End of Month (EOM) etc. & as well as on demand like till

now, Current shift etc. The following reports shall be available as minimum.

TRUCK MONITORING REPORTS

Product Loading

Bay Loading Report

Customer wise Report

Bay wise Totalizer Report

Product wise Totaliser Report

Tank Truck Movement Report

Tank Inventory Report

Tank Reconciliation Report

Exception Reports

Manual Loading Report

Additive dosing Report- Product Wise, Bay wise, Total & its reconciliation

Ethanol blending Report & Bay wise, Total & its reconciliation

Cancelled Truck

Sick Truck

Detailed Audit

Detailed Alarm



81 | 3 5 9

Detailed Event

Operator Trail

Error Log

Tank inventory report

Tank inventory report – product wise

TRUCK MONITORING REPORTS-STATISTICS

• Truck movement reports – consolidated

• Bay Idle Report/ Daily Productivity Report

• List of trucks loaded – consolidated

• List of trucks loaded ( customer wise )- consolidated

• List of trucks loaded (preset wise)- consolidated

• List of trucks loaded (baywise)-consolidated

• List of loaded trucks (productwise)- consolidated

• List of cancelled trucks – consolidated

• List of sick trucks – consolidated

• List of cards available with planning room

• List of cards available with security staff

• List of privileged, non privileged, officer, security cards

• Card usage report which search from live records the card is with driver or

planning room or security .

• Card usage history report for particular date or months criteria and last used with

date and time stamping.

In addition the following pre formatted reports should be available on the

system



82 | 3 5 9

o Operator trail report

o Device trail report

o MOV/ROSOV Report

o Alarm duration report

o Device attribute report

o Customised report

o Changes to database – exception report

o Batch controller data comparison with LRC data- exception report

o Exception report –Consisting of changes / cancellations and manual creation of

data at the end of day

Periodic Reports

All the reports shall be as per HPCL’s format.

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

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

should provide scope for database generation & configuration with multilevel

security access into the system. All the communication between LRC and

peripheral units shall be established through secured data transfers. The

networking communication shall be selected keeping in view the number of

peripherals & instruments connected on the network and with higher thruput.

Provision shall be available to export reports to XML, PDF, HTML, Microsoft word,

Excel , ODBC database ,Microsoft mail, Microsoft exchange etc. All reports shall

show date and time stamping of the report as well as for the contents of the

report

End of day or end of month shall be with following features

• Manual nature

• Automatic nature

• Combination of Manual and Auto nature



83 | 3 5 9

Manual nature : In this the user shall be prompted to proceed with end of day at

certain preconfigured time. A pop up shall come on the screen indicating user to

perform EOD or EOM or combination of EOD ,EOM. The user shall be given

choice to perform EOD or postpone. The popup for reminder in case of

postponement shall come after every half an hour interval till the EOD or EOM

activity is completed. The EOD,EOM start time and end time shall be logged in

event screen with user id, date and time stamping.

Automatic nature : In this case if the EOD,EOM is selected for automatic nature

the system shall perform automatic EOD, EOM at the preconfigured time. This

time shall be user configurable and different from manual EOD ,EOM time. The

system shall prompt the user with necessary messages like system performing

auto EOD,EOM and other information in subline like generating TFMS file,

generating backup etc .

Manual and Automatic nature : In this case two time slots needs to be

preconfigured. The time slots shall be user configurable. First the system shall

generate pop up at the time of manual EOD,EOM time with user having option

of proceeding ahead with EOD,EOM or postponing it. In case of postponement

the reminder messages to the user shall appear on screen after every 30 minutes

till the time for auto shutdown is reached. When the time for auto EOD or EOM

is reached, the system shall prompt for the same to user .

All events pertaining to EOD,EOM or combination of EOD & EOM like start and

end of EOD,EOM, TFMS file generation start and end shall be logged in event

section with date and time stamping.

In case a user has not performed manual EOD or EOM and the system has not

been able to perform auto EOD or EOM , the EOD file shall be generated by

system automatically next day before start of any operation. After logging of the

user on next day the system shall check about previous EOD or EOM and incase

the same has not happened, the system shall display popup about EOD or EOM

not completed for previous day and start of EOD,EOM to be activated

automatically. In such cases the user shall be restricted on Index screen and no

other activity shall be allowed to be carried out by software. The TFMS file



84 | 3 5 9

generation shall pick up the last healthy readings on the previous day instead of

current readings.

Software shall have the provision that the user can view the TFMS file generated

of particular date or combination of dates in report section.

It has to be ensured that TFMS file generation for JDE is part of TAS software

and is loaded in LRC.

Following activities minimum need to be done for completion of EOD

1 Shifting all current records of TT loading and TFMS to history database

2 Shifting all current but acknowledged alarms to history database.

3 Shifting all current events , current operator actions to history database

4 Generation of TFMS file for onward transmission to JDE for operational

reconciliation.

Verifying that TFMS file is not generated on the same date earlier.

a. End of Shift operations.

At the end of each business shift (As declared by the terminal operations

personnel), a number of activities occur that allow terminal personnel to reconcile

current inventory values against the shift's activities. The system shall perform an

end of shift. All transactions that occur between each end of shift process shall

be assigned a shift number.

A number of reports shall be generated at end of shift, and trial reports shall

also be generated throughout the day, defined as activity from start-of-shift

until time of report generated. These reports are the following as minimum.

Product Loading Summary Report

Product Loading Detail Report

Bay Loading Summary Report



85 | 3 5 9

Bay Loading Detail Report

Tank Truck Movement Report

Bay Idle Report/ Daily Productivity Report

Tank Reconciliation Report

b. End of day Operations

At the end of each business day, a number of activities occur that allow terminal

personnel to reconcile current inventory values against the day's activities. The

system shall also allow the operator to start the end – of – day process, either

manually or automatically.

When the EOD is declared, the LRC system shall perform all the activities as

intended for EOD and store the product inventory data in its memory and it shall

be transmitted to ERP, as and when it is demanded from ERP system.

The TFMS file generation for onward transmission to ERP shall be part of end of

day event .When EOD ( either auto or manual) is performed the system shall

show a popup indicating TFMS file generation to the user.

c. Day Start Operations

At every Day Start , the System should fetch the current totalizer & shall compare

it with previous Day end totalizer reading. In case of any discrepance, alarm shall

be raised & the further process can be continued only after authorization from

the designated person

Similarly the System should also check the Gross level of all the product tanks &

if the variation is more than the configurable limits then alarm shall be raised &

the further process can be continued only after authorization from the

designated person



86 | 3 5 9

d. End of Month Operations

End of Month processing shall be similar to End-of Day processing, except for

several key aspects such as:

Month End is normally at midnight through user excersiable option on the

last day of the Month

End of month could happen at a different time of day than normal End of Day

processing if chosen by the authorised operator.

Pop up alarm indicating Month end

Operator shall have the option of postponing EOM report

Reports pertaining to ADDITIVE,ETHANOLs:

i. ADDITIVE,ETHANOL quantity cumulative loaded in day or through defined period

in number of days.

ii. ADDITIVE,ETHANOL quantity loaded in each loading point day wise , time wise or

combination of these

iii. ADDITIVE,ETHANOL quantity loaded truck wise along with FAN no ,date, time

stamping

iv. ADDITIVE,ETHANOL quantity loaded customer wise along with truck no, filling

advice note (FAN), date and time stamping.

v. Exception report with detail as truck number, date , time, loading point number,

ADDITIVE,ETHANOL quantity under dose or over dose



87 | 3 5 9

vi. Incase truck is over dosed or under dosed and the truck is allowed to leave depot

premises , report showing user id of person authorized to release such loads

along with date and time stamping. Incase truck is under dosed or overdosed

with ADDITIVE,ETHANOL quantity , the Batch controller shall stop the loading at

that particular point displaying ADDITIVE,ETHANOL underdose or Overdose at

loading point level and at control room TAS software. Alarm also to be

generated in software with truck no and loadin point no stating

ADDITIVE,ETHANOL underdose or overdose. The truck shall be resumed to fill

with balance quantity if supervisior card is shown at gantry or if TAS user allows

through software to resume loading. Facility to resume loading along with

password protection to be provided in software. Software shall logged in card

details and user id with date and time stamping for such event.

vii. Pump fail to start report

viii. Pump trip report

ix. ADDITIVE,ETHANOL meter factor report. The same should be generated after

reading meter factor stored in batch controller.

x. ADDITIVE,ETHANOL meter factor change report. This report shall indicate

previous meter factor for all points and current meter factor for all points,

changed by (user id of user), date and time stamping when factors were

changed.

xi. PPM change report: The report shall indicate the old PPM of the

ADDITIVE,ETHANOL which was doped in main product and the revised PPM

after change. The report shall also show the user id along with date and time

stamping, which has changed the PPM of ADDITIVE,ETHANOL in software.



88 | 3 5 9

ALARMS AND EVENTS MANAGEMENT

An alarm of event needs to be recorded and possibly acknowledged. The

characteristics of alarms and events are as follows:

- Alarms / Events shall be generated by any system task

- Alarms / Events shall be signified within the system by a condition code, which

consist of the following components.

- FACILITY, which represents the system component which detected the alarm

condition and generated the alarm message.

- SEVERITY, which represents the relative importance of the alarms with

respect to other alarms in the system

- IDENTIFICATION, which represents the symbolic name used internally by the

system tasks to refer to alarm condition.

- TEXT, which represents the message text which is to be output when the

alarm condition occurs.

When alarms are annunciated, the above components provide additional

information about the circumstances surrounding the alarm condition.

Alarms / Events may be automatically refreshed periodically for as long as the

alarm condition persists.

Alarms / Events may be either a single stage alarm, where the alarm condition

can reset automatically, or a dual-stage alarm, where an operator shall

acknowledge the alarm condition before the alarm condition can be reset.

The logging of alarms, events and summary of all details shall be obtained with

out disturbing scanning sequences.



89 | 3 5 9

Alarms screen needs to be separately provided in the TAS software. System

alarms shall be put in separate screen which shall be named as System Alarm

screen. Apart from system alarms all alarms originated shall be logged in Alarms

screen. All the alarms unless and until they are acknowledged shall scroll in the

scroll bar provided in bottom of all screens. Alarms to be classified minimum in 3

stages with respect to priority viz.

Emergency alarms

High priority alarms

Low priority alarms

All emergency alarms shall be with audio facility. The speaker for audio facility

shall be installed inside the control room and one speaker inside the admin

building. The speakers shall be box type speakers with weatherproof protection.

The audio alarm shall have volume control and minimum 20 db shall be there

even if the volume of the speaker has been kept at minimum. The amplifier unit

of the same shall be kept at control room. The required cabling of speaker or any

other part from control room to administrative building is in vendor scope. All

the alarms shall be configurable ie depending upon the site requirements the

alarm shall be configured as emergency alarm, high priority alarm or low priority

alarm.

Following alarms shall be defined in emergency alarms category as minimum:

Failure of TFMS communication to control room.

Failure of one LRC/TAS server

Failure of one entire Ethernet network

Failure of one CPU of PLC

Failure of both CPU of PLC



90 | 3 5 9

Failure of any one or all hard disk of servers

Failure of one gateway or both gateway

Stopping of service of TAS vendor or HPCL service in gateway server in the active

gateway server

Entire failure of I/O rack

Failure of one or both terminal server communication.

Failure of one channel of all batch controllers.

Tank leakage alarm

Tank HI HI alarm for all or individual tank.

Incase of emergency alarms as mentioned above( minimum) , the audio system

shall announce the fault/ alarm name in both the speakers simultaneously for

example Server failure alarm shall be announced in English language as Server

failure.

The list indicated above is minimum and can be increased during FAT, FDS,

project execution, SAT, warranty, AMC.

All alarms description shall not be in coded form and the alarm should be easily

understandable by any of the operating staff of depot. Alarm screen shall specify

for each alarm the area for which alarm is generated and the source from where

alrm is generated .

Once the alarm is acknowledged by any user the same shall be logged in system

with user id, date and time stamping.

Alarms irrespective of the category of the alarm shall follow the following colour

coding scheme of the text of alarm

Red - Alarm generated, not acknowledged, site condition not clear.



91 | 3 5 9

Blue - Alarm acknowledged by TAS user however condition at field level is

not clear.

Yellow - Alarm which was generated earlier , condition at field level is now

clear however the alarm is not acknowledged by TAS user.

Green - Alarms generated, Condition at site is clear and acknowledged by

TAS user.

Alarm screen shall have minimum following columns to clarify the end user about

the condition of alarms

Date

Time

Category of alarm

Description of alarm

Area

Source

Trip value

Present value

Any alarm will turn from Red colour to Yellow colour ( or colour change to depict

change in field condition ) based on the present value the system has received

for that tag.

Area column shall indicate the area like TT gantry, Tank no XXX , Gantry bay no

XXX etc.

Source column shall indicate LRC server 1, PLC etc

A help file containing the detailed description of each alarm , various options

possible for trouble shooting of that alarm shall be part of TAS software in tab

HELP and sub tab Alarms help file. Such file shall contain separate portions for

Alarms and System alarms. The file shall provide user facility to search either full



92 | 3 5 9

or part of the string of alarm description and display the relevant pages. The file

shall be in pdf format. Adobe reader for the same to be provided in the system

for all machines. System shall permit TAS user to take a print out of the file ,if

required by depot operating personnel for their future use.

A report shall be provided to produce a summary of all events of a specified type

occurring in a period.

Operator trial report

A report shall be provided to produce a summary of all operator actions relating

to a specific operator in a specific period.

Device Trail report

A report shall be provided to produce a summary of all events of a specified type

occurring in a period on nominating devices.

Device attribute report

A report shall be provided to devices selected by one of the attribute criteria

• Out of services

• Alarm suppressed

• In manual mode

Customised reports

In addition , configurable report generation facilities using standard report

generator such as crystal report must be provided to allow custom reports to be

produced.they shall be able to be configured at any time with the system online.

These reports shall be able to access any data base values and have the facility

for carrying out calculations in order to produce averages, summations,

efficiencies or any other derived values.

EVENT MANAGEMENT: All events like card shown at gate barrier, gate barrier

opened and closed for TT no TT driver acknowledgement at gantry by RIT,

proximity card shown at gantry, RIT stop, ESD, pump start, pump trip, pump stop,

tank truck compartment starting and ending etc shall be logged in events. A

separate tab in Index screen shall guide the user to events screen. The event

screen shall record all the events happening inside the terminal on real time basis

with time and date stamping. Facility to search part or full string of the



93 | 3 5 9

description shall be made available in the screen. The screen shall be auto

refreshed . The data pertaining to previous day or history shall be recorded and

stored in history. At any stage it shall be possible to search previous events from

history record. The screen shall provide user facility to search events with From

To date concept.

The system events and actions can be clubbed together in separate screen

termed as System events and actions. This screen shall capture all such events

and actions with date and time stamping which has been performed by system.

The screen shall provide user facility for search as defined for events apart from

system generated events.

Events shall be separated from operator actions . A seprate screen of operator

action shall be provided in software. Such screen shall capture online real time

basis the actions performed by various TAS users. All the operator actions shall

be logged in system with user ID, date and time stamping along with the

description of action performed. The example of such operator actions include

issue of FAN slip and proximity card , change of tank mode, end of day etc.

Facility to search part or full string of the description shall be made available in

the screen. The screen shall be auto refreshed . The data pertaining to previous

day or history shall be recorded and stored in history. At any stage it shall be

possible to search previous events from history record. The screen shall provide

user facility to search operator actions with From To date concept.

Configuration of these reports should only require entry of the schedule

information and other parameters such as Device name/ Tag, filter information,

Time interval for search ,and destination printers to fully configure the report.

Specifically no programming , scripting shall be required.



94 | 3 5 9

DESIGN CRITERIA FOR TERMINAL AUTOMATION SYSTEM (TAS)

INTERFACING WITH JDE (ERP) SERVER

The JDE machine shall interface with TAS server or LRC / TAS SERVERS (Loading

Rack Computer) to transfer the data files between them using the interface

programs provided by the TAS vendor developed using the protocol details given

by HPCL. The objective for interfacing the JDE machine with LRC / TAS SERVERS is

to transfer the necessary data between these two systems to avoid the re-

entering of data so as to ensure the consistency of the data in both the systems.

The interfacing between LRC / TAS SERVERS and JDE machine will be based on

the following:

JDE machine will be initiating requests with files as parameters through programs

of TDM to get the necessary data from LRC / TAS SERVERS. The reply files from

LRC / TAS SERVERS will be written onto the JDE Server system in pre-designed

formats under specified directories.

The JDE machine and LRC / TAS SERVERS will be connected through Ethernet

with TCP/IP suite loaded on both the servers.

All the programs required for various pre-defined data requests will be

developed by the suppliers of automation software and hardware and all the

source programs will be made available on JDE machine and LRC / TAS SERVERS.

The details of protocol for interface with the JDE machine shall be given to the

successful bidder during detailed engineering stage.



95 | 3 5 9

Typical scheme is given above

The following points should be noted for effective implementation of TAS and

interfacing with JDE:

• LRC software should have the facility to maintain the IP addresses of the

Gateway Server in *.ini files. The daemon program should read the IP

addresses from the *.ini file and communicate with servers through TCP/IP.

It should be possible for HPCL to carry out the changes in the IP addresses

of the Gateway servers / LRC Servers and other machines in the network

depending on the business requirements.



96 | 3 5 9

• There should be a provision in the LRC software to add/modify/delete

brands by HPCL. This is required since new brands are being introduced in

the market. A front end application through which the location personnel

can enter the new brands or update / modify the existing brands shall be

available. The changes to the brand master shall be reflected in the LRC

software including the MIS reports (Color changes, bay changes etc.) The

brand master could be maintained in a table or in a product.dat file.

• There shall be facility to change the product on the given bay without

actually having to restart the LRC server / software on LRC server. e.g.

HPCL location would like to use bay no. 1 for Power in the morning. After

3 hours location would like to change the bay to MS. Location should be

able to do so without having to restart the LRC server / software on the

LRC server.

• In case of any problem with the batch controller only that specific bay shall

be affected and the same should not be affect the other bays.

• In case of any problem with the LRC system and for some reason it is

required to restart the LRC server, data pertaining to all the trucks which

are under filling or waiting to be filled must be retained in the LRC server.

Especially the partly filled trucks information about the product and

quantity filled should be retained in the LRC and after restarting the filling

should start from that particular point.

• In case LRC is restarted the cards which are issued should not be

invalidated for the entire day. It shall be possible to re use the same cards

during the day.

• There shall be provision to store the Product Wise, Date Wise, Time Wise

15 degree Density and Temperature in LRC as per relevant ASTM table. In

case the Density meter / Temperature meters are not working location can

keep on entering the Density and Temperature product wise and same

should be sent to JDE through the post load packet.



97 | 3 5 9

• The post load packet should have a facility to send 10 digit alpha numeric

seals / abloy lock information.

• The Pre load and the post load packets formats should comply to the

Interface document of HPCL (See below – Terminal Automation Protocol

Between JDE and LRC).

• The post load data packet should be downloaded to the Gateway server

without waiting for any request from JDE.

• JDE will communicate with the LRC system through a Windows Gateway

Server through TCP/IP. The Windows Gateway Server should have

Windows 2008 OS.

• Vendor shall develop a daemon program which will be polling the

directories as defined by HPCL. Also there shall be a provision to add or

delete the directories to be polled. The directories to be polled by the

daemon shall be kept in *.ini file. A log / report shall be maintained about

the activities done by the daemon program. The daemon program should

not require a change / modification in case any new brands are added or

deleted by HPCL. Daemon program shall be installed as a service and

started automatically once the Gateway server is booted.

• FAN Slip shall be printed through the LRC system on a pre printed

stationary or plain stationary. Option shall be provided to the location and

depending on the selection appropriate printing program should be used

for printing the FAN Slip.

• LRC 1 and LRC 2 shall work in hot standby mode incase of failure of any

one machine the other should take up the activities.

• The vendor should provide standard configuration of the LRC Servers , OIC

terminals, printers for printing the FAN Slips and printing of MIS reports



98 | 3 5 9

• Standard MIS reports should be provided by the vendor. The formats shall

be finalized and given by HPCL E & P department in consultation with the

Terminal.

• The vendor shall provide a proper documentation of all the software. It is

the responsibility of the vendor to provide an environment for compiling

his daemon program if required.

TERMINAL AUTOMATION PROTOCOL BETWEEN JDE AND LRC

HPCL has implemented J.D.Edwards (ERP) Software at all the locations all over

India. J.D.Edwards operates on a Centralized Architecture.

The JDE Software Communicates with the LRC through the Gateway Server using

the JDE Daemon / Polling program. The JDE Software creates various request

files under different directories with same name as FAN Slip Number. The LRC

Daemon / Polling program on the Gateway Server should constantly scan the set

of Directories.

JDE communicates with the Gateway server through the set of JDE daemon

programs. The JDE daemon programs are responsible for polling files from the

Batch Server to the Gateway server. The Gateway server is a Windows 2008

Server and is located in the respective location. The LRC Daemon / Polling

program is supposed to constantly scan the required directories and pick up the

flat files from the respective directories and put the acknowledgement files in

appropriate directories on the Gateway Server.

If the LRC Daemon / Polling program finds any request file in one of the

directories on the gateway server it collects the data from these and sends it

across to LRC. LRC on receiving this information should register the data sent by

the LRC Daemon / Polling program and send a reply to the JDE server through

Daemon program.

The Interfacing program on receiving the reply for the request sent, creates a

reply file in the respective directories with the file name same as FAN Slip

Number.

The JDE daemon programs after making the request will be waiting for the reply

to arrive from the LRC by scanning the respective directories. When the reply file

is created in the respective directory by the Interfacing program, the JDE daemon



99 | 3 5 9

programs collects the data from these files.

The LRC Daemon / Polling Program should be constantly scanning the different

directories on the Gateway Server for request files to be sent LRC or received

from LRC.

LRC Daemon Program should continuously check the health of the

communication link between the Gateway Server and LRC Server.

The LRC Daemon / Polling programs for picking up files from the Gateway server

to LRC and receiving files on the Gateway server from LRC is required to be

developed by the vendor.

The Directories used for Communication between JDE and LRC are as given

below :

authorise : To Store files for Trucks that are Authorised by JDE. This

files will be created by JDE and Deleted by the

COMMUNICATION Program

authstatus : To Store files to Indicate authorisation status of a

Truck to JDE.

These files will be created by the communication

program

loadover : To Store files for trucks for which loading is over

These files will be created by the Communication

Program and deleted by JDE Daemon Program

cancelloading

To Store files for trucks for which loading is to be

Cancelled.

These files will be created by JDE and deleted by

Communication Program

cancelstatus To Store files to Indicate cancellation status of a

Truck to JDE.

These files will be created by communication program

And deleted by JDE.

Loadstatus To Store the Loading Status of a Truck



100 | 3 5 9

1). Authorise Trucks (c:\jde\authorise)

When the truck is to be filled, the truck driver is asked to report to the

Marketing Terminal. The Data pertaining to the Customer, Destination,

Truck has to be entered in to the JDE . This data is commercially verified by

JDE and then downloaded to the LRC through the Interfacing

/Communication Program.

Every Truck that is entering in the terminal for filling will be given an

Unique FAN Slip Number, with which the truck will be identified

throughout the system. This FAN No. will be generated by JDE.

The JDE Software after validating the data creates a request data file in the

c:\jde\authorise directory with the file name similar to the FAN Slip

Number.

The Authorization request file contains the following data in the ASCII Text

format.

S.no. Data Item Length

Type



101 | 3 5 9

1. FAN Slip Number 06 Numeric

2. Authorisation Date (DD/MM/YYYY)

10 Character

3. Truck Registration Number 14 Character

4. Oil Company 04 Character

5. No.of Compartments 01 Numeric

6. Capacity of Compartments

(To be Specified for Each

Compartment)

06 Numeric

7. Calibration Expiry

Date(DD/MM/YYYY)

10 Character

8. Method of Delivery (Via Code) 03 Character

9. Remarks(First Three Digits will be

TT Code)

50 Character

10. No.of Customers 01 Numeric

11. Location Code 04 Character

12. Location Description 30 Character

13. Contractor Code 05 Character

14. Contractor Description 30 Character

15. Customer Code 06 Character

16. Customer Description 30 Character

17. Destination Code 06 Character

18. Destination Description 30 Character

19. No. Of Products 01 Numeric

20. Product Quantity 06 Numeric

21. Product Code 08 Numeric

22. Product Description 30 Character

Note 1 : Item No. 11 to 19 referred above are to be repeated for Each Customer

Note 2: Item No. 20 to 22 referred above are to be repeated for each product

Note 3: Please refer Annexure 1-A for Data Sample for c:\jde\authorise directory



102 | 3 5 9

The Communication/Protocol program should continuously scan various

directories for request files to be sent to LRC. Once a file is found in the directory

c:\jde\authorise it should read the file and send the request to the LRC.

LRC after receiving the information should register the Truck and send a reply to

the Communication program which keeps waiting for the reply to be received

from LRC.

When the reply is received from LRC, the Communication program should create

a reply file in the directory c:\jde\authstatus. After the creation of the reply file in

the c:\jde\authstatus directory the request file should be deleted from

c:\jde\authorise directory by the communication program. The reply file will be

created with the same name as request file name which would contain one

character code for the JDE Package. The file will be deleted by the JDE program

after getting this information.

C:\jde\authstatus

Response :

1) Authorisation Successful.

2) No Product requested

3) Compartment Allocation Failed

4) Fan Slip Number is Duplicated

9) LRC communication Failed.

Value 1 indicates successful authorisation of a truck. Values 2,3,4,9 indicates

errors.

A Sample File Format is given below :

Sample File (File Name - 1 in Authstatus Directory)

1: Truck Authorisation Status indicating Successful Authorisation

3) Truck Loading Completed (c:\jde\loadover)



103 | 3 5 9

Loadover directory is used to store files for trucks for which loading is completed.

Communication program continuously communicates with the LRC to find out

the latest loading status for all the authorised trucks. After the loading is over and

seal numbers allotted, the LRC should indicate that loading of a truck is over by

putting in the status file in the c:\jde\loadstatus directory and the data file in

c:\jde\loadover directory. Then the LRC communication program collects all the

loading information for that truck from LRC and creates a data file in the

c:\jde\loadover directory.

The JDE daemon program will pick up the information for the respective FAN

numbers from the loadover directory. The LRC communication program should

keep the information of all the trucks which are loaded in c:\jde\loadover

directory automatically.

The file in the c:\jde\loadover should contain the following data in the ASCII Text

format. This file is to be created by LRC.

Sr.No. Data Item Length Type

1. FAN Number 06 Numeric

2. No.of Compartments 01 Numeric

3. Time of Filling (HH:MM:SS) 08 Character

4. Product Code 08 Character

5. Volume filled 06 Numeric

6. Volume at 15 Degree

Centigrade

06 Numeric

7. Product Density 06 Float (9.9999)

8.

Product Density at 15 Deg.

Centigrade

06 Float (9.9999)

9. Temperature 05 Float (99.99)

10. Top Seal Number (or Abloy

Lock no.)

10 AlphaNumeric

11. Bottom Seal Number(or Abloy

Lock no.)

10 Alpha Numeric

Note 1 : Item No. 4 to 11 should be repeated for Each Compartment



104 | 3 5 9

Note 2 : Please Annexure – I-B for Sample Data file c:\jde\loadover

directory

4) Cancel Truck Loading

After the truck is authorised, some times the truck will have to be

cancelled due to some reasons.

This operation is carried out by JDE by creating the cancel request file in

the directory c:\jde\cancelloading. The name of the request file itself tells

the Truck corresponding to the FAN number is to be cancelled.

The truck can be cancelled by the JDE operator only when the truck has

not started filling.

The LRC communication program while scanning the directories finds this

request in the cancel directory, then it should send the data to the LRC.

The LRC after verifying the Truck status cancels the Truck if it is not already

taken up for loading and then it should send reply to the communication

program.

The LRC communication program collects this information from LRC and

creates a reply file for the JDE in the Directory c:\jde\cancelstatus.

Response

1) Truck Cancellation Successful

2) FAN details not found

3) Truck Under Loading

4) Truck Already cancelled by LRC

9) Communication Failure between LRC and Gateway Server

Value 1 Indicates successful cancellation of a truck.

Note : There should be a provision to cancel a truck from LRC after loading

is taken up and before completion of loading.



105 | 3 5 9

Annexure I-A

Sample Data format for a Truck going to 3 customers (c:\jde\authorise)

Fan No. 000001

Authorisation Date 12/01/2004

Truck No. GJ/06/A/5340

Oil Company HPCL

No. of Compartments 3

Capacity of Compartment 1 004000



Calibration Exp. Date 05/10/2005

Method of Delivery (Via Code) 003

Remarks (First 3 digit TT Code) 052

No. of Customers 3

Location Code 0446

Location Description LONI TERMINAL

Contractor Code 06621

Contractor Description BHATIA TRANSPORT SERVICE

Customer Code 117804

Customer Description AECS CAR CARE CENTRE

Destination Code XXXXXX

Destination Description PUNE

No. of Products 1

Product Quantity 004000



106 | 3 5 9

Product Code 09500006

Product Description H S D

Location Code 0446





Customer Description AMBICA PETROL DEPOT


Destination Description POONA

No. of Products 1



Product Description M S

Location Code 0446





Customer Description AMRAPALI SERVICE STATION

Annexure 1-A ..........Contd


Destination Description PUNE

No. of Products 1



Product Description H S D

Note : Via Code = ‘001’ Indicates Company Truck

Annexure I-B

Sample Data format for c:\jde\loadover file

000001 FAN No.

3 No.of Compartments



107 | 3 5 9

08:45:30 Time of Filling

09560006 004000 003980 0.8950 0.8970 28.50 0010211111

0010221111 Comp. 1

09500006 004000 003975 0.8950 0.8970 27.50 0010231111

0010241111 Comp. 2

09500006 004000 003960 0.8500 0.8550 30.00 0010251111

0010261111 Comp. 3

Details of Compartments Product Code, Volume Filled, Volume at 15 Degree,

Product Density, Product Density at 15 Degree, Temperature, Top Seal No. and

Bottom Seal No.

Note:

1) The spaces in the post load packet sample data to improve

readability and not a part of the actual post load packet.

2) The directory c:\jde\authorise is only indicative. The C: or D: should

be configurable and not hard coded in the daemon programs.

Directories should be configurable



108 | 3 5 9

JDE-TFMS INTERFACE

In TAS locations, bulk tank readings like Gross dip, water dip, temperature &

density are automated & displayed thru TFMS workstation/ OIC. As part of the

JDE TAS interface the readings will be recorded by the automation system &

downloaded in the predesigned format as shown, in text file in a designated

directory – c:\jde\tfms (configurable) in the Gateway server. The file will be

created once a day only either at day-end i.e. when the operations at the

locations are over or predefined time (configurable).

The format for the data will be

Field Name

Data Type

Description

Item

Size Decimal Remarks Remarks1

Business Unit String 5

Tank ID String 8

Date Date 10 DD/MM/YYYY

Time Numeric 6

24hour format

HHMMSS

Description String 30

Tank Capacity Numeric 15

Unit of Measure String 2 LT

Item Number Numeric 8

JDE Item

Number

Product Level Numeric 7 2 in CMs 99999.99

Product Gross

Quantity Numeric 15 3 in Litres

Product Net Quantity Numeric 15 3 in Litres

Average Temperature Numeric 6 2

Degree

Centigrade 999.99

Density @ 15 Numeric 6 4 9.9999

Water Level Numeric 15 2 in CMs 999.99

Water Volume Numeric 10 3 in Litres

Tank Alarms Numeric 3

Tank Mode Indicator Character 1

R- Receipt / D -

Dispatch / I -

Idle

Tank Status Character 1

Active / Inactive

/ Repair

Following points should be noted

1. Fields are delimited by a “|” character



109 | 3 5 9

2. Should use ASTM 54B Table Only

3. Density field should be in format 9.9999. Density should be @ 15

4. The Business Unit should have JDE location code (Size 5)

5. Tank IDs should match the tank IDs of the JDE system. Details of the tank

IDs should be taken from Location In-charge & they should correspond to

IDs in JDE system.

6. Quantities should be in Litres.

7. Tank Alarm has to be 1/2/3/4 ( 1 - L, 2 - LL, 3 - H, 4 - HH)

8. Tank Mode Indicator has to be R/D/I ( R - Receipt, D - Dispatch, I - Idle)

9. Tank Status has to be A/I/R ( A - Active, I - Inactive, R - Repair)

10. Any value not available should have blank or 0 if numeric as default. Null

values i.e. two consecutive "|" should not be there

11. Each tank details would come as separate line as per the fields in the

above table. A location having 15 bulk tanks will have 15 lines &

information will be coming as per the details above in the table separated

by “|”

12. The name of the file would LLLLL_DDMMYYYY_HHMMSS.TXT

Where

LLLLL – is the location code

DDMMYYYY – Date Month & Year

HHMMSS – Hours Minutes & Seconds

A sample file data would be as shown below – 11457|TK1|10/06/2009|070826|FR-

HEXANE|516470.856|LT|09280006|00456.90|485620.00|0.000|35.20||003.60|4971.00|000|I|A

11457|TK2|10/06/2009|070826|FR-

MS|848086|LT|13220006|00753.10|817307.00|797602.000|34.40|0.7366|008.60|7466.00|000|I|A

11457|TK3|10/06/2009|070826|Tank for SKO|590|LT|09330006|00000.00|-01881.00|-

1872.000|20.00|0.7908|004.20|2471.00|001|I|A

11457|TK11|10/06/2009|070826|FR-

HEXANE|236607.302|LT|09280006|00306.30|212238.00|0.000|34.60||014.00|7292.00|000|I|A

11457|TK14|10/06/2009|070826|FR-

MS|84415|LT|13220006|00147.10|62081.00|60568.000|33.90|0.7189|010.20|6922.00|000|I|A

11457|TK20|10/06/2009|070827|Tank for

FO|56806|LT|09800006|00085.60|54042.00|53319.000|34.20|0.9763|000.00|2780.00|000|I|A



110 | 3 5 9

Automation system shall record Totalizer/Meter readings located at the loading

points. As part of the JDE TAS interface these readings will be recorded by the

automation system & downloaded in the predesigned format as shown, in text

file in a designated directory – c:\jde\meter (configurable) in the Gateway server.

The file will be created once a day only either at day-end i.e. when the operations

at the locations are over or predefined time (configurable).

Vendor needs to provide Day Open and Day End button in software . At the time

of day start, user shall be prompted to start day. User can click from any of the

machines, and once the same is clicked Day start event shall be acknowledged by

TAS with tagging as Day Start time, User ID, date and time stamping. At the same

time system shall capture all totalizer readings and TFMS reading for all the tanks.

Day Start event shall be checked by event of previous Day End. In case previous

day event has not been done the system shall prompt for previous day end first.

Once previous day closing event is completed, then only new day event can be

done. During day end event system shall send totalizer file and TFMS readings to

JDE as per protocol along with separate file for tank valve, data sent to JDE

through reports, Day end shall be provided with auto and manual option. Day

end and Day start shall be done once and same shall be password protected.

Data Description

Data

Type

Data

Size Format

Business Unit String 5

Meter Number String 10

Description String 30

Serial No. String 25

TAS Item Number String 8

Meter Status Character 1 A/N

UOM String 2 KG/LT

Closing Meter Reading Numeric 15

Date - New Closing Reading Date 8 DD/MM/YYYY

Time - Reading Numeric 6 HHMMSS

Following points should be noted

1. Fields are delimited by a “|” character

2. The Business Unit should have JDE location code (Size 5)



111 | 3 5 9

3. The name of the file would LLLLL_DDMMYYYY_MR.TXT

Where

LLLLL – is the location code

DDMMYYYY – Date Month & Year

TT – String to be appended to show TT performance

A sample file data would be as shown below –

11397|BC-01B| METER FOR BS-III HSD|1|16830006| A|LT|78514892|01/10/2010|230005



112 | 3 5 9

DOCUMENTATION

LEGEND: I – Information , A- Approval F – Final delivery of equipment,

SN

Description For

Information/

Approval

Final Docu -

mentation 4

Prints

1.0 GENERAL

1.1 Vendor engineering and service

personnel organization chart including

set up for this project.

I

1.2 Training facilities at work I

1.3 Descriptive catalogue / literature I

1.4 System architecture A

1.5 Functional Design Specification A F

1.6 Procedure for dismantling existing

instruments, equipments, cabling,

structure etc. wherever applicable

A

1.7 Operational Philosophy A

1.8 Progress report (Fortnightly) I

1.9 Safety Report ( Fortnightly)

1.10 Document Control Sheet (Fortnightly) I

1.11 Payment Control Sheet (Monthly) I

2.0 ENGINEERING DOCUMENTS

2.1 System Architecture A F

2.2 Detailed list of component A F

2.3 Individual data sheet A F

2.4 Power Requirement – KVA A F

2.5 Heat dissipation – Kcal /H I F

2.6 Individual G.A.Drawing

a) Flow metering system

b) Densitometer, PT

c) VFD & Soft Starter

A F

2.7 SYSTEM CABINETS

a. Arrangement of modules I F

b. Structure, dimension, construction, etc. I F



113 | 3 5 9

2.8 AUXILIARY CABINETS

a. Arrangement of modules A F

b. Structure, dimension, construction etc. I F

2.9 Power supply distribution diagram A F

2.10 Cable layout A

2.11 System drawing (loop

diagrams,reports)

A F

2.12 Wiring diagram A F

2.13 Terminal strip diagram A F

2.14 Hardware Design Module

2.15 Software Design Manual

2.16 Interlocking scheme

2.17 Control Room layout

2.18 Graphics/ MMI A

2.19 MIS Formats A

2.20 Interconnection diagram I F

2.21 Earthing System A F

2.22 Diagnostic software details I F

2.23 Instrumentation Diagram

2.24 As built drawing F

2.25 VFD SLD & configuration A F

2.26 Control Scheme of Feeders A F

3.0 CERTIFICATES

3.1 Authority approval for

Ex-Proof, IS, Weather Proof ( shall also

be submitted along with Data sheets

for approval)

F

3.2 Vendor’s guarantee /warranty F

3.3 Original Software Licenses F

3.4 Certification of Installation for

Metering system & Densitometer

I

4.0 INSPECTION AND TEST

4.1 Inspection and test report from

Vendor’s quality control department

F

4.2 Imported shipping documents along F



114 | 3 5 9

with test certificate

4.3 Factory acceptance tests procedure for

system

A

4.4 Factory acceptance tests procedure for

Batch accuracy tests

A

4.5 Site Acceptance Test procedure A

4.6 Pre-Power Up Report A

4.7 Pre-commissioning Test & procedure A

5.0 MANUALS (BOTH FOR VENDOR’S &

SUB –VENDORS SUPPLY)

5.1 Vendor’s & Sub-vendor’s test

Procedure

F

5.2 Installation manual F

5.3 Operating manual for hardware &

Software

F

5.4 Maintenance manual for hardware &

software

F

5.5 Software configuration manual F

5.6 HOTO Report covering all the details of

the Project( to be submitted in both hard

form & CD)

A F

6.0 ELECTRONIC DOCUMENTATION F

6.1 System configuration, softwares in CD I F

7.0 QULAITY ASSURANCE PLAN A F

NOTE :

a. The above documents cover the minimum requirements and shall be

supplemented with other requirements listed in the specification, if any.

Any other documents required to understand and maintain the system,

as felt necessary till handing over of the project, shall be supplied by the

vendor.

b. All documents shall be supplied in English language as per following.

- Approval/ Information - 2 sets

- Final -4 sets

c. DVD – 2 sets (soft copy)

d. One set of final detailed termination wiring interconnection diagram

shall be kept inside each cabinet and equipment.



115 | 3 5 9

e. Name and address of subsystem vendors with name and telephone no.

of contact persons.

f. As built drawings shall be laminated and properly bound with index

sheet for preservation and future reference.

g. All drawing which are submitted for approval, shall be submitted on

DVD as a final document (after approval) along with HOTO Report



116 | 3 5 9

TECHNICAL SPECIFICATION

TECHNICAL SPECIFICATIONS SUPPLY OF NEW INSTRUMENTS/EQUIPMENT

Technical Specifications/ information given in this section serve as the minimum

guidelines to the Bidder. The bidders are requested to visit the location, study its

requirement, design the most suitable system and shall quote accordingly.

The equipment shall be reliable and field proven, High-grade components of

proven quality having high MTBF (at least 10 years minimum) shall be selected to

achieve the desired functions.



117 | 3 5 9

TECHNICAL REQUIREMENT & SPECIFICATION FOR TANK TRUCK GANTRY

AUTOMATION:

Tank Truck Gantry Automation shall include but not limited to the following

o The Vendor shall design the flow metering system to suit different set of

process flow condition (Flow, temperature, pressure etc.) such that the

combined accuracy of the flow metering system after site calibration of the

equipment shall be +/-0.05% of the Batch. The metering system shall be

checked with reference to the new W&M stamped Mobile Prover Tank of

capacity 2 KL

o Electronic Metering System for primary product (MS, HSD, SKO) shall

comprise of Batch Controller, Positive Displacement meter, Digital Control

Valve, Strainer cum Air Eliminator shall be provided. The Batch Controller

will control one Loading point & its Blending and dosing operation.

o Blending System comprising of Positive Displacement meter, Digital

Control Valve, Strainer cum Air Eliminator for blending the Secondary

Product like ethanol in the Primary Product. Rate of blending shall be User

configurable. The current rate of blending is 5% which may go up to 20%.

The System design shall cater to blending of maximum 20%

o RTD shall be provided at each loading point & its input shall be taken in

the Batch Controller.

o Remote Interaction Terminal for operation by Tank Truck Crew member.

o Earthing Relay shall be provided for each Loading point.

o The Additive blocks functional in the existing Gantry shall be dismantled,

and reinstalled & commission in the New Gantry at the designated points.

All SS piping, tubing’s etc required for the purpose shall be in Vendor’s

scope. W&M Stamping and CAMC of Additive System, being free issue

item, is excluded from Vendor’s scope



118 | 3 5 9

o Calibration & Weights & Measure (W&M) Stamping: The New SS Mobile

Prover Tank shall be calibrated w.r.t depot calibration shed & stamped by

Weights & Measure (W&M) Department. The Calibrated & W&M stamped

Mobile prover tank shall be used for calibrating the new Flow metering

system as per the Calibration procedure given in this document. W&M

stamping shall be done by the Vendor for the new Flow metering system

(Main product, secondary product) as per the W&M/ Legal metrology

requirement. The meter factor/’K’ Factor for all the Products (Main,

Secondary, Additive) shall come under W&M configuration parameter

such that these cannot be altered after providing the W&M sealing.

Stamping of these newly supplied equipment by state W&M Department

& the entire coordination shall be in the scope of the Vendor during

execution, stabilization period, 2 year Warranty period & 5 year

Comprehensive AMC period. All liaison & incidental charges shall be borne

by the Vendor. HPCL will reimburse the statutory charges for stamping

during warranty & AMC period against submission of Original receipt in

the name of HPCL. Statutory Charges paid during project execution &

system stabilization shall not be paid separately & shall be in the scope of

Vendor In case the W&M stamping is required before the due date for

reasons not attributable to HPCL, all charges including the statutory fees

shall be paid by the Vendor. If the reasons are attributable to HPCL,

Statutory fees paid shall be reimbursed by HPCL against submission of

Original receipt in the name of HPCL.

o FRLS Cables, Double compression Cable Gland, Flameproof Junction box,

etc. from main JB to respective instrument shall be part of that equipment.

o All these Automation equipment can be mounted either on the Gantry

Platform or on the floor with suitable foundation/ Structural Steel support.

Pipeline up to the last manual isolation valve (before the SAE) will be

provided by HPCL.

o All Structural Steel like angles, flats channels beams, brackets etc. required

for mounting/ supporting these equipment or any existing equipment

shall be in the scope of the Vendor.



119 | 3 5 9

SPECIFICATION FOR BATCH CONTROLLER FOR WHITE OIL

Make : Vendor to Specify (from the approved

vendor list)

Model No : Vendor to Specify

Qty : Refer BOQ

Type : Microprocessor based field mounted,

configurable, indicating, Single Channel

(One BC for each Loading Point)

Service : For White Oil Application Area Classification : Zone I, Gr II A/II B , T3

Inputs (from each loading

point)

: Pulse input from pulse transmitter of

main product line meter

Pulse Input from pulse transmitter of

2nd product for blending


Additive Injection 1st meter


Additive Injection 2nd meter

Start, Stop, Acknowledgement digital

input from RIT

Safety permissive/Interlock inputs like

earthing inputs (bonding &

static),Loading Arm Position, overspill

Temperature input (RTD Pt-100)

Serial input

Manual Call Point

Emergency shut down

Outputs (to each Loading

point)

: Digital control signals to solenoid

valves of set stop valve in Main

Product

Digital control signals to solenoid

valves of set stop valve in Secondary

Product

Digital control signals to 2 nos. of



120 | 3 5 9

additive injection system.

Pump Demand contacts for Main

Product pump, , Blending product

pump & Additive Injection pump

Digital Output to various lamps on

RIT

Trip the Pump in case of DCV

malfunction/ DCV non closure at the

configurable value above the preset

quantity. The Output to be

hardwired to the PLC.

Alarms Interlock failure

Pulse Transmitter failure

RTD Failure

Flow Rate out of limits

Unable to close valve meter

Communication failure

Mode Change from Auto to Manual

Under dosage of Additives

Over dosage of Additives

Under blending of Secondary

Product

Over Blending of Secondary Product

Un-authorized flow

Communication port : Dual redundant RS 485 Serial link to

Terminal server

Maximum of 4 Batch controllers

shall be multi-dropped on the same

transmit & receive data lines (i.e

Single loop) and taken to the control

room.

Interface for proximity Card Reader

The baud rate for communication of

batch controller shall be capable for

transmission of min. 19200 bps

Power requirements : 230 V AC +10% to -15%, 50Hz +/- 5%



121 | 3 5 9

Data entry : Alpha numeric entry pad

Online Self diagnostics : Required

Memory capacity & backup

: Non Volatile RAM capable of retaining

data. Minimum 200 transactions. All data

pertaining to One Truck load of 20 KL shall

be treated as one transaction

Battery : Internal Lithium battery / flash memory

shall be provided for data retention.

Battery Life : Min 8 years

Meter Linearization : Min 5 point over 10 – 100% flow rating of

meter by entering "K" factor of meter in

memory

Scan Time : Max 300 m sec

Display Type : Alpha Numeric, Backlit Two Liquid Crystal

Display Non Glare / Vacuum florescent, 8

Character Numeric & 16 Character Alpha

Numeric. Visibility from at least 2 mtr.

Distance

Display Parameter (Dynamic) : Pre Set Quantity

Loaded Quantity of each

component(Main product,

Secondary Product & Additive)

Balance Quantity

Flow Rate

Temperature

Diagnostic Alarm

Totaliser reading for Main Product,

Ethanol & Additive

Engineering Unit, Control Mode

3 LEDs for Alarm, Auto Mode and

permissive power

User selectable data display

Enclosure : Explosion proof to IS-2148, Gr. II A &

II B Weather proof to IS-2147, IP-65

Protection : Radio Frequency Interference

Protection



122 | 3 5 9

Electromagnetic Interference

Protection

Electrical Transient Suppression on

all power, communication and data

input & output to provide

protection from transient over

Voltage.

Approvals /Certification : PESO(CCOE) approved

Ex Proof to Zone-1, Gr II A & II B

Weather Proof to IP 65

W&M Model Approval : OIML approval as

per R 117 for Custody Transfer

Batch Accuracy of the

Electronic Metering system

: Shall be 0.05% of batch over the full flow

range

Functions : Indication & Totalization

Batch Control

Display & Totalizer of Each Product

(Main Product, Secondary Product

being blended & Additives) Locally

as well as on Remote on the TAS

System

Blending of Two products ( Blending

% configurable from TAS System) at

each loading point

Additive Injection (Dosing PPM

configurable from TAS System) with

2 additives per loading point.

Meter factor linearization (min. 5

points over 10-100 % flow rate)

Dynamic flow display

Programmable ramp up/down for

multistage opening/ closure of set

stop valve

Batch summary

Executing local loading (min.200

Batch to be stored for auto retrieval

by TAS System when



123 | 3 5 9

communication is established)

Automatic Flow optimization

Temperature Compensation

Trip the Pump (only particular

product) in case of DCV

malfunctions/ DCV not closing at

the preset quantity.

Stop the Loading in case of Under

dosing/over dosing of Additive and

or Ethanol Product

Stop the loading in case of Power

failure of the product pump.

Shut the DCV/Trip the Pump when

ESD is activated.

Slow opening/closing of shut off

valve

Cut Off flow through meter at Power

Failure

Local Start/Stop Operation.

Ramp up & Ramp down operation

after every interruption

Manual deletion of memory shall

not be permitted. Memory shall be

auto delete.

Totalizer shall be non-resettable.

Audit Trail

Security & Data Integrity

: Only Authorized Person shall have

the access to calibrate or alter

function of the metering system.

System shall be designed to limit

access for the purpose of altering

any input variables that may affect

the measurement.

Minimum three Layer Password

protections/hardware protection

shall be available. Separate

password shall be available for any



124 | 3 5 9

basic database configuration

affecting volume measurement like

setting of ‘K’ factor, Separate

password shall be available for

operator for various activities like

alarm acknowledgement & other

system operation & separate

password shall be available the

other for system operation like

changing the System Mode ( Auto

to Manual or vice versa).

A Security code shall be used

anytime changes/edit are performed

that will alter the quantity measured

or deletion of memory

Changes to any Flow parameter shall

be captured in the Audit trail as a

part of event log in the TAS System.

Change in Pulse Security shall be

logged in the system with time,

date, unique ID & the Original and

revised pulse error defined. TAS

shall display Pulse security enabled

/disabled in the Control Room

Each time a flow parameter

constant, that affects the calculated

volume, is changed in the system

the old & new values along with the

date, time & unique ID shall be

logged

Any time memory/ data is erased it

shall be recorded along with the

date, time & unique ID shall be

logged

Non-resettable totalizer reading

shall also be captured



125 | 3 5 9

All such changes in Shall be

generated as exception reports.

Keyboard Type : As per OEM standard

Keyboard Function : Configuration entry

Operator Data entry

Display Selection

Alarm Acknowledgement

Start/Stop

When in Auto mode Key Pad shall

be disabled other than Start/Stop

Button

Key Lock : Required ( Through Password)

Audit Trail : Any changes affecting the Volume

reported shall be logged with Date,

time & unique ID. The Audit Trail

may consist of Single or multiple

records.

Any Change in the Meter

Factor/’K’factor shall be logged in

the TAS System


(either Remote or local) shall be

logged in the System.

Totalizer for each Batch Controller

shall be logged when “End of Day” is

run & shall be available in the report

form for reconciliation & it shall be

send to JDE.

Salient Features : Each batch controller should be in a

position to operate in standalone

mode.

Each batch controller should be able

to store at least 200 batches in local

mode which can be retrieved later

by the automatically by TAS System

along with Truck Number. Provision



126 | 3 5 9

shall be available in the Batch

Controller for input of Truck No &

Load No

Sequential Blending as well as inline

Blending & dosing

Meter Factor/’K’factor shall be

available in the MMI of TAS System


shall be available from remote

through TAS System. Facility shall be

provided in the system for the user

to incorporate the reasons of

change in the mode. Mode Change

at local level shall be available only

when TAS is not operational/

communication failure



127 | 3 5 9

SPECIFICATION FOR FLOW METER (POSITIVE DISPLACEMENT METER) FOR

MAIN PRODUCT

Make : As per approved vendor list

Qty : Refer BOQ

Type : Oval gears / tri-rotor design / rotary vanes

Casing : Double case

Size : 3”

Service : MS, HSD, SKO, Hexane .

Power Supply 230V AC +10 % to -15%, 50 Hz +/- 5%

Materials

Body : Carbon Steel ASTM A – 216 Gr. WCB/ IS

6240 Gr. B Rotor Elements : Anodized aluminum/ Carbon Steel ASTM A –

216 Gr. WCB

Wet parts : Aluminum / SS 304

Seals : Viton/ Buna N ( Only Buna N seals for MS &

Ethanol)

Outer Housing : Carbon steel

End connection : 3", class 150#, RF serrated ANSI B 16.5

Flange : RF Serrated ANSI B 16.5

MOC for Rotary Vane / Oval

Gear / Bi-Rotor/Tri-Rotor

: Anodized Aluminum / Carbon Steel

Bearings :

SS 316 / Tungsten Carbide / Ni-Resist and

Carbon (for Naptha)

Other Parameters

Minimum Design Pressure : 15 Kg/sq cm

Normal Working Pressure : 1-10 Kg/Sq Cm

Operating Temperature : As defined in the design parameter

Body Hydro test Pressure : 15Kg/ Sq cm minimum.

Flow Range : 150 – 1500 LPM

Linearity : ± 0.1`% of the reading

Repeatability : ±0.02% over 10:1 flow range

Rangebility : 100% to 10% of max. flow range

Mounting & Coupling : Horizontal / Vertical, Magnetic



128 | 3 5 9

Calibration : Meter shall be factory Calibrated & also at

the Location. Weights & Measure stamping

is a must at all Locations irrespective of the

place of manufacturing

Direction : Bidirectional. Direction of Flow shall be

clearly stamped or cast on the body

Color Coding : MS- Dark Orange No 591 (IS 5)

SKO- Golden Yellow No 356 (IS 5)

HSD- Oxford Blue No 105 (IS 5)

NOTE: Total pressure drop across meter assembly – The strainer, Air eliminator,

PD meter, Shut off valve shall be limited to 1.3 Kg/ Sq cm under all process

conditions.



129 | 3 5 9

SPECIFICATION FOR DUAL PULSE TRANSMITTER FOR MAIN PRODUCT

Make : As per approved vendor list. ( Both Meter &

Pulse Transmitter shall be from the same

OEM)

Qty : Refer BOQ

Application : To convert volumetric flow to pulse

Operating Range : Up to 1500 LPM

Type : Opto- Electric, serrated disc type/ Inductive

type / Magnetic Inductor type/ Approved

OEM standard

Max Pulse frequency : Up to 2 Khz

Pulse Resolution : Min. 100 pulse per revolution

Output : Dual pulse stream to Batch Controller, each

pulse shifted by 90 deg. with each other.

Confirms to pulse security level A as per IP-

252/76, ISO 6551 and API chapter 5

Materials

Body : Aluminum Alloy LM 25 TF/ LM6

Operating torque : To suit the P.D meter

Mounting : On the O/P shaft of the PD meter

Power Supply : From the Batch Controller

Shaft Rotation : Bi-directional

Pulse security To be provided through verification pulse



130 | 3 5 9

: generated through additional grid element.

Supply current : MFR STD

Allowable vibration : 1 G’s at 10-150 Hz,

Supply Voltage : 8-24V DC

Power Supply : From Batch Controller

Enclosure : Intrinsic Safe or Ex-proof to Zone 1 , T3 Gas

Group IIA / IIB as per IS –2148

Weather proof to IP 65 as per IS 2147

Signal Transmission : 20M From counting instrument

Housing : Explosion Proof

Approval : PESO(CCOE), CMRI, CENELEC

Cable Entry : ‘1/2" NPT (F) or as per design



131 | 3 5 9

SPECIFICATION FOR AIR ELIMINATOR CUM STRAINER (FOR POSITIVE

DISPLACEMENT METER OF MAIN PRODUCT)


Qty : Refer BOQ

Type : Wire Mesh Basket type

Size : 3”

Mounting : Pipeline

Service : White Oil

Design : As per ASME Section VIII

Design Pressure : 15 Kg/cm2

Working Pressure : 1.5 to 10 Kg /cm2

Materials

Mesh : 60 mesh of SS 304 for White Oil

Body : Carbon steel as per ASTM A 216 Gr. WCB

Seal : Viton /Buna N

Flange : Carbon Steel

Float : Float actuated pilot operated

Float & Reed Material : Stainless Steel 304

Basket : CS Reinforcement sheet / SS 304

Differential Pressure Gauge : Required with ½” Tapping

Air Release Body : Carbon steel to ASTM A 216 Gr. WCB

Drain Connection : ¾” NPT, 150# Flange end with CS Drain

Valve with blind. Proper arrangement for



132 | 3 5 9

collection of product through drain shall be

provided

Vent : ¾” NPT (F)

End Connection :

Inlet : 3" ANSI 150 Flanged :RF serrated

Outlet : 3" ANSI 150# Flanged, RF serrated`

Reed switch : Required. It shall be capable of giving output

signal so that the batch can be suspended.

In case of differential pressure across the

suction side and discharge side of SAE is

greater than 1 kg/cm2 then the loading for

that point shall be suspended with an alarm

in TAS software as well as at batch controller.

Alarm description shall be termed as

“Strainer choked”.

Color Coding :

MS- Dark Orange No 591 (IS 5)





133 | 3 5 9

SPECIFICATION FOR DIFFERNTIAL PRESSURE GAUGE ACROSS STRATINER

FOR MAIN PRODUCT

Type : Direct

Make Model No :

As per approved Vendor list

Model No :

Vendor to specify

Mounting :

Local across strainer

Dial Size :

6”(150mm) White Color with black

graduation

Material :

Cast aluminum

Bezel ring :

Press fit

Window Material :

Toughened glass

Enclosure :

Weatherproof to IP 65

Element material & Type : SS 316, diaphragm /Piston

Socket material : SS 316

Zero Adjustment : Micrometer pointers

Connection : ½” / ¼ “NPT (M), 2 nos.

Connection location :

Bottom

Accuracy :

± 2% of FSD

Over range protection :

As per IS 3624

Blow out protection :

As per IS 3624

Range :

0-2 Kg / Sq.Cm

Maximum Static Pressure :

15 Kg / Sq.Cm

Accessories : 3 way manifold- SS 304



134 | 3 5 9

SPECIFICATION FOR DIGITAL CONTROL VALVE FOR MAIN PRODUCT


Model : Vendor to Specify

Type : Diaphragm type digital control with linear

characteristics, Electrically actuated

hydraulically operated. Alternatively

piston type DCV is also acceptable.

Size : 3” (80 mm)

Type of Body : Globe

Qty : Refer BOQ

Service : White Oil

Flow Range : 1500 LPM (Maximum) ,150-1200 LPM

(Normal Flow Range )

Max. working pressure : 15 Kg/sq. cm

Test Pressure : 1.5 times the Design pressure i.e. 22.5

Kg/Sq cm

Operating Pressure : 1.0Kg/Sq cm -4 Kg Sq cm

Mounting : Horizontal, Downstream of PD meter

End connection : 3" ANSI 150# Flanged, RF serrated for

Main Product & 1.5” ANSI 150# Flanged,

RF serrated for secondary product

Leakage Class : Class VI

Failure Position : Close

Materials

Valve body : Carbon steel A 216 WCB / SS 304

Valve cover : Cast steel A 216 WCB

Spring : Stainless steel AISI 304

Internal parts : Stainless steel AISI 304 / CS

Needle Valve/ Ball Valve : SS 316 body & needle/ball, tubed

through compression type fittings, 2 Nos

( One at upstream & one at downstream)

Tubing & Pipe : SS 316

Diaphragm material : Viton/ NBR-LS

Trim : SS 316

Seals : Viton/Buna N



135 | 3 5 9

Body type : Inline

Solenoid Valve

Type : 1 No. Normally Open (NO) &

1 No. Normally Close (NC)

SOV Make : ASCO

Body : Stainless Steel

Trim : SS 304

Mounting : On Digital Control valve


Test Pressure : 1.5 times the Design pressure i.e. 22.5

Kg/Sq cm

Elec. Connection : Min ‘1/4" NPT (F)

Limit switches : Single for closed position indication,

explosion proof, class I, Gr IIA & IIB

Enclosure : Explosion proof class 1, Group II A &II B,

T3 & Weather proof to IP 65

Power Supply : 230V +10% to -15% AC , 50 Hz +/-5%

Coil Insulation : F Type

Approval/Certification for

Digital Control Valve

: CCOE

Features Required : Fail Safe irrespective of line

pressure

Bubble Tight Shut off (at Zero

pressure)

No reverse flow

Valve close on Power Failure

Adjustable rate of opening &

closing of Valve.

Pressure Drop

Color coding MS- Dark Orange No 591 (IS 5)





136 | 3 5 9

SPECIFICATION FOR POSITIVE DISPLACEMENT FLOW METER FOR

SECONDARY PRODUCT ( Max Blending 20% V/V) :

One Set of Flow metering System (PD Meter, Strainer Cum Air Eliminator, Set

Stop Valve, Pulsar) is required for each MS Point for Blending of Ethanol. The Size

of metering system shall be min. 1 1/2 inch. The actual size may vary based on the

design & detailed Engineering by the Vendor. The Current Blending of Ethanol in

MS is 5% v/v. However, it may go up to maximum 20% v/v in future stage wise.

Facility shall be provided in the TAS Software (password protected) with the User

for changing the blending proportion. Change in the blending proportion shall

be logged with time, Date, Unique ID, previous blend ratio & the new blend ratio.

The specification for Flow Metering System (PD Meter, Strainer Cum Air

Eliminator, Set Stop Valve, Pulsar) required for Ethanol will be same, except the

size which shall be min 1 1/2 inch, as for the main product unless otherwise

specified

Flow meter type : PD meter, Single/Double case, SS 316

wetted parts

Size : Suitable for tapping of 1 ½”, expander/

reducer suitable for site Installation shall be

in the Vendor’s scope.

End Connection : ANSI class 150#, RF serrated ANSI B 16.5

Service : Ethanol

Flow rate : 40 LPM to 400 LPM

Body Material : Carbon steel A 216 WCB

Rotor Material : Stainless Steel 316

Accuracy : +/-0.5%

Linearity : 0.15%

Repeatability : 0.05%



137 | 3 5 9

Seals : Buna N

Strainer cum Air

Eliminator

: Integral type

Pulse transmitter : Dual pulse

NRV : Lift/swing Check Valve

Color Code : Purple

NOTE: Batch Controller shall control the Blending proportion based on recipe &

product code



138 | 3 5 9

Specification for Digital Control Valve for Ethanol



Type : Diaphragm type digital control with linear

characteristics , Electrically actuated

hydraulically operated.

Size : Min 1.5” and to suit the design

Type of Body : Globe

Qty : Refer BOQ

Service : Ethanol

Flow Range : 40-400 LPM (Normal Flow Range )

Minimum Design pressure : 15 Kg/sq. cm

Test Pressure : 1.5 times the Design pressure i.e. 22.5 Kg/Sq

cm

Operating Pressure : 2 Kg/Sq cm -10 Kg Sq cm

Mounting : Horizontal, Downstream of PD meter

End connection : 1.5 “ ANSI B 16.5, 150# ASTM A 150

Leakage Class : Class VI

Failure Position : Close

Materials

Valve body : Carbon steel A 216 WCB

Valve cover : Carbon steel A 216 WCB

Spring : Stainless steel AISI 304

Tubing & pipe : Stainless steel AISI 304

Interconnecting Tube

Fitting

: Stainless steel AISI 304

Trim : Stainless steel AISI 304

All Internal Parts : Stainless steel AISI 304

Needle Valve/ Ball Valve : 1 No. Stainless steel AISI 304 , tubed through

compression type fittings,

Diaphragm material : Buna N

Seals : Buna N

Solenoid Valve

Type : 1 No. Normally Open (NO) &

1 No. Normally Close (NC)



139 | 3 5 9

SOV Make : As per approved make

Body : Stainless Steel

Trim : SS 304

Mounting : On Digital Control valve


Test Pressure : 1.5 times the Design pressure i.e. 22.5 Kg/Sq

cm

Elec. Connection : Min ‘1/4" NPT (F)

Limit switches : Single for closed position indication,

explosion proof, class I, Gr IIA & IIB

Viscosity :

Enclosure : Explosion proof class 1, Group II A &II B, T3 &

Weather proof to IP 65

Power Supply : 230V +10% to -15% AC , 50 Hz +/-5%

Coil Insulation : F Type

Approval/Certification : PESO (CCOE)

Features Required : Fail Safe irrespective of line pressure

Bubble Tight Shut off at zero line

pressure

No reverse flow

Valve close on Power Failure

Adjustable rate of opening & closing of

Valve.

Low Pressure Drop



140 | 3 5 9

SPECIFICATION FOR DIFFERENTIAL PRESSURE GAUGE (Secondary Product)


Qty : Refer BOQ

Mounting : Across Strainer

Dial size : 100 mm

Dial : Aluminum

Colour : White dial with black engraving

Bezel ring : Press fit

Unit of measurement : kg/cm2

Pressure element : Diaphragm, SS, Piston

Accuracy : ± 2 % of FSD

Zero adjustment : Through micrometer pointer

Over range protection : 125 % of FSD

Process connection : Through 1/2" NPT (M)

Service : For Ethanol Strainer in TLF Gantry

Range : 5000mm water column adjustable throughout

the range

Materials

Case : Die cast Aluminum

Window : Toughened glass

Movement : SS 316

Element : SS 316



141 | 3 5 9

Socket : SS 316

Standard : IS 3624



142 | 3 5 9

SPECIFICATION FOR BASKET TYPE STRAINER CUM AIR ELIMINATOR

(Ethanol Service)


Model No : Vendor to specify

Qty : Refer BOQ

Mounting : In line upstream of 1½” PD meter

Design Code : ASME Sec VIII

End Connection : Flanged, ANSI 150# RF

Mesh Size : 60

Mesh Material : SS 316

Seals/ O-Ring : Buna N

Flange Material : ASTM A 105

Flow Rate : 40 LPM to 400 LPM

Pressure : 1.5 Kg/ Sq. cm – 10 Kg/ Sq. cm

Vent : Required

Drain Valve : CS Drain Valve with blind. Also proper

arrangement of draining of product shall be

provided.



143 | 3 5 9

SPECIFICATION FOR CHECK VALVE FOR ETHANOL SERVICE BEFORE

TAPPING


Quantity : Ref BOQ

General

Type : Lift/ swing Check Valve

Rating : ANSI Class 800

Service : ETHANOL

Size : ‘1/2” to 1 ½”

Cover : Bolted

End Connection : Socket Weld ended

Applicable Codes : BS : 5352, ANSI B 16.34,

Testing Code : BS : 6755 Part I

Hydrostatic Test Pr. : Shell /

Seat

: 3000 / 2200 psi

Material :

Body / cover : ASTM A 105

Disc : 13% Cr. SS, Stellited

Seat ring : 13% Cr. SS, Stellited

Fasteners : ASTM A193 Gr. B7/A194 Gr. 2H



144 | 3 5 9

RESISTANCE TEMPERATURE SENSOR

Type : PT – 100, 3 wire Simplex element as per DIN

43760 standards. Input shall be taken to the

Batch Controller

Inserts :

Mineral insulated, sheath – 316 SS, OD 6 mm

Insulation Resistance :

More than 500Ω at 500 VDC

Nipple Union : 316 SS

Head and Cover : Die Cast Aluminum with SS chain

Cable Entry : ½ ” NPT

Enclosure class : IP – 65

Area Classification :

Zone II, Gr. IIA / IIB T3

Terminal block :

ceramic with spring loaded screw

THERMO WELL

Type : Bar stock drilled 316 SS, Tapered

Hot End O,D : 16mm

Immersion length : STS (Design shall be in such a way that 2/3rd of

product pipe I.D. to be immersed)

Cold End O.D : 21mm

Tapping : At 45 degree w.r.t. Product pipe of horizontal



145 | 3 5 9

(X)-Axis

Process Connection :

1 ½ “ ANSI 150# RF 125 AARH Flanged

Instr. Connection :

½ ” NPT (F)

Bore Diameter :

To suit element

Hydro test :

1.5 max operating pressure

Make/Model No. :

STS

Signal Source : RTD Pt 100 to DIN 43760

Local Display : Alphanumeric LCD Display

Accuracy : +/- 0.15% of Input

Mounting : Threaded connection on main pipeline header

going to TLF.

Output : 4-20 mA signal proportional to temperature.

Functions :

RTD linearisation, upscale or downscale for open

circuit / short circuit sensor-Smart transmitter

Protection :

Circuit protected against surges, lightning,

reverse polarity, reverse insertion

Enclosure :

IP-65,

Execution :

Intrinsic safe with active barrier in control room



146 | 3 5 9

SPECIFICATION FOR REMOTE INTERACTION TERMINAL (RIT)


Model : To be specified by the Vendor

Qty : Refer BOQ

Enclosure : Explosion proof suitable for T3,Gas Group

II A & II B as per IS 2148 and Weather

Proof as per IP 65

Push Buttons : 3 nos. for start, stop & acknowledge

Indicators : LED Cluster -3 nos. ( Red, Amber & Green)

LED shall be cluster design & each LED

shall be bright so as to be clearly visible in

the Day light.

LED Cluster shall be soldered on glass,

epoxy PCB and varnished to corrosion

inhibition.

Lamp Housing & clear lens shall protrude

out of Exd. housing for 270 degree viewing

angle.

NOTE: Indicator lamp combined with

Push Button is also acceptable.

Power supply : 230 V AC + 10% to -15%, 50 Hz +/- 5%



147 | 3 5 9

SPECIFICATION FOR EARTHING DEVICE



Function : Detect & Earth the tank truck.

Detect that the Crocodile Clip is

clamped on Tank truck and not on any

other Earth Structure.

Detect Resistance of the Earthpit/Grid

To detect & provide the Bonding of

Tank Truck with the loading arm

Interlock with the existing Manual

copper braided Earthing strip.

Allows loading only when loop

resistance is less than 2 Ohm Connection : Earthing connection through SS/ Brass

Crocodile clamp. Length of the Flexible coil

shall be minimum 16 Ft

Signal Input : From Body/Brass Strip of the Tank

Truck at the bottom for detecting &

providing the Earthing

From the Body of Tank Truck at the

top/ Loading Arm for providing &

detecting the bonding

From the Manual Earth Strip to detect

the loop.

Protection : Intrinsically safe/ Explosion proof class 1,

Group II A & B, T3 & Weather proof to IP 65

Intrinsically safe Isolator

mounting

: In explosion proof junction box suitable for

mounting in class I div. II, Gr llA and llB

Input : To Batch Controller

Control output : 2 Nos of Potential free contact (SPDT) rated

for 110 V DC 0.5 amp/ 230 V AC 1.0 Amp

Power supply : 24 - 35 VDC, supplied from batch controller

or 230VAC +/- 10%, 50Hz, ± 5%



148 | 3 5 9

Input : To Batch Controller

Indicators : Red – vehicle not earthed

Green - vehicle earthed

Enclosure : Explosion Proof & weather proof to IP 65,

NEMA 4/IS 2147 & NEMA 7/IS 2148

Area Classification : IEC Zone 1 , Gr II A, II B T3

Approval/ Certification : PESO (CCOE)

Functional requirement for Earthing and bonding interlock

Tank truck loading shall be interlocked with earthing and bonding . The earthing

relay shall have two probes in minimum. One probe shall be used for earthing of

TT and the other probe shall be used for bonding of TT. The earthing relay shall

be combined unit for earthing and bonding. Apart from the earthing and

bonding clamps of new earthing relay, the existing earthing wire needs to be

integrated. The system shall also detect that the clamps are attached to tank

truck earth only and shall not give green indication if they are attached to

existing MS structures like catwalk, gratings, gantry structure etc. The system shall

also monitor at each loading point level the value of resistance of each earth

pit/earthing grid to which the earthing relay is connected. The system shall be

designed such that when all the three clamps (one clamp for earthing of new

earthing relay, one clamp for bonding of new earthing relay, one clamp of

existing earthing) are put and all are found to be healthy and resistance of loop

is less than 1 ohm, then loading of particular compartment shall start.

In case of failure of any of the contacts or the earthing resistance going beyond

the cut off value, then loading shall stop immediately

NOTE : A 16 sq mm cross-section braided copper strip of 3 m length shall be

provided with each earthing relay.



149 | 3 5 9

SPECIFICATION FOR PROXIMITY CARD READER



Qty : Refer BOQ

Type : Proximity type

Operation : Access control

Sensing Distance : 25 mm

Enclosure : Intrinsically safe/ Explosion proof class 1,

Group II A & B, T3 & Weather proof to IP

65/NEMA 4

Power : 230 V AC + 10% to -15%, 50 Hz +/-5%

Connections : With Terminal Server in the Control Room

Card media : Laminated cards

Card Dimension : As per manufacturers standard

Card Thickness : Min 1.8mm

Communication : 2 no RS485 serial port

Battery : V Lithium, with 8 years min life

Baud rate : 9600

Protocol : To be indicated in the offer

Additional feature HPCL logo and location name to be printed

on the cards.



150 | 3 5 9

SPECIFICATION FOR SS PROVING TANK FOR PD METER


Type : Mobile SKID with pump filling facility, quick

connect coupling, valves and accessories.

Suitable for Top Loading as well as Bottom

Loading

Qty : Refer BOQ

Accuracy : ± 0.1%

Capacity : 2000 Ltrs

Material of Construction : SS 304

Gauge glass : Shall be provided at Top and Bottom

Drain valve : Shall be provided

Fill Pipe : 4” Slotted pipe suitable for Top loading

through 2 ½ inch loading arm shall be

provided up to 100 mm from the bottom.

Vent : Design & provide suitable Vent for loading

products up to 1500 LPM flow rate

Gauge Glass Resolution : +0.1% of tank cap.

Graduation Marking : As per API MPMS chapter IV for prover

system

Top Cover : Required. It shall be hinged with locking

arrangement

Displacement tube volume : +0.5% of tank cap.

Plug valve size : 3"



151 | 3 5 9

Process connection : 3”, 150# inlet

3”, 150# outlet to drain pipe

Mounting : On Skid, Chassis mounted with suitable

wheels for towing

Gauge glass : Shall be provided with Mounting accessories

Drain connections : Shall be provided

Accessories : Pump & flame proof Motor with starter and

Piping. . Plug with FLP type 32 A rating socket

shall be provided on skid. Temperature Gauge

3 Nos., Spirit Level 2 Nos. For pump design Q

may be taken as 200 LPM and H as 20 M for

all type of products handled. Providing three

phase connection & laying cable from MCC to

Gantry shall be in the scope of the Vendor.

Spare Feeder if required shall be provided as

a part of MCC modification

Dimensions : As per weights & measures standards

Other Features : Leveling Jacks shall be provided

3 Phase FLP Socket : 1 No each on both Gantry. Cabling for the

same is also part Vendor’s scope



152 | 3 5 9

SPECFICATION FOR TOP LOADING ARM SELF SUPPORTED TYPE Make : As per approved vendor list

Qty : Refer BOQ

Description : Swivel, Top loading

Inboard Arm : 3" NB Seamless pipes, quality

conforming to ASTM-A106 Gr. B Sch.40

Outboard Arm : 3” Aluminium conforming to AA 6063 T6/AISI

63400

Elbows and Reducers : 3" NB 90 Deg SR Elbows , quality conforming

to ASTM-A234 Gr. WPB, Sch.40 Swivel joint : Material conforming to ASTM A 106 Gr.B/ A-

105 having High Carbon Steel balls, ball races

are to be hardened to min. 500 BHN, sealing

rings of material shall be Viton/PTFE.

Aluminum swivel joints should have

replaceable ball races for longer life.

Material of Aluminum Swivel joint shall be

aluminum alloy. Aluminum swivel joint should

have steel ball races to achieve longer lift

Type of Swivel joints : Swivel joints have to be split type design so

that seals can be replaced without removing

the steel balls.

Aluminum drop pipe : (73 mm OD x 63 mm ID) Aluminum pipe of

1000 mm long with tapered end on one side

& other side screwed.



153 | 3 5 9

Spring Balancing System : Quality conforming to IS: 1239. Helical Spring

box with spring of material conforming to EN

47/45.

Inlet Flanges : Raised face serrated finish, ASA class 150, with

holes drilled according to ANSI B 16.5 face to

face as per ANSI B 16.1 made of ASTM A 105

material

Intermediate Flanges : Flanges other than inlet flanges in the loading

arm shall have dimensions as per TTMA & will

be made of IS 2062 & aluminum alloy.

Balancing : Spring Type (Torsion / Compression)

Design Pressure : 15 Kg/ sq.cm

Working Pressure : 2-8 Kg/Sq cm

Hydrostatic Test Pressure : 15 Kg/ Sq Cm

Operating Temp : 0 - 50 deg.C

End connections : 3" ANSl 150# WNRF FLANGED

Seals : Viton

Working envelope : Reach 3 - 4 mtr.(Typical). 4 mtr. X 6 mtr. X 1

mtr.(Vertical)

Vacuum Breaker : ½” integral viton Diaphragm type with SS

nipple. It shall be at the apex of the system

where vacuum is generated

Filling Position locking

Arrangement

: A suitable locking arrangement for the

outboard arm shall be provided to prevent



154 | 3 5 9

jerking action of Loading Arm as well as lock

the outboard arm at the operation desired

position while filling tankers.

Locking chain shall be provided

Parking Lock : A suitable locking arrangement for the

inboard arm shall be provided to lock the

loading arm in parking position so that it

remains in parking place. Lock should be

spring loaded so that locking in parking place

is automatic & should be easy to operate.

Loading Arm type : Self supported Top Loading. Quantity for Left

hand type & Right hand type shall be as per

individual location requirement.

Inlet Pipe entry : To suit the site condition

DESIGN REQUIREMENT

1. Loading Arm shall be self supported type. Extra bearing support which

creates obstruction to the movement of manpower & other equipment

should not to be required by the Loading Arm i.e. Design of Loading arm

should be such that it do not require any extra Bearing support.

2. Base swivel joint should be capable of taking bending load of the loading

arm. Loading shall be checked of bending load by applying 40 Kg weight

at the end of inboard arm and will be checked for smooth rotation.



155 | 3 5 9

3. Swivel Joint should be offered for Cycle testing of 20000 Oscillations of

Min. 270 degree and should be checked for pressure testing at 10 Kg

under rotation after the same.

4. The swivel joints shall be designed to make the loading arm maneuverable

with minimum effort. All swivel joint should be of split type design and

have minimum type rows of chrome steel hardened balls fixed in suitably

hardened carbon steel guide ways. Material conforming to ASTM A 106

Gr. B/A-105 having HCS Balls, ball races are to be hardened to 500 BHN,

seal of VITON / PTFE. Sealing surfaces of Swivel Joint should have overlay

with SS material. Aluminum swivel Joint shall be Aluminum Alloy.

Aluminum swivel joint should be hardened Ball races to achieve longer lift.

All Swivel joints of steel or Aluminum should be of Split type design.

Swivel joint made of Aluminum should have replaceable snap type ball

races in which balls moves.

The quantum of force required at the end of outboard arm to move the

outboard arm in horizontal place and in vertical plane and the complete

loading arm from the base swivel joint in horizontal plane without fluid &

checked on shop floor will be as below:

- In Horizontal plane : 1 Kgf

- In Vertical plane (downward pull) : 4 Kgf

- From base swivel in horizontal plane : 2 Kgf

5. Seals of swivel shall be of Metal inserted Viton material. Swivel joints shall

be completely leak proof under operating pressure and vacuum. The

tightness of seal shall not hinder the easy operation of swivel joint.

6. Spring Balance Assembly:

The Outboard arm and drop pipe shall counter balanced by spring

balancing Mechanism will be of Helical Compression spring type



156 | 3 5 9

with totally enclosed cover design. Spring box should be such that,

setting of the spring tension can be done by any one [person at site

without any special tools, Helical spring assembly.

The spring shall have in-build provision to limit downward travel

and upward travel of outboard arm.

The expected life of spring is 2 Lakh cycles. The spring shall be

designed with excellent fatigue resistance properties and adequate

strength to perform operation throughout the lift of the spring.

TESTING AND INSPECTION BY TPI

• Visual and Dimensional inspection and witnessing hydrostatic testing of 100%

Loading Arms.

• After assembly, the arms shall be subject to the following tests:

a) Balancing Test:

This is conducted in Loading arm to demonstrate that the arms are

mechanically counterbalanced. Test under no hydrostatic pressure.

Quantum of Check : 100%

b) Performance Test (Maneuverability test of Swivels):-

Rotate the swivel joints for three cycles in forward & three cycles in reverse

Direction to demonstrate that swivel joints can be easily operated and

operating torque required are in following range.

– In horizontal plane : 1 Kgf

– In vertical plane (downward pull) : 4 Kgf

– From base swivel in horizontal plane : 2 Kgf

Quantum of check 100%

c) Hydrostatic Shell Test:



157 | 3 5 9

The loading Arm is pressurized to 15 Kg/cm2 using water as test fluid &

pressure Held for 15 minutes. Requirement : No leakage is allowed.

Quantum of check: 100%

d) Radiography:

10% of all the carbon steel butt weld joints in a loading arm shall be

radiographed.

Quantum of check : 10% quantity

e) Manufacturer of the Laoding arms Test Certificate, indicating details of

materials for Inboard arm, outboard arm and drop pipe & scope of

Inspection indicated above, shall be provided along with supplies. Also

verification of material of construction (thru mill Test report).

Quantum of check 100%

f) Life cycle testing of swivel joint of each type shall be done & the

certificates shall be offered for verification during inspection.

Additionally Aluminum swivel joint shall also be tested for endurance test

for 20,000 cycles, which will be witnessed by TPIA.

Quantum of check : 1 No of each type of swivel joint.

g) Bending moment test for springs & base swivel joint shall be done & the

certificates shall be offered for verification during Inspection. Additionally

Bending moment test shall be done for split flange type of Swivel joint &

witnessed by TPIA.

Quantum of check : 1 No of each type of swivel joint.

h) Forces required for movement of loading arms to be checked for

conformity with purchase order requirements.

Witnessed by TPIA - 20%

i) Certificate for chemical analysis of seat ring material



158 | 3 5 9

Quantum of check : 1 No. sample per batch.

j) Vacuum test: Closing inside and inlet side. The loading arm assembly to

be tested at (-) 0.15 BAR vacuum condition inside and hold for 15 minutes

(no drop at vacuum gauge permitted).

PAINTING

• Loading arm and the accessories shall be painted one coat anticorrosive

paint and two coats of enamel paint of colour code shade as given below :

• HSD - OXFORD BLUE

• SKO - GOLDEN YELLOW

• MS - DEEP ORANGE

• The colour code shall be given with a spray gun to get a shining finish.

Aluminium nozzle shall not be painted.

NOTE:

• One extra O ring shall be supplied with each loading arm.

• Locking facility to be provided :

i) When loading arm in parking position

ii) When loading arm is inserted in T/T



159 | 3 5 9

TECHNICAL SPECIFICATIONS FOR SLEEVED PLUG VALVES

The existing isolation valve at the Gantry shall be dismantled & re-installed.

However, if the existing isolation valve is not suitable Vendor shall supply new CS

Sleeved Plug valves as required. 2” / 1 ½” Sleeved Plug valves shall be non-

lubricated, PTFE sleeved with high pressure sealing areas circumferentially around

internal body bore tap & bottom and 360 degree port defining lips and adjacent

relief areas for sleeve expansion with 2 degree taper plug & three point

adjustment

Plug valve should be of short pattern , teflon sleeved type, wrench operated plug

valves. Valves should be of ANSI 150 lbs rating and should confirm to BS 5353.

Sleeved Plug Valves should provide “ Bubble Tight Shut Off”. These valves should

be maintenance free and quick shut off ( quarter turn) type. There should not

have any metal to metal contact in a Sleeved Plug Valve to avoid sticking

problems. Sleeved plug valves should have downward tapered plug to avoid any

adjustment to maintain sealing integrity.

DESIGN FEATURE

TYPE Non lubricating sleeve

BODY ASTM A216 WCB

COVER ASTM A216 WCB

PLUG ASTM A351 CF8M

SLEEVE PTFE

TOP SEAL KIT Fire safe As per API 607

END Flanges 150 Class serrated raised face

OPERATION Wrench operated

TESTING ANSI B 16.34

BODY Hydrotest : 32 Bar

Seat Hydrotest : 21 Bar

BOLT/NUTS ASTM A 193 Gr B7/ASTM A 194 Gr 2H



160 | 3 5 9

ENDS SHOULD HAVE RAISED FLANGES CONFORMING TO ASA 150 CLASS WITH

HOLES DRILLED AS PER ANSI-B-16.5

WORKING PRESSURE 150 PSI

CS WRENCHES: Operating wrenches suitable for operating this type of valves.

THIRD PARTY INSPECTION by approved agency

All Valves (100 %) shall be tested by manufacturer's quality control officials,

before offering the valves for inspection.

All test certificates for material conformance and pressure test shall be verified

and endorsed by the third party inspection agency.

Testing procedure shall confirm to API-598. / BS 6755 -PART-I

The following tests will be witnessed by the third party inspection agency

a) Hydraulic shell test.-100 % Valves.

b) High pressure closure test -10 % Valves selected at random in one batch.

(Minimum of TWO Valves to be tested)

c) Low pressure closure test on 10% valves selected at random in one batch.

(Minimum of TWO Valves to be tested)

In addition they shall also do the following:-

a) Overall dimensional check on assembled valves for conformance with

drawings/specifications.

b) Identification against Manufacturer's test certificates.

General Calibration Guideline for the Flow metering System



161 | 3 5 9

Vendor shall submit the elaborate calibration procedure based on the following

general guidelines:

• Existing 2KL Mobile prover tank stamped by W&M shall be used by the

Vendor for calibration of the new electronic metering System.

• Temperature of the Prover tank shall be recorded

• Meter linearization shall be done at multiple flow or single flow as per the

process requirement at an individual location & as directed by the

Engineer-In- Charge.

• Compensation for Temperature shall be incorporated so that meter

performance is consistent & repeatable at all the process condition

• Accuracy & Repeatability shall be established as per the specification

before W&M stamping

• All Calibrated metering system shall be W&M stamped



162 | 3 5 9

SPECIFICATION FOR HYBRID TANK FARM MANAGEMENT SYSTEM

GENERAL

The existing Hybrid Tank Farm Management System (TFMS) shall be part of

Terminal Automation system for custody transfer & inventory management of Oil

product tanks. These products are stored at locations in Floating Roof Vertical

Tanks (FRVT), Conical Roof Vertical Tanks (CRVT), Underground tanks (UGT)

located inside the respective Tank Farm area. Additionally the TFMS software

shall have all graphics, logics etc to interface the tank farm equipment in the

second phase as given in the list of facilities

All basic parameters along with the inventory calculations shall be available in all

the Client Machine at the control room, Terminal Manager Room & Planning

Room.

Scope

The Vendor’s scope shall include integration of the existing Tank Farm equipment

& new Tank Farm equipment with the New TAS/TFMS software. Also the software

shall have all graphics, logics etc to interface the tank farm equipment in the

second phase as given in the list of facilities. These Phase-II Tank farm equipment

shall be interfaced with the new Software in Phase –II by the Vendor during

execution/ Warranty/ CAMC. All field work from Tank to CIU will be undertaken

by HPCL & the scope of TAS Vendor interface will start in the Control room after

CIU.

The Tank Farm Software shall have approval for Custody Transfer application

from Indian W&M & any of the following:

German PTB / equivalent

Netherlands Measuring Institute, NMI / equivalent

Tank Farm software calculations, conversions and corrections shall be API

standards, OIML requirement and as per ASTM (latest) compliant. The above

approval shall be certified from the above agency.



163 | 3 5 9

A. Salient Features

The Tank Farm management system (TFMS) shall be able to measure tank

levels, temperature, water levels and product density. Based on the

measured values, the TFMS shall provide Inventory calculations as per the

API standard & latest ASTM Table 54 A & 54 B.

The system shall be able to perform alarm and error handling for all

system components.

TFMS shall have the capability to provide an RS-232 or RS 485

communications interface for data transmission

TFMS shall be provided with diagnostic features, which monitor the signal

performance and hardware status.

TFMS shall be able to communicate with Programmable Logic Controllers

or Distributed Control Systems or Supervisory Control and Data

Acquisition packages or other systems.

All parameters of TFMS shall be relayed to the JDE at “End of Day”

operation for inventory reconciliation

The system shall be capable to provide as minimum the following

measured data.

- Gross level measurement

- Water Level measurement

- Observed product density

- Standard Product density at 15 Deg

- Observed Temperature

- Volume calculation according ASTM/API tables, which includes Total

Observed Volume (TOV), Gross Observed Volume (GOV), Gross

Standard Volume (GSV), Net Observed Volume(NOV), Net Standard

Volume(NSV),

- Water Volume, Available (pumpable) Volume and Available Space.

- Product Flow calculation.

- High, high-high, low, low-low alarms.

- Gauge diagnostics and status information.



164 | 3 5 9

- Leakage Alarm

- System Diagnostics

- Batch Handling

B. TFMS Software

1. The system software shall have the following capabilities:

a) Continuous & automatic data acquisition of level, temperature

from field instruments

b) Real time volume calculation from level and tank capacity tables.

c) Different data screen representation for tank details like level,

temperature, density, volume etc. and summary of details

including histograms, inventory, capacities, volume correction

factor etc.

d) Comprehensive programmable logging of all alarms and events,

summary of all details without disturbing scanning sequences.

e) Continuous on-screen listings of significant happenings

occurring during run time.

f) Totalization of volume and mass for group of tanks selected.

g) Trending facility for Oil level, Water Level, Density and

temperature (average as well as multi spot) including both real

time and historic.

h) Programmable alarms for high and low level, temperature,

volume through audio visual display.

i) TFM system MMI shall be user friendly with easy to use

command structures, windows and cursor control facilities.

j) Archival and retrieval facility of tank data.

k) The interlock and shutdown logic on programmable logic

controller.

l) Process flow scheme with graphic mimic on operator interface

console.

2. Tank Farm Management software shall be certified & shall meet al

technical & functional requirement as specified in this tender document.



165 | 3 5 9

Original paper License shall be submitted for each location clearly

mentioning Name of HPCL Location & Project Detail

3. Enhanced inventory management and tank monitoring functionality shall

be available by means of software applications running on Windows

platform, designed on industry standard open connectivity architecture.

4. The HMI shall be able to calculate tank inventory values according to the

latest API standards & ASTM Table. All values in the calculations process

shall be displayed.

5. The system shall be able to accept multiple users with different privileges

independently of the Windows TM operating system. The system shall

have freely configurable task related privileges for operators operator

managers, service managers etc. It shall be possible to seal the HMI

meteorologically to prevent unauthorized tampering of the system. The

method of sealing shall be approved by the NMI (the Netherlands)/ the

PTB (Germany)/ W&M , India. It shall be possible to change the security

level of certain function. All function shall have a preset security password

level.

6. Logging on and off of different users shall be stored as event for

traceability. The system administrator with the highest level of authority

and password handles the assigning of user accounts.

7. The systems shall be capable of storing unique volume tables and

correction factors, with at least 1000 strapping points for each tank. These

tables will provide level to volume conversion of the tank.

8. The system shall provide for open connectivity for users to extract

appropriate data using commercial of the shelf software e.g. MS Excel or

MS Access etc.

9. The operator interface shall have full network support over standard LAN,

using commercial of the shelf hardware and software.



166 | 3 5 9

10. The system shall have clock synchronization for all systems operator

stations.

11. The system shall have the capability to support hot-stand by redundancy

without the need for external switches.

12. The following modules/views are considered to be required as a minimum

for the tank inventory system.

- Alarming; audio/visual alarms

- User configurable tank grouping

- Events

- Field commands

- Manual overwrite

- Views; tank related as well as group related

- Tank detail

- Tabular data

- Bar graph's

- Tank icons.

- Batch Handling

- Rate of Change Computation (Flow)

- System Diagnostics

- System and Data Recovery

- Leakage Alarm

13. The system shall be able to generate reports in different formats. All

reports shall be publishable on printers, via e-mail or as a file. All reports

shall be generated manually or automatically by user-defined schedules.

Minimum required reports are:

• Tank reports

• Inventory balance reports

• Alarm Reports

14. All reports may be retrieved through on local communications.



167 | 3 5 9

15. The system shall have an input for ambient Air temperature. The system

shall be able to use this temperature value, combined with the product

temperature, for compensation of thermal tank shell expansion.

16. The system shall generate multiple High, Low and safe alarms for levels,

temperature, pressure and water bottom level. Configurable time delays

shall be provided for each process variable to minimize nuisance alarms.

17. The system shall have configurable static and dynamic grouping of tanks.

18. The system shall generate leak alarms based on the change in level or the

Net Standard Volume of the products in the storage tanks.

19. The system shall display the last health reading of temperature when the

product level fall below 300 mm ( First spot position)

20. The System shall display last healthy reading of density when the product

falls below “H min” level.

21. The system shall be capable of performing online self-checks on each tank

gauge and data collection or control units. As a minimum, the following

features shall be included:

- All field inputs, including level, temperature, pressure and water

level shall be monitored for faults. All faults shall be annunciated

and logged. The error indications shall be categorized, such as

communication failure. Gauge failure or software failure.

- All diagnostic information shall be displayed, alarmed, stored in

historical files and included in reports. This diagnostic information

shall include details of all types of failures, system status and

configuration modifications. All diagnostic alarms shall be

presented locally or distributed via e-mail.

- In case of failure of any one gauge, alarm shall be generated &

flashing red shall be displayed. Last healthy reading shall not be

displayed in this case rather “Error” shall come.



168 | 3 5 9

- In case of entire communication failure, TFMS failure shall come on

the MMI. Last healthy reading shall not be displayed in this case

o The system shall have the capability for historical and real-time

trending analysis.

o The system shall store data the data (min. 1 year) on hard disk for later

analysis documentation and traceability. The data stored shall be

achieved for use as & when required.

o The system shall be capable of sending reports automatically using fax,

email or print services.

o It shall be possible to integrate data of other databases, residing in the

same computer or network environment, in the same report audible PC

alarms.

o The system shall provide an audible and visual indication to the operator

of an alarm condition and provide the operator the ability to acknowledge

the alarm and disable the audible indicator.

o The system shall provide the operator with the ability to disable the

audible portion of an alarm but the visual alarm shall not be disabled until

the alarm condition has been corrected.

o The system shall provide a calculated volume rate of change (FLOW) based

on the true level rate from the radar gauge and the tank capacity table.

o The system shall provide importing and exporting flow indications based

on volume movements in the tank. Indications of ‘estimated end time of

batch” shall be provided based on user set points. The batch handling shall

be able to handle multiple destinations and sources. The Batch function

shall generate printable batch reports.

o The TFMs system shall be OPC compliant



169 | 3 5 9

o The system shall be able to communicate with remote station via Internet

and telephone connection for remote viewing the data. The system should

be connected via OPC server link to remote station.

o Physical key, if any, provided for the software if lost or damaged during

execution, commissioning, warranty period or AMC shall be replaced by

the Vendor at no extra cost to HPCL

o TAS system shall have JDE Interface for relaying the Tank farm data at the “

End of Day”.

o The System shall be capable of sending SMS for high severity alarms like

HI-Hi Alarm to the Users defined.

o System and Data Recovery: The tank gauging software shall be capable of

data backup of all system configuration and process parameters. The

system shall also be capable of retrieving all configuration parameters

once a system failure has cleared.

o Tank Farm Management Software (TFMS) shall reside in Hot Standby

configuration either in LRCs as a part of application software or as a

separate software. All data shall be available with LRC & graphics shall be

available in all clients Machine Alternatively, The Tank Farm Management

Software shall be installed on two separate PCs on Hot standby

configuration. Both the TFMS PCs shall operate in Master-Slave

configuration with the field devices. Tank data and device configuration

data shall be replicated from primary tank server to backup tank server

resides in TFMS software in two separate PCs wherever there is a change

in tank data or device configuration settings. At any point of failure at

primary TFMS PC or primary tank server, the active connection from

primary tank server to field devices is transferred to backup tank server

automatically which then will take over the role as primary tank server. In

case of restoring of the original primary TFMS PC or primary tank server,

the same shall be updated with latest tank data or device configuration

settings from secondary tank server automatically and shall remain

functioning as a secondary tank server till the primary tank server fails or

manual switching over. Graphics of tank farm shall be available on the



170 | 3 5 9

entire client Machines. LRC shall take the data from the Tank Farm

machine designated as “Primary” until unless there is failure either

communication or hardware in which case it should take data from

secondary TFMS client Machine. All data of Tank farm shall be available

with LRC & no data shall be lost in the event of failure of any or both the

Tank Farm machine. The offered Tank Farm software shall have the

required approval & meet all the functional & technical requirements as

stipulated in the respective sections of this document.



171 | 3 5 9

SPECIFICATION FOR RADAR GAUGE FOR U/G TANKS


Model No : Vendor to specify in line with the following

guidelines :

Radar Gauge shall be mounted on the

Still Well Pipe.

Qty : Refer BOQ

Tank Dimensions : As per Annexure. Vendor to cross check the

details during Site visit

Type : Microwave Type

Technology : Frequency Modulated Continuous Wave

Service : As defined in the design parameterAll these

tanks are buried at least 1 mtr below the

Ground level.

Factory Accuracy : +/- 1 mm

Installed Accuracy : +/- 3 mm

Resolution : +/- 1 mm

Supply voltage : 230 VAC +/- 10%, 50 Hz +/- 5%

Distance (Range) : 0.8 mtr to 6 Mtr

Input : From the Multi--Spot Temperature

element cum Water level sensor

From the Density meter

Output : To the Tank Side Indicator

RS-485 through CIU to the TAS System



172 | 3 5 9

Wireless output

Antenna Type : Array /Planer Still Well

Antenna Material : Polyphenylensulfid/AISI 316

Sealing : Teflon

O Ring : Flourosilcon/Viton

Housing Material : Anodized Aluminum

Mounting : On the Still Well Pipe.

Still Well Pipe : Supply & installation of suitable 6” slotted Still

well pipe is required

Lightning Protection : Required

Canopy for protection : Inbuilt

Ingress Protection : Conforming to IP 66 & 67

Safety Class : Explosion proof Zone 1, Group II A & B, T3

Approval/Certification : CCOE (PESO)

CIU & TFMS Software : Shall be provided in the Control Room

Tank/Water Product

Interface

: 0-500 mm max at the Tank Bottom



173 | 3 5 9

SPECIFICATION FOR SPOT TEMPERATURE SENSOR


Type : Single spot RTD Pt 100

Service : On the U/G Tank

Qty : Refer BOQ

RTD spot : Pt 100 shall be 500 mm from the bottom.

RTD Type : Pt-100, grade A as per DIN Class standards

OD : 1” Typical

Instrument Connection : Threaded

Overall length of sensor : To suit the tank height

Enclosure : Explosion proof Zone 1, Group II A & B, T3 and

weather proof to IP 65

Process connection : Flanged

Output : To RTG

Accuracy : +/- 0.25OC

Sheath : SS 316

Lead wires : Copper

Measuring range : -10 to 100 deg C

Certification : CCOE

Oil-Water Interface Probe : Integrated with Spot Temperature at the

Bottom for Tanks other than Ethanol.



174 | 3 5 9

SPECIFICATION FOR WATER INTERFACE PROBE


Type : Capacitance Type/ Equivalent

Service : To measure Water -Oil Interface for White Oil

products like MS, SKO, HSD, etc.

Qty : Refer BOQ

Factory Accuracy : +/- 2 mm over a probe length of 500 mm

Installed Accuracy : +/- 5 mm over a probe length of 500 mm

Sensing Length : 500 mm

Probe Material : SS Sheathing

Protection : Probe IP68 & WIP convertor IP65/NEMA 4

Power Supply : Vendor to specify

Output Transmission : 4-20 mA

Mounting : Integrated at the bottom with Spot Temperature

other than Ethanol service

Bottom Weight : Required

Certification/Approval : CCOE(PESO)



175 | 3 5 9

SPECIFICATION FOR ONLINE DENSITOMETER FOR U/G TANK


Model No : Vendor to Specify

Output : RS 485/ HART output

Type/Operating principle : Resonate frequency tuning fork vibration

type

Accuracy : +/- 0.0025 g/cc

Repeatability : 0.0001 g/ cc

Ingress Protection : Weather Proof to IP-65

Hazardous Area Classification : Zone I & II, Gr II A,II B T3 as per IS 2148

Approval : CCOE

Density : 0.5-1.0

Vibration effect : Negligible

PTFE Coating : Required

Note: Both Standard Density & Ambient Density shall be available in the Tank

Farm System



176 | 3 5 9

SPECIFICATION OF TANK SIDE INDICATOR/ DATA AQUISTION UNIT


Qty : Refer BOQ

Mounting : For each tank Inside the Tank Farm on the

Structure.

Display : Liquid Crystal Display for parameters like

Product Level, Water Level, Temperature

(Individual as well as Average). It shall have

the hinged cover for closing the screen

Power : From RTG

Communication : Digital

Protection : Explosion proof class 1, Group II A & B, T3 &

Weather Proof IP 67

Output : Digital

Enclosure : Explosion proof (CCOE Certified)



177 | 3 5 9

SPECIFICATION OF CONTROL ROOM EQUIPMENTS

TECHNICAL SPECIFICATIONS OF LOAD RACK COMPUTER

Make : As per approved Vendor List

Model : To be furnished by vendor

Quantity : As per the Bill of Quantity

Service : Load Rack Control Server for Terminal

Automation System

Form Factor : Tower

Processor : 1 x Intel Xeon Quad Core @ 2.0 GHz / higher

capacity as available at the time of supply (Dual

processor capable)

L2 Cache : Minimum 12 MB ( 6 MB x 2)

Chipset : Intel E 5500 / 5000Z or equivalent ,latest chipset

suitable for processor

Front Side Bus : Intel Quick Path Interconnect

RAM : Minimum 4 GB ECC , DDR3 Low Power

Hard Disk Drive : 3 No 146 GB SAS HDD (15K RPM) Hot Swap

HDD

Hard Disk Controller : Integrated Smart Array E200i with 256 MB

cache, BBWC Controller or PERC 6/ I SAS/SATA

Controller with 256 MB Cache

Power/ Cooling : Redundant Hot plug power supply

Dual processing support : Required

Networking : 2 nos of Integrated 10/100/1000 GB network

interface card with RJ 45/UTP interface with



178 | 3 5 9

wake on LAN enabled .

Expansion Bays : Min 3 Nos

SLOTS Minimum 5 nos PCI Slots

I/O Ports : Minimum 1 Serial, 4 USB ports, VGA Port

Graphics : Suitable Graphics Adapter with Video RAM 16

MB Min.

Keyboard/Mouse : PS/2 or USB Windows Keyboard and scroll

mouse with mouse pad

Optical Drive : DVD Writer as per OEM standard

Operating System : Windows 2008 server edition preloaded and on

media (CD) with paper license and recovery

media .All necessary drivers for all components

for Windows 2008 should be supplied with the

server(s).

Monitor : Min 21” TFT colour monitor

Resolution: 1280 x 1024 (SXGA)

Contrast Ratio : 400 :1

Viewing angle 150/140 (H/V)

Response Time < = 20 ms

Brightness – 250 nits

RAID LEVEL V

The LRC shall have Internal RAID V controller with 3 Hard disks of 146 GB.

RAID diagnostics

The system shall have software for checking RAID diagnostics. The level of RAID 5

shall be clearly demonstrated by the system. In case of defective hard disk ,it shall

be possible to replace the same online without shutting down the system. Hot

spare or cold spare drive shall not be acceptable. The system shall show auto-build

of data on the new drive.



179 | 3 5 9

TECHNICAL SPECIFICATIONS FOR CLIENT PCs (OIC/TTES/TFMS)

The Vendor shall supply, install and commission Client PCs. These Clients may be

located at different places at the all over the of the terminal and shall be

connected to the server over LAN. The Client component of the application

software has to be developed suitably to run on these PCs.

The OIC and TTES computer shall have the same functionalities built in so that

they are interchangeable.

The Client PCs shall be at least of following configuration.

Make : As per approved Vendor list

Model : To be furnished by vendor

Quantity : As per price bid

Form Factor : Mini Tower

Service : Client-Operator Interface Console/TTES Computer

Processor : Intel Core to Duo Processor, E7400 (2.2 GHz, 800

FSB)

L 2 Cache : 2 MB

Chip Set : Intel G33 CHIPSET or latest chipset suitable for

processor & high performance Graphics

RAM : 2 GB ECC PC-2 6400 DDR-2 800 MHz Expandable

to 8 GB

BIOS : With built in diagnostic setup, APM/ACPI/DMI

support

Hard Disk Drive : 1 x 320 GB 7200 RPM SATA HDD

Hard Disk Controller : Integrated EIDE /SATA Controller

Networking : 2 nos of Integrated 10/100/1000 NIC with RJ

45/UTP interface with wake on LAN enabled.



180 | 3 5 9

Slots : Four : 2 PCI Exp, 2 x PCI (Full Height )

Keyboard : PS/2 104 Keys Windows Keyboard

Mouse : PS/2 Scroll Mouse with Mouse Pad

I/O Ports : Min 1 serial ; 1 parallel and 6 USB ports

Optical Drive : DVD ROM

Audio : Microphone Jack Line In & Line Out

Graphics : Intel Graphics media accelerator 3100 – Integrated, NVIDIA

Ethernet : Integrated 10/100/1000 NIC with RJ 45 UTP

interface with wake on LAN enabled

Display : Min 21” TFT colour monitor * (See Note)

Resolution: 1280 x 1024

Contrast Ratio : 400 :1

Viewing angle 150/140 (H/V)

Response Time < = 20 ms

Brightness - 250cd/sqm

Manageability : Wake on LAN , DMI 2.0 compliant, WFM 2.0

compliant

Operating System : Windows 7 Professional preloaded and on media

(CD) with paper license and recovery media

All necessary drivers for all components for

Windows 7 professional should be supplied with

the server (s)

Installation : The Computer shall be installed with Windows 7

professional version and configured as per

guidelines given by HPCL at the time of installation.

Machine to be tested and certified for windows 7

and copy of the certification should be given

Note:

SMPS shall be able to support at least one additional device, viz. internal CD

writer/ additional 80 GB HDD complete with adequate power connectors etc.



181 | 3 5 9

Minimum one external and one internal drive bay each, shall be free after fixing

all devices as per specs

*Note -- One of the client PC i.e. Terminal Manager PC shall be supplied with

approved make of LCD TV 42” and PC , TV shall have required compatibility ports

for operation.



182 | 3 5 9

PRINTERS

Supply, install, and commission dot matrix printers required for text and graphics

output. The printers shall be put on the LAN and shall be accessed over the LAN.


Type : Dot Matrix Printer

Quantity : 2 per Terminal / depot

Print head : 24 pin

Columns : 136

Print speed : 560 cps

Print direction : Bi-directional with logic seeking

Interface : Serial / parallel/ Ethernet

Fonts : Built-in with optional font card

Paper feed : Push Tractor & Single Cut sheet feed

Emulation : IBM & EPSON emulation

Printer Drive : Suitable Drivers for Windows

2008/Windows 7



183 | 3 5 9

TECHNICAL SPECIFICATION FOR TERMINAL SERVER



Qty : As per BOQ with

Service : To provide interconnection to devices over

Ethernet Network

Peripheral/Device

Communication Speed

: Min 9216 BPS

Dual LAN Redundancy &

Dual Host Redundancy

: Required

Peripheral/Device Connector : Peripheral Ports with RJ connector support

Data Format : Asynchronous Data Transfer

LAN Protocol : TCP/IP

LAN Connector : Modular RJ 45

LAN interface Speed : 10/100 Mbps

Power Supply : 230V AC +10% to -15%, 50 Hz +/- 5%

Operating Temperature : 0 to 50 Deg C

Humidity : 10 to 95% RH



184 | 3 5 9

SPECIFICATION FOR ( PROCESS PLC) PROGRAMMABLE LOGIC CONTROLLER

(PLC)

General

• Programmable logic controller (PLC) shall be dual redundant hot standby

PLC with dual processors and single I/O for all process DI & DO as

specified.

• The CPU for PLC shall have minimum of 32 bit processor to enhance the

processor speed.

• Programmable logic controller (PLC) system shall be programmable,

modular microprocessor based safety system, which shall be used for

implementation of safety shutdown/interlocks and terminal operation

monitoring.

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

high-grade components of proven quality and proper design of system

electronics. The system shall be highly reliable, high-integrity safety system

on both qualitative and quantitative technologies. Redundancy shall be

provided as a minimum, as per this specification to improve system

availability, reliability and safety. Due consideration shall be given to the

environmental conditions particularly for field mounted subsystems.

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

adding additional modules, which shall be easily accessible for

maintenance and repair. The modules shall be suitable for inserting in 19"

rack / DIN rail mounting. The types of modules shall be kept to minimum

possible in order to have interchangeability and low spares inventory.

• The PLC shall have a very high noise immunity in order to ensure safe and

reliable operation when subjected to electrical radio frequency

interference and electromagnetic disturbances expected in a plant. The

design of system electronics shall be in compliance with the

electromagnetic compatibility requirements as per 'IEC-801-

Electromagnetic compatibility for Industrial Process Measurement and

Control Equipment'.



185 | 3 5 9

• The system shall have extensive set of self-diagnostics hardware and

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

automatically at frequent intervals for identifying any fault in software or

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

interface console level.

• Operation of the PLC shall be completely unaffected by a momentary

power loss of the order of 20 milliseconds.

• The scan time of programmable controller shall be of the order of 100

milliseconds. Scan time of PLC is defined as the cycle time taken by the

system to read input, process input executing logic, and update control

output for all the logic configured within the system. Other activities like

diagnostic routines, output/dump of data to peripherals, or any other

activity, which consume processor time, shall also be accounted while

computing scan time.

• On-line replacement of any module shall be possible in such a way that

the removal and addition of the module shall be possible without de-

energizing the system. Further, there shall not be any interruption in the

system while replacing a faulty module except for the inputs/outputs,

which are being handled, by that module.

• The process control system shall be based on open system architecture i.e

the system shall have inherent capacity to integrate and exchange

information with other brand system devices and platforms via industry

standard communications, platforms and protocols such as MODBUS,

Profibus, Foundation Fieldbus, OLE for Process Control (OPC) or Ethernet

TCP/IP.

• The system shall be able to support various types of field buses. As a

minimum, profibus DP, Modbus should be available. At least up to 4 lines

per controller should be operated simultaneously. Ideally even different

types of field busses should be operated simultaneously on the same

controller.

Spares philosophy



186 | 3 5 9

Installed engineering spare modules of 5% shall be provided in

input/output subsystem on module basis and/or with a minimum of one

module of each type to enhance the system functional requirements for

future.

In addition the system shall have the following minimum spare capability

o I/O racks of PLC shall have 20% useable spare slots for installing

both digital & analog I/O modules of each type in future. These

racks shall be part of the offer.

o The processor system shall have the capability to execute logic for

at least double (100%) of the installed I/O's .

o Whenever relays are used to interface process Input/outputs with

PLC 5% additional relays shall be provided. In addition, 20% spare

space shall be provided in cabinets to install 20% additional relays

in future.

System Configuration: The system shall consist of following major subsystems:

-

Input /Output subsystem

The I/O modules shall be mounted in the I/O racks located in control room i.e.

I/O modules shall be general purpose unless otherwise specified. I/O devices

interface with PLC shall be at I/O racks only.

The maximum number of input/outputs per module shall be limited as

follows:

SN Type of Configuration No. Of I/Os

1 I/O Sub-system 32 for Digital inputs

08 for Analog inputs

08 for Analog ouputs

32 for Digital outputs



187 | 3 5 9

• Each I/O shall be electrically isolated from external control circuit by

suitable means. The minimum isolation level between I/O and logic circuit

shall be 1000 VDC. I/O status indication shall be provided for each I/O

module.

• Each I/O shall be protected against reversal of polarity of the power supply

voltage to I/O .

• Each DI module shall have LED for each I/O channel to indicate the status

of each input/output.

• Each input shall be provided with filters to filter out any noise in the input

line or noise because of input contact bouncing.

• PLC inputs shall be provided with potential free/dry contacts unless

otherwise specified.

• All the inputs shall preferably be double ended i.e. two wires per input and

not common return for all inputs.

• The interrogation voltage (24V DC / 110 V AC) to the input/output contact

shall preferably be powered from separate redundant power supply units

and shall not be a part of PLC

• Output contacts from the PLC shall be potential free/dry contacts with

contact ratings as given below. Wet contracts/ powered contacts/TTL

outputs etc., shall not be acceptable. Suppression device for each output

contact is to be provided.

• The output contact rating shall be as follows

Sr. Applicable For VOLT Current

No. Rating

1. All output cards for driving 110V DC 0.5 A

Solenoid valves and alarm

annunciator. 24 V DC 2.0 A

2. All output cards for driving

LT motors/pumps/solenoids 230V AC 5.0 A



188 | 3 5 9

• Input type shall be intrinsically safe with barriers for analog input modules.

Only Active Barriers shall be employed for achieving galvanic isolation,

wherever applicable.

• Each Input/output shall be short-circuit proof and protected by fuse. Visual

indication of fuse down/blown must be provided for each output as a

preferred choice.

• The I/O modules; interface modules shall be of the same make/

manufacturer & same family as the principal manufacturer of processor

system.

Processor System

• The offered processor type shall have a minimum reference capacity to

handle 2000 real time I/O. Redundancy shall be provided such that in case

of failure of the primary processor, the secondary processor shall take over

automatically without any time lag. Both processor shall access the inputs

simultaneously. The changeover shall be bumpless and the system shall be

safe. Redundancy shall be provided for complete processor subsystem

including CPU, memory, power supply & host system communication

interface.

• Memory shall be non-volatile. However, incase volatile memory is

provided, rechargeable battery backup shall be provided for a minimum of

one year to keep the stored program intact. A battery drain /pass

indication shall be provided .The size of the memory shall be sufficient for

storage of the program instructions required by the logic schemes. 20 %

spare capacity shall be available.

• In case of failure of complete processor system i.e. both processors

system, outputs shall take fail-safe automatically.

• It shall be possible to generate the first out alarm output by the PLC in

case where a group of parameters are likely to trip the system.

Communication Sub system



189 | 3 5 9

The communication subsystem shall be a digital communication bus that

provides reliable and high speed data transfer between the processor subsystem

& I/O subsystem.

Redundancy in communication subsystem shall be as follows unless otherwise

specified.

Communication Interface between each I/O rack & the dual processor system

shall be via separate dedicated dual redundant communication link in multi-

drop mode. Daisy chained redundant communication bus to establish

interface between I/O racks & processor system shall not be acceptable.

The communication interface between each processor subsystem and host

LRC system shall be dual redundant consisting of two separate

communication interface modules located in / from each individual processor

rack and two individual communication links, with each one configured in

redundant mode. Use of PLC processor CPU port for establishing host

interface connectivity shall not be acceptable.

In case of redundant communication subsystem on the failure of the active

device the redundant device shall take-over automatically without

interrupting the system operation.

Information about the failed device shall be displayed locally as on well as the

console. It shall be possible to manually switch-over the communication from

main bus/device to redundant bus/device without interrupting the PLC functions.

The mechanism used by the system for error checks and control shall be

transparent to the application information/program. Error checking shall be

done on all data transfers by suitable codes. All communication interfaces shall

be galvanically or optically isolated.

Self diagnostics



190 | 3 5 9

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

shall be able to identify the system failures at least upto module level

including redundant components and power supplies through detailed

CRT displays report print outs and logic programming.

• At the local level, failure of a module in any subsystem shall be identified

by an individual LED.

• Self-diagnostics shall be provided to detect faults (which make the

contacts in fail safe mode) in the input and output modules. Each

module shall have separate arrangement for self-diagnostic facility. This

may be achieved by automatically running the testing software at cyclic

intervals.

• Testing software shall be capable of detecting faults in case of normally

closed system as well as in normally open system.

• Feedback shall be provided internally from the output voting logic system

to detect any latent faults of the system.

Power supply distribution

PLC system shall be powered with 230 V AC +/- 10%. Power pack shall be 100%

redundant with safety factor of 1.5. The distribution network for AC power supply

shall be designed such that a single power fault in any branch system shall not

cause a trip of the entire system. The distribution network for interrogation

voltage shall be designed such that a single fault in any branch shall not cause

trip of the logic other than where the fault has occurred. Sequential starting of

various load centers shall be provided whenever specified.

PLC System Cabinets

All PLC system cabinets shall be completely wired with all modules in place.

Inside cabinet wiring shall be done using ribbon type pre-fabricated cables.

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

bottom entry of cables through gland plates of preferably 3 mm thickness.



191 | 3 5 9

Cabinet structure shall be sound and rigid and shall be provided with removable

lifting lugs to permit lifting of the cabinets.

Cabinet shall be fabricated from cold rolled steel sheets of minimum 2 mm

thickness suitably reinforced to prevent warping and buckling. Doors & side

panels shall be fabricated from cold rolled steel sheet of minimum 1.5mm

thickness. Cabinets shall be thoroughly debarred and all sharp edges shall be

grounded smooth after fabrication. Panel shall be confirming to degree of

protection minimum as per IP-31.

Cabinet finish shall include sand blasting, grinding, chemical cleaning, and surface

finishing by suitable filter and two coats of red lead primer by spray. After drying,

final paint shall be applied. This can either be NC or epoxy depending upon the

customer requirements. Outside color shall be light grey as per IS 631/RAL7035.

Inside of the panel shall be painted with high gloss white color. Base channel

shall be painted black. Non-welded panel shall be powder coated.

Each cabinet shall be approx 2100 mm high (excluding 100-mm channel base),

1000 mm wide and 800 mm deep, in general. Construction shall be modular

preferably to accommodate 19" standard electrical racks.

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

doors and drawers shall be limited to 600mm. However, standard design of

cabinets from approved PLC manufacturers shall be acceptable.

Cabinets shall be equipped with the front and rear access doors. Doors shall be

equipped with lockable handles and concealed hinges with pull pins for easy

door removal. Cut-outs shall be properly shaped and devoid of sharp edges. They

shall be made by nibbling process or by drilling and filling. Gas cutting under any

circumstances shall not be used for making cutouts.

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

by wire fly screen shall be provided in cabinet doors. Further two ventilation fans

shall be provided.

Illumination shall be provided for all cabinets by incandescent lamps,which shall

be operated by door switch.



192 | 3 5 9

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

segregated manner. Cable glands shall be provided for incoming and outgoing

cables to prevent excessive stress on the individual terminals. All metal parts of

the cabinet shall be electrically continuous and shall be provided with a common

grounding lug.

The front doors for the PLC cabinet shall have toughened glass / acrylic window

for visual ergonomics.

Earthing

Each cabinet, console and other equipment supplied as a part of PLC system shall

be provide with an earthing lug. All these lugs shall be properly secured to the

AC mains earthing bus.

All circuit grounds, shields and drain wires of control cables shall be connected to

the system ground bus which shall be electrically isolated from AC mains earthing

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

All barriers, if used, shall be securely grounded. Safety barrier ground wire shall

be capable of carrying a maximum fault level current of 0.5 A at 250 V r.m.s per

barrier.

Note : all panels shall have earth leakage detection system installed which shall

prevent earth leakages current.



193 | 3 5 9

PLC I/O LIST: The following I/O List shall be taken as minimum. Vendor shall submit the

Typical I/O List along with the un-priced bid as per their scheme. Actual I/O List shall be

submitted along with PLC Data Sheet after detail design engineering & FDS

S.N DESCRIPTION QTY AI AO DI DO

1 ESD ( No. of ESD X)

ESD

Where Y= No. of TLF Pumps+

Submersible Pumps+ TWD Pumps

Z= No. of BCU

A= Power Trip of TFMS Equipment

B= Power Trip of Gantry Equipment

X X Y+Z+A+B

2 Header Line

Pressure Transmitter

No of PT=X

X X

3 TTL Gantry. No. Of Batch Controller=X

Pump Demand

X 4X

4 Additive Pump. 2 Pump for each Skid of Additive. No. Of Skid= X

Run, Trip, Local remote 2X 6X

Pump Start Command 2X 2X

Local Permissive 2X 2X

5 Fire Water System ( No of Fire Engine= X)

Run, Trip, Local remote X 3X

Pump Start Command X X

Local Permissive X X

Pressure Switch (Y)

Y Y



194 | 3 5 9

Manual Call point Z Z

6 Water Tank ( No Of water Tanks =X)

Level Transmitter X X

7 Control Room UPS (No of UPS=X)

UPS Failure Alarm X X

8 Barrier Gate ( No Of Barrier Gate =X)

Open, Close, Local/Remote X 3X

Open Command* X X

9 Product Pump ( No Of Product Pump =X) Controlled through MCC

Run, Trip, Local remote X 3X

Start & Stop from Local Push

Button

X 2X



Start & Stop from LCS X 2X

10 Product Pump Controlled through VFD ( One per product, No of product X)

Start Command X X

VFD Status X X

Pump Run, Trip, VFD,DOL X 4X

Emergency Stop X X

11 Ethanol Pump ( No of Ethanol Pump =X)

Run, Trip, Local remote,

Emergency Stop

X 4X



195 | 3 5 9



12 DCV ( No of DCV=X)

Open X X

13 Total

14 Add 10% spare

15 Grand Total

Note:

• The above is the min. list of I/Os which shall be provided

• IS Barrier & Interposing relays shall be provided as per the design

• Removal of Start Command shall stop the pump.

• Barrier Gate shall be closed through Infra-Red Sensor

• Start Command shall be removed in case of ESD & Tank Low level



196 | 3 5 9

SPECIFICATION FOR UNINTERRUPTIBLE POWER SUPPLY

SCOPE

The specification covers the design, manufacture, testing at works and dispatch in

well packed condition of Parallel Redundant Uninterrupted Power Supply System

of min. 15 KVA (vendor to specify the requirement as per the format “Power

Consumption and UPS requirements form” enclosed with this specifications).

The scope shall include, but not limited, to the following:

• Full wave controlled rectifier

• Inverter

• Static switches

• Storage battery

• Transient Voltage Surge Suppressor

• Isolation/output transformer to achieve desired output voltage

• UPS Distribution Boards

• Interconnecting cabling between various units of UPS

• Any other items required, but not specified, for safe and reliable operation

of UPS system.

STANDARDS

The equipment shall conform to the latest issue of the following and relevant

Indian Standard specifications or equivalent specification of the country of origin

or IEC specifications.

• IEC 62040-1-1 : General and safety Requirement

• IEC 62040-3 : Performance requirement and test method

• EN 60529 : Degree of protection provided by enclosure



197 | 3 5 9

The Quality System for the engineering and manufacturing facility shall be

certificated to confirm Quality Systems Standards ISO 9001 for the design and

manufacture of Power Protection systems for computers and other sensitive

electronics

The equipment shall also conform to the provision of Indian Electricity Rules and

any other statutory regulations in force from time to time.

DESIGN AND OPERATIONAL REQUIREMENTS

• The UPS unit and its associated equipments shall be suitable for operating

at the specified rating continuously with the specified voltage and

frequency variations under the ambient conditions without exceeding the

temperature rise limits specified in relevant standards and without any

detrimental effect on any part.

• The UPS system shall be based on latest generation of Pulse Width

Modulation (PWM) design with proven performance. IGBT based design

for Rectifier and Inverter section is must.

• The input to the UPS should have tolerance limit of be 415V +10% & -

20%

• Parallel Redundant scheme : Under normal operating conditions, both

inverter units should run in parallel sharing 50% load in synchronism and

supply uninterrupted A.C. power to load. On failure of one of these

inverters, the faulty inverter should get automatically disconnected from

the load and healthy inverter should supply 100% load in synchronism.

• The UPS unit shall be suitable for 0.7 lagging to unity power factor. The

overall power factor may be taken as 0.8 lagging unless indicated

otherwise.

• Output voltage shall be selected as 220V , 230V Or 240 V AC. The

maximum waveform distortion of the output voltage shall not exceed 2%

RMS for linear loads and 3% RMS for non-linear loads. The UPS unit shall

be suitable for operation for non-linear loads having crest factor of 3.



198 | 3 5 9

• The inverter steady state output voltage and frequency (free running)

variation shall not exceed ± 0.05 Hz for specified input power supply

condition and no-load to full load condition.

• Voltage dip / rise on sudden application / throw of 100% load or on

changeover from inverter to bypass or vice versa shall not exceed 15% and

shall be recovered within 20 msec to rated voltage.

• UPS shall be designed for overload of 125% for 10 min. and 150% for

1minute after which drooping characteristic shall come into operation.

• On failure of the main supply, inverter unit shall continue to supply rated

load from the separate battery bank for 30 min. duration.

• Charger shall simultaneously supply entire power necessary for inverter

and to keep the battery of required capacity in fully charged condition.

Provision for automatic charging in both float and boost shall be made.

• Battery shall be Ni-Cd. The battery capacity shall be decided considering

load power factor as 0.8 de-rating factor. Battery Backup shall be

dedicated for the UPS with 30 min. back up .

• The ventilation fans to be provided shall be fully redundant and connected

to the output from the inverter. It should be possible to operate inverter

for about half an hour even after the failure any one of the fan without

temperature rise inside the inverter cubicle exceeding the safe operating

temperature limits.

• In case of inverter failure due to any reason or overload, affected unit

should be isolated and changeover to other inverter to bypass should take

place automatically.

• Noise level at a distance of 1 m from UPS panels shall not exceed 70 dB(A)

• UPS system shall be provided with necessary control protection metering

indication alarm & annunciation for reliable and safe operation of the

system.



199 | 3 5 9

• Fast acting semi-conducting fuses Or electronic trip scheme shall protect

all semi-conducting devices. These fuses/ trip shall be coordinated and

appropriate to ensure the functionality and safety of load

• The battery may be taken out of service for maintenance during which

period it shall be possible for the inverter to continue operation-taking

power from the rectifier. The input filter of the inverter shall be suitably

designed to take care of this operational requirement.

•••• UPS system shall be suitable for both floating output and earthing of one

leg in case of single-phase system/star-point in case of three-phase

system.

•••• Potential free contact, min 3 Nos to be provided for remote indication.

CONSTRUCTIONAL DETAILS

•••• The equipment shall preferably be supplied in enclosed, dust & vermin

proof, floor mounted, sheet steel enclosure. In case, it is necessary to

provide opening for ventilation, this should be closed by fine mesh.

Minimum degree of protection for enclosure shall be IP 21 as per EN

60529 / IEC 529 Or IP- 31 as per IS-13997.

•••• Enclosures shall be fabricated with cold rolled sheet annealed steel of

minimum thickness 1.6 mm.

•••• The door hinges shall be concealed type. The doors and the removable

covers shall be provided with non-deteriorating neoprene gaskets in order

to ensure dust and vermin proof condition. Gaskets shall be held in

position in groove in shaped sheet steel work or these shall be of U type.

•••• All external hardware shall be cadmium-plated steel. Hardware for fixing

the removable parts shall be provided with retaining devices.

•••• UPS unit shall have a single panel for accommodating rectifier, inverter

units, Output Transformer and I/P , O/P switch gears, terminals /

connectors etc.



200 | 3 5 9

•••• Distribution boards shall be of fixed type single front execution in fully

compartmentalized design and divided into distinct panels each

comprising of bus-bar chambers, individual feeder modules and vertical

cable alley.

•••• Mounting height of components requiring operation and observations

shall not be lower than 300 mm and higher than 1800 mm.

•••• All the live parts, which are accessible after opening the front cover/back

cover, shall be properly insulated or provided with insulating barrier to

prevent accidental contact. Bus bars of distribution boards shall be PVC

sleeved.

•••• All the wiring shall be properly laid and ferruled at both ends, PVC

channels may be used for wiring. For control wiring, minimum 0.5 sq-mm

copper conductors shall be used.

•••• The power connections may be made by PVC insulated flexible copper

cables or taped copper / aluminum strip. Bottom entry shall be provided

for cables

•••• A suitably sized earth bus shall be provided at the bottom of panel with

provision for earth connection at both ends to existing earth grid.

•••• All panels shall be of same height so as to form a bank, which shall give

good aesthetic appearance.

•••• The following electrical protection should be available:

i. Input under voltage

ii. Input over voltage

iii. DC Over voltage

iv. DC Under voltage

v. Input current limit

vi. Battery under voltage



201 | 3 5 9

vii. Battery deep discharge

viii. Black start on low charge of batteries

ix. Battery current limit

x. High ambient temperature

xi. Output short circuit protection

xii. Rectifier short circuit protection

xiii. Output over voltage

xiv. Output under voltage

xv. Output over current

xvi. Battery over temperature alarm

xvii. Inverter / Converter device over temperature

xviii. Transformer over temperature

COMPONENTS DETAILS

• All components shall conform to relevant IS/IEC standards and shall be of

reputed make. Makes of all components shall be subject to purchaser's

consultant's approval.

• Thyristors, diodes and transistors : The thyristors, diodes and transistors

shall have adequate safety margins to withstand specified operating

conditions. A factor of safety of minimum 2 shall be taken against voltage

surges.

• PCBs :All electronic control & monitoring printed circuit cards shall

preferably be modular plug in type. PCBs shall be firmly clamped/ screwed

in position so that vibration or long usage does not result in loose

contacts.



202 | 3 5 9

• Transformers and Chokes : All transformers and chokes shall be of dry type

and air-cooled. This shall be class 'F' insulated, vacuum impregnated. Class

F insulated cast resin transformers and chokes are also acceptable.

• Electrolytic Capacitors: These may be polarised aluminum type 1, suitable

for long life and category 1, as per IS-4317 or equivalent IEC. The capacitor

shall preferably be self-healing type. These shall be so located in inverter

panels that the operating temperature does not exceed 65 degree C

maximum.

• Instruments : In case, the system does not use LCD based digital metering,

Ammeters & voltmeters shall be moving coil type of class 1.5 accuracy as

per IS -1248. These shall be flush mounting type of minimum size of 96

mm x 96 mm and shall have taut band scale of 240. Frequency meter shall

be of reed type having range of 45 Hz to 55 Hz. Mimic Display should be

available to indicate status of various parameters.

• Static switches shall be naturally commutated type with parallel inverse

connected thyristors. These shall be rated for continuous duty for 100%

load. Short time rated static switches are not acceptable.

• Moulded Case Circuit Breakers: For isolating devices of various equipment,

molded case circuit breakers shall be used. These shall be provided with

overload and short circuit protective devices and shall conform to IS-2516.

SPECIFICATIONS FOR NI-CD BATTERY

Scope

This standard covers the technical requirements of design, manufacture, testing

at works and dispatch in well packed condition of batteries and accessories.

Standards to be followed:

The design, manufacture and testing of the battery shall conform to the latest

issue of the following standards:

IS 10918-Vented type Nickel Cadmium Batteries.



203 | 3 5 9

IEC-623

Operating requirements

The battery shall be able to deliver rated ampere when discharged at the ½ hours

rate of discharge to a final voltage of 1.1 V per cell for Ni-cd Battery under the

ambient conditions.

General Design and Constructional Features

The battery shall be of Ni-Cd type rates for specified voltage. Each battery bank

shall consist of a specified number of cells.

Each cell shall be contained in a closed top container preferably transparent and

unbreakable and shall incorporate positive plates, negative plates and separators

of adequate dimensions. Nickel Cadmium battery of pocket plate type (positive

plate).

The battery bank shall be complete with all necessary components such as lids,

plugs, separators and buffers, inter-cell connectors, lead coated bolts and nuts

cell insulators etc.

The required quantity of electrolyte plus 10% extra quantity shall be supplied in

suitable non returnable containers along with the battery.

Battery stand to be provided by vendor with rubber pads. Incase battery stand is

of metal then rubber sheet to be provided between battery base and metal base.

Battery stand to be provided by the vendor with rubber pads. Incase battery

stand is of metal then rubber sheet to be provided between battery base and

metal base.

Accessories:

The following accessories shall be supplied with each battery bank:-

(a) 1 Set – For Ni-Cd battery, Mild Steel stand with Alkali resistant paint is to

be provided as per requirement.



204 | 3 5 9

(b) 1 Set – Inter row, inter-tier and inter-stand connectors and takeoffs. These

shall be sized suitably to have adequate current carrying capacity and

mechanical strength.

(c) 1 Set – Cell Insulators

(d) 1 Set – Stand Insulators

(e) 1 No – Center Zero cell testing voltmeter Scaled 3-0-3 Volts

(f) 2 Nos – Syringe type hydrometers for measuring the specific gravity of the

electrolyte.

(g) 1 Set – Connecting Bolt wrenches

(h) 1 No – Rubber Syringe for tapping cells

(i) 1 No – Wall mounting type teak wood holder for Hydrometer and

Thermometer.

(j) 1 No – Acid/Alkali resisting funnel

(k) 1 No – Acid/Alkali resisting jug

(l) 1 Pair – Rubber Gloves

(m) 1 No – Rubber apron

In addition, the battery shall be subjected to stage inspection at works and

inspection at site for final acceptance.

These inspections shall however, not absolve the vendor from his responsibilities

for making good any defect, which may be noticed subsequently.

Drawings and documents

The vendor shall furnish drawings and documents as per Annexure – I.

All drawings and documents shall have following description written boldly.

Name of client

Name of third party inspection / consultant

Enquiry / Order Number with Project / Plant Name

Code NO and description

Make / Model No STS



205 | 3 5 9

SPECIFICATION FOR TRANSIENT VOLTAGE SURGE SUPPRESSOR



Quantity : Minimum one at the input per location.

Technology : Metal Oxide Varistor + Surge Capacitance

Protection : Transient, Surge & Noise. All mode protection

Line to Line, Line to neutral, Line to Ground

and Neutral to Ground

Maximum Continuous

operating Voltage

: Min 320 V

Response Time : < 0.5 ns

Protection Level : 0.8 Kv

Surge Current Capacity : 50 kA

EMI/RFI Attenuation : 40 dB typical

Monitoring : Monitoring LED indication & DRY contacts

Connection/Installation : TVSS Parallel . Installation shall be on the

Feeder at Input or on the output as required

by the design

Approval : UL approved, ISO 9001/2000

Safety : NEMA 12/IP55 enclosure, silver link fusing

with thermal protection

Operating Temperature : 0º C to +50 º C

Capacity : Continuous

Operating Freq Range : 47 – 63 Hz



206 | 3 5 9

Operating Humidity Range : 0 % to 95%

• Painting

o The enclosures after suitable pre-treatment shall be painted with

two coats of anti-rust paint followed by two coats of anticorrosive

paint.

o All paints shall be carefully selected to withstand tropical heat and

extremes of weather. The paint shall not scale off, crinkle or be

removed by abrasion due to normal handling.

o Electrostatic powder paint shall be preferred.

• Tests and Inspection: The UPS units shall be subjected to test as per relevant

standards. The test shall include, but not limited to the following: -

o Rectifier & inverter soft starting

o Regulation test

o Heat run test for 8 hours

o Overload test

o Test for changeover time in synchronized and de-synchronized mode.

o Test for dynamic response and transient performance

o Sequence & transfer test

o Noise level measurement

o Test to check the selectivity of protective devices

o Alarm test (simulation of various fault conditions)

o Measurement of harmonic distortion

o Ventilation test (operation without fan)

o Insulation test / Megger Test

o Current division in parallel UPS

All the above tests shall be carried out in presence of purchaser's representative

in addition the equipment shall be subjected to stage inspection during process

of manufacture at works and site inspection.



207 | 3 5 9

Following drawings and documents for all equipment’s of UPS system shall be

supplied

NOTE: UPS load calculation to be furnished.

UPS failure to be taken as hardwired contacts to PLC

Sr.

N

o

Description

After Order

For

Approval

Final

No. Of

copies

No. Of Copies

1 Specification Sheet 3 3

2 Technical Particulars 3 3

3 Block Diagram 3 3

4 General Arrangement drawings and

foundation plan

3 3

5 Calculation for battery sizing 3 3

6 Feeder Details for Distribution Boards 3 3

7 Descriptive literature and catalogues -- 3

8 Bill of materials 3 3

9 Schematic & Wiring Diagram 3 3

10 Installation, operation & maintenance

manual

-- 3



208 | 3 5 9

SPECIFICATION SHEET -

Input parameters

Parameters Specifications

Nominal input voltage 415V 3-Phase with Neutral and dedicated

Earth

Permissible input voltage range + 25% , -30%

Nominal Input frequency 50 Hz

Permissible input frequency variation +/- 10%

Input power factor 1.0 (Unity)

Input Current Distortion - I – THD <= 10%

Power walk in 12-15 seconds

Operation with reverse Phase

sequence

Possible

Intermediate DC circuit parameters


Permissible DC voltage variation –

Inverter

To be specified in the Data Sheet

DC bus OV trip To be specified in the Data Sheet

End of discharge DC bus voltage To be specified in the Data Sheet

Types of batteries supported SMF

DC ripple < = 2% rms

Maximum Battery back up time 30 min.

Black Start Possible

No. of batteries To be specified in the Data Sheet

Output parameters


Output power 10kVA/8kW

Output power factor 0.8 Lagging

Nominal output voltage 230 VAC



209 | 3 5 9

Output voltage regulation +/- 1%

Output voltage distortion for 100%

load

<=2% at linear load and

<=3% at non- linear load

Nominal output frequency 50Hz

Output frequency tolerance +/-0.1%

Output frequency synchronisation

range

+/-1Hz,+/-2Hz, +/-3Hz

Output crest factor capacity 3:1

Transient response at 100% step

load

+ / - 15% with recovery time of 20 msec

Configuration Parallel redundant

Overload capacity 10% overload for 1 hour

25% overload for 10 minutes

50% overload for 1 minute

Mechanical parameters


Protection grade IP21

Ventilation Forced – Air cooled

Cable entry Front end – Bottom

Color / Panel finish Dark structured grey, Silver

Base castor wheels Yes

Sheet metal thickness Nominally 2mm, 3mm as required at stress

points

Environmental parameters


Operating temperature range 0oC to 45oC

Storage temperature -10oC to 70oC

Relative humidity 0-95% RH Non-Condensing

Maximum altitude with full rating 1000 Meters

Altitude de-rating 1% per 100m between 1000m & 2000m

Acoustic noise with rated load at 1

meter

< = 60 dBA

Altitude de-rating 1% per 100m between 1000m & 2000m



210 | 3 5 9

LED/LCD Display


Input Supply On / Off / Fault

Rectifier On / Off / Fault

Battery On / Off / Fault

Inverter On / Off / Fault

Inverter side St. Sw. On / Off / Fault

Common Alarm On / Off / Fault

System Parameters on LCD

1) Input voltage Line to Line Required

2) Input Current Required

3) Input frequency Required

4) DC Bus voltage Required

5) Battery voltage Required

6) Battery charging current Required

7) Output voltage Required

8) Output current Required

9) Output frequency Required

10) Output KW /KVA Required

11) Ambient temperature Required

12) Inverter temperature Required

13) Output transformer temperature Required

14) Input transformer temperature Required

15) DC Bus mode of operation Required

Protections

1) Input under voltage Required

2) Input over voltage Required

3) DC Over voltage Required

4) DC Under voltage Required

5) Input current limit Required

6) Battery under voltage Required



211 | 3 5 9

7) Battery deep discharge Required

8) Black start on low charge of

batteries

Required

9) Battery current limit Required

10) High ambient temperature Required

11) Output short circuit protection Required

12) Rectifier short circuit protection Required

13) Output over voltage Required

14) Output under voltage Required

15) Output over current Required

16) Battery over temperature alarm Required

17) Inverter / Converter device over

temperature

Required

18) Transformer over temperature Required



212 | 3 5 9

SPECIFICATION FOR PRODUCT PUMP AUTOMATION

General

The Product pumps shall be either controlled though Variable Frequency Drive

(VFD/ Soft Starter) or through Star Delta Starter as applicable. Vendor shall

provide VFD system as given in the scope of this tender. The Scope of the

Vendor in Product Pump Automation shall include, but not limited, to the

following.

• VFD system as per the scope so as to control the pump through Automation.

It shall be possible to operate the pump through TAS in case of VFD failure

and in standalone mode in case of PLC failure. Submersible pumps, other than

Ethanol, will be operated by TAS/Start delta starter interface. • Supply, laying, termination, loop checking, testing & commissioning of Cables,

Glands, Explosion proof Junction Box etc. as required for between Control

room to VFD System. Existing Cables, JBs etc. if suitable may be used by the

Vendor. All cables from VFD System to pumps will be in HPCL scope

• Development of Pump control screen in TAS Software with two different

modules, one through Starter & the other through VFD. It shall be possible to

operate both the logic simultaneously for pumps of different product or

same product catering to different category of Tanks ( A/G or U/G)

• Supply, installation, commissioning & integration of Local / Remote Selector

switch. • Any change in PLC logic, additional modules, any other software, hardware

changes etc. shall be in the scope of the Vendor

• It shall be possible to stop the pump from Local push button even if the

pumps are operated in Remote mode.

• Permissive for Local operation shall be available.



213 | 3 5 9

SPECIFICATION FOR VARIABLE FREQUENCY DRIVE SYSTEM

GENERAL

The different mechanical equipment for which the VFD / Soft Starters etc.

covered in the specifications are under various stages of tendering and

placement of order. As such the ratings indicated are tentative and may be

subject to changes depending upon the mechanical equipment supplier. For all

such changes the prices quoted for the components by the bidder and agreed

by the HPCL shall be applicable. However the changes will be limited to +/- 10%

of the rating given.

Detail specification

Details of VFD & Soft Starters are as given below :

1. VFD/Soft Starters for Tank Truck loadings pumps. (VFD: 1No, Soft

Starter: 6 Nos.)

a) No. of Centrifugal Pumps: 6 (Six)

b) Power : 55 kW (Motor Rating)

c) Discharge Rate : 4800 LPM

d) Product to be pumped : HSD

2. VFD/Soft Starters for Tank Truck loadings pumps (VFD: 1 No, Soft

Starter: 3 Nos)

a) No. of Centrifugal Pumps: 3 (Three)



d) Product to be pumped : MS


Starter: 3 Nos.)

a) No. of Centrifugal Pumps: 3 (Three)





214 | 3 5 9

d) Product to be pumped : SKO

Note : For items 1,2 & 3 HPCL may add one more Pump of the same capacity for

each product in future. The VFD supplied shall have all the provision except

physical soft starter to include this pump in future


Starter: 3 Nos.)

a) No. of Submersible Pumps: 3 (Three)



d) Product : Ethanol

• Supply of connected items like nickel plated brass cable glands, Glands,

tinned copper lugs for all power and control cable shall also be included

in scope of VFD/Soft Starter supply.

• Each set of product loading pumps consisting of one VFD with associated

control gear, Motor starter consisting of soft starter and associated

control gears for each pump of a product group of pump, suitable

instrumentation for feedback control and energy measuring, data

acquisition, monitoring & transmission of data to the Terminal

Automation System, recording and reporting system for individual

motors.

The system envisaged for tank truck loading at will be as follows:

For each product group of drives, there shall be preferable two sets of

panels adjacent to each other as follow :

• VFD panel consisting of a common VFD (with control and programming

unit on panel door) with associated control gear/ protections for a group

of product pumps and pressure signal converter/isolator unit (two for two

analog pressure input signal for each product group of pumps), energy



215 | 3 5 9

meter and energy data acquisition and transmission system,

programming interface, displays, lamps, MCCBs/ switches, auxiliary

contractors, MCBs etc. I/Os from following interlocking panels shall also

be wired to the PLC. Central Interface Unit (CIU) and RS-485 to Ethernet

converter with built-in power supply unit as may be required for energy

meter data acquisition and transmission shall be located in this panel.

• Interlocking control panel (may have number of vertical panels as per

requirement) shall consist of Soft Starters (With control and programming

unit on panel door with associated switch gear MCCB,CTs, Contactors etc

for VFD connection and Soft Starter connection to each motor of the

groups of pumps, thermistor relay units for motor (30 KW and above) for

over temperature monitor and protection, one Digital Speed indicator for

VFD driven pump, energy meter and energy data acquisition and

transmission system for each soft starter, displays, lamps, switches,

auxiliary contactors, MCBs etc.

The Bidder should note the following:

o Modification of schemes / changes in components, if any

suggested during scrutiny/approval of drawings and execution of

work, shall be carried out successful contractor at no extra cost.

o The scope of Vendor includes all associated items/ sensors/

interlocks required for smooth and efficient working of system and

required during installation, testing & commissioning. All such

items are deemed to have included in the Vendor’s scope.

o All Safety interlocks, necessary to ensure maintenance operation

shall be provided.

o The VFD shall be connected to PLC through Ethernet bus (10/100

MBPS) for exchange of information/data/ commands. Pump shall

start based on the command from PLC in desired format and also

transmit the energy consumption data and other information

about the status/ operation of the drives and starters to PLC. The

communication format for the required exchange of information /



216 | 3 5 9

data for desired controls, reporting and monitoring system of the

bidder shall be submitted by him during detail design engineering.

POWER AND CONTROL SUPPLY

• 415 ± 10% V, 3ph 50 ± 5% Hz, 3 phase will be made available by the

HPCL. Different voltages required for various other purposes shall be

obtained by providing suitable MCB/MPCB, transformer, rectifiers etc in

each panel separately. The electronics shall be suitable for voltage and

frequency variations of ± 15 % and ± 6% respectively.

• 230V AC supply for illumination lamp operated by door switches and

power socket.

• 110V AC control, indication lamps.

• Input/ Output interrogation voltages.

a) Digital Input to PLC : Potential free from the field instruments/

MCC & interrogated at 24 V DC.

b) Analog input to PLC : 4 – 20mA DC, 2 wire, loop power 24V DC

c) Digital output from : Potential free to the field instruments /VFD /

PLC Soft Starter / panel & interrogated at

24V DC but contacts used in 110 V

Control circuit.

d) Analog output to : 4 – 20mA DC, loop power 24V DC

Alternatively the soft starters/VFD shall communicate directly to the

controller on modbus/ Ethernet protocol. Vendor shall include the

necessary communication module along with cable and other

accessories.

CONTROL MODES AND PHILOSOPHY OF CONTROL

o The main objective of the control system is to provide facility to start

any pump of the group with one VFD and run the same on VFD to

control the required set pressure in the line by switching in other



217 | 3 5 9

pumps (one by one) on their respective soft starters. At any time

during control if two or more pumps of a group are to be operating

then it shall be assured that soft starter driven pumps must run at

rated load and VFD driven pump can be lightly loaded. Both VFD and

soft starters work for energy saving while controlling/ maintaining the

set header pressure.

o Three mode of control are envisaged for operation and maintenance

of the pumps i.e. Local /Remote/Maintenance. The mode of

operation is selected at local control station of the respective pumps.

o Local mode of operation is envisaged mainly for testing of the pumps.

Each pump can be started and stopped from their respective LCS but

with permission contact from PLC for the particular group pumps.

Stop/Emergency stop PBs on LCS and at the Gantry shall stop the

pump in remote mode also. It shall be possible to operate the pump

manually in case of communication failure/PLC failure from the LCS.

Alarm shall be generated in the system for the failure. It shall be

possible to run the pump in case VFD failure thru soft starter

o Remote mode of the operation is the normal mode of the operation

and control for group of the pumps. All the pumps are selected in

REMOTE mode from their LCS. The operation shall be carried out from

the PLC.

o The group start command shall be provided by PLC based on the

Pump demand from the BCU & starting/stopping of further pumps

shall be done. A PID loop is envisaged in the PLC to control the

pumps to maintain the header pressure for proper loading. First one

of the selected pumps of the group is started and allowed to run. The

PLC shall monitor the VFD run pump speed and as soon as the speed

rises above the set speed a command is generated by PLC to start the

next pump with its soft starter and at the same time control speed of



218 | 3 5 9

the VFD run pump speed. Even after the start of the second pump the

VFD run pump increases then the command is given to third pump.

Under all the condition the VFD run pump is controlled and

monitored continuously. All the pump control work independently to

conserve/ save on energy consumption. From VFD there shall be

continuous feedback of VFD driven pump speed for the above

purpose. 4 – 20mA feedback shall also be envisaged to indicate the

speed of the VFD controlled pump on the digital indicator with motor

ID and speed in RPM. In case of PLC failure or communication failure

it shall be possible to operate the pumps through VFD in standalone

mode and bidder shall include all hardware/ software provision

required for the same. In case of VFD failure also, it shall be possible

to start & run the pumps. PLC shall monitor drives and their energy

consumption and shall further generate necessary reports including

energy consumption reports –pump wise and product group wise.

o There shall be provision to record the date, time and the number of

times the system is run on soft starter.

o All the addressable digital energy meters shall be connected on 10/100

MBPS Ethernet bus with the PLC.

o All meters shall have digital indications but the energy meter (as per

IEC-1248) shall have RS-485 port to communicate energy

consumption and other data to central interface unit (CIU). The CIU

shall have digital display and built-in soft keys for parameter setting/

selection and monitor the data from CIU shall be taken to PLC

through convertor (RS-485 to Ethernet 10/100 MBPS ). Energy

transducer shall have accuracy as per IEC 687/1036. The CIU at a

location shall have connections to energy indicator cum transducer

installed in motor soft starter circuit and VFD circuits so that motor

data collected by transducer are read by CIU periodically and displays

the same on its indicator and transmit data (real time



219 | 3 5 9

KVA/KW/PF/AMP/VOLT and KWh for selected time interval) to PLC

with motor ID.



220 | 3 5 9

TECHNICAL SPECIFICATIONS

VARIABLE FREQUENCY DRIVE (VFD) UNIT

VFD unit shall mainly consist of a three phase Six pulse rectifier bridge

with necessary three winding transformer, D.C link with reactor and

capacitors, inverter bridge, control system (microprocessor based). The

VFD unit shall have cooling fan and this shall be controlled based on heat

sink temperature.

The VFD shall be pulse width modulation (PWM) type with flux vector

control for closed loop speed control with pump header pressure

feedback for high accuracy and good dynamic performance. Pressure

shall be maintained at set value by speed control of the motor operating

on VFD and switching motors operated on soft starters.

VFD shall control operation and speed of product group pumps through

TAS PLC (at the Control room)

The unit shall comprise of an incoming microprocessor based MCCB with

suitable over current, short circuit & earth fault releases, three winding

transformer, three phase twelve pulse diode bridge rectifier acting as the

line converter and three phase inverter as the load converter

interconnected through DC link reactor and capacitor unit and output

reactor. The MCCB incomer shall be fully rated having short circuit

withstand 50 KA for 1 sec minimum. For the inverter unit IGBT’s shall be

used. The outgoing of the unit shall include reactor, contactor and

thermal over load relay with (1NO + 1NC) contacts. The unit shall also be

equipped with thermister relay also for motor ratings 30 KW and above.

But these contactors, thermistor relay & over load relay shall be located

in interlocking panel.

Line side filter shall be provided to contain line side current/ voltage



221 | 3 5 9

harmonics within the limits of IEEE/ IEC standards.

Contactors shall be 3pole air break, electro-magnetically operated. The

contacts shall be made of special silver alloy suitable for higher switching

frequency. The contacts shall have minimum bounce. The contactor shall

have mechanical ON/OFF indication. The coil shall be rated at 110V AC

and operate satisfactorily from 50 to 110% of rated voltage. Minimum

size of contactor shall be 16A.

All the buster works of VFD system shall be of copper only.

Circuit Boards shall be conformal coated

The unit shall have fully digital microprocessor based regulation and

control system with suitable interfaces for communication with the PLC as

well as the required instruments and signals. The microprocessor shall

carry out all the functions required from the unit including triggering

protection, self-diagnostics, operator & various parameterization

interfaces.

Suitable operator panel unit for programming/ debugging and control

shall be provided. Display of faults, alarms as well as diagnostics

messages shall also be available in plain text on this operator panel on

the cubicle door. It shall be sealed type with membrane switches & LCD

display unit. It shall be connected to the VFD control board thru

communication cable and installed on the panel door. This shall also be

user configurable for simultaneous display of two process parameters

customized to user scaled units for simultaneous display. Besides the

above, the following PBs and lamps shall also be provided on the door

and connected to the VFD

1. START PB

2. STOP PB



222 | 3 5 9

3. Fault reset PB

4. LED indication lamp for power on (R,Y,B), Drive ready drive on,

drive fault, off, overload trip etc.

All required high speed electronic protections shall also available with

unit apart from self diagnostic features. A few are listed below.

Over current instantaneous trip

Short circuit protection for converter/ inverter

Adjustable current limit.

Earth fault protection

Over temperature at heat sink.

DC bus under voltage & over voltage

Control & regulated power supply failure

Phase reversal protection.

Abnormal conditions shall initiate alarm and shut down drive based on the

nature of the fault.

Instruments

1. Digital speed indicator.

2. Digital Energy meter (accuracy class 0.5 0r better)

3. All meters shall have digital indications but the energy meter (as per

IEC-1248) shall have RS-485 port to communicate energy

consumption and other data to central interface unit(CIU).



223 | 3 5 9

VFD unit shall have the following operational features :

• Auto tuning.

• Parameter lock

• Power loss ride through.

• Adjustable acceleration/ deceleration.

• Adjustable starting torque

• Suitable for constant torque/ squared torque application as per

requirement.

• Torque boost at start (adjustable)

• Adjustable switching frequency.

• Analog inputs/ outputs of the converter shall be galvanically isolated

type. Digital outputs shall be potential free type. Minimum I/Os shall

be as per enclosed drawings with spares.

• Components for the same function and rating shall be of identical

design, make and of modular construction to reduce the inventory.

DESIGN CRITERIA

Input voltage : 415V (+10%, - 10%), TPN

Input frequency : 50 ± 5% Hz,

Ambient temperature : 50 Deg C

Output Voltage : 0 – 415 input voltage, 3 phase

Output frequency : 0-60 Hz, 3 phase as required.

Resolution : 0.01 Hz

Communication for which : RS-485, Ethernet (10 or100 MBPS )

Hardware provided in

Equipment

TESTS

Following tests on the test motor at the factory shall be performed

as part of testing requirements for VFD units:



224 | 3 5 9

Factory test:

Insulation resistance

Light load test

Checking of auxiliary devices

Control system test.

Efficiency test

Site Test:

Insulation resistance

Light load test

Rated current test

Checking of auxiliary devices

Control system test.

Efficiency test

SOFT STARTERS

Selection Criteria

Soft starter shall be provided for the each pump as per typical SLD. Design

and selection of soft starters shall be done taking into consideration the

fact that the soft starters are to operate continuously (with bypass

contactor) and with all reasonable precautions and provisions for the

safety of operating and maintenance personnel. The soft starter rating

shall be at least equal to motor KW rating at 50°C and other specified site

conditions.

All the busbar works of soft starter system shall be of copper only.

The soft starters have digital control using microprocessor based digital

regulation & control. This shall be provided with six thyristors in power

circuit and shall have all controls suitable for energy saving also.



225 | 3 5 9

Individual soft starter module for each motor shall be with MCCB with

built-in releases, 3 core CTs for connection to energy meter, Energy Meter,

surge suppressor, soft starter, Contactors and Overload relay. The digital

regulation and control system shall be compatible for operation from PLC

provided in VFD panel.

Salient Features

Soft Starter for AC drives shall comprise of following features:

1) The other protective features for the Soft starter shall include

following:

• Electronic type AC surge suppresser with fuse monitoring device

• Harmonic filters

• AC incomer under voltage & over load

• Negative Phase sequence protection & monitoring

2) Suitable for soft start I current limit I full voltage mode of operation.

3) Built in energy saver feature when motor is lightly loaded or is

running on no load. Soft starters are expected to run at or near rated

loads. If loads less than rated loads are encountered then VFD shall

alone control the motor.

4) Regulation & control equipment

• The digital drive regulation shall be considered and speed and

torque accuracy of drives shall be as required for the process.

• The regulation equipment shall be able to carry out all the control

functions including following important features.



226 | 3 5 9

• Current feedback & controller

• Adjustable acceleration I deceleration time.

• Adjustable starting torque.

5) Pulse transformers & trigger models

6) Protection, indication & annunciation devices.

7) Load side filter

Protection Features Protection, Indication and Annunciation

• The protection of the soft starter is to be provided as per the

clauses stipulated in IEEE-444 as suitable and required for each case

and shall generally include the following.

• Control power supply failure

• Ventilation failure

• Wrong phase sequence

• Motor stalling monitor

• Any other protection as required for particular application.

• The indications shall be provided as listed but not limited to the

following:

• Speed indicator of motor as required.

• Digital Energy meter (accuracy class 0.5 or better) shall also be

provided in soft starter circuit.



227 | 3 5 9

• All meters shall have digital indications but the energy meter (as per

IEC-1 248) shall have RS-485 port to communicate energy

consumption and other data to Central Interface Unit (CIU).

• The annunciation shall be provided as listed but not limited to the

following:

• Main power ON

• Control supply ON

• Incoming breaker trip

• Phase loss

• Microprocessor healthy

• System faulty

• Following shall also be annunciated

Motor Faults

• Over load relay or Thermister relay

• Over current

• Over voltage

• Earth fault

Soft Starter status

• Readiness



228 | 3 5 9

• Fault

• Run

SPECIFICATIONS OF PANEL COMPONENTS AND LCS

Control Transformers

Control transformers of adequate rating shall be provided for 110 V AC control

supply for each PANEL. Higher rating shall be selected based on actual

requirement with 50% margin and voltage drop in control transformer shall be

less than 3% at peak KVA requirement during coil pickup.

MCB shall be provided for primary side of control transformers. MCB of suitable

rating shall be provided on the secondary side.

Voltmeter class 1.5 and scale 0-250 V.

Control transformer shall be horizontally mounted in one of the bottom

compartments with adequate ventilation.

The transformer shall be double wound, dry type with class E insulating materials.

The control supply for the motor feeders shall be fed through suitable rated

MCBs in the modules.

Control transformers shall be provided with +/- 5% and +/-10% voltage taps on

415 V side.

The control bus of the PANEL shall be electrolytic grade copper only and will be

designed to carry the transformer rated secondary current as well as withstand

the available short circuit level.

Molded Case Circuit Breaker (MCCB)



229 | 3 5 9

Adjustable inverse time overload and I or instantaneous magnetic releases shall

be provided suitably. Operating handle, door interlock and padlocking at ON/OFF

position shall be provided. Symmetrical breaking capacity shall not be less than

the system short circuit level. At least 1 NO and 1 NC auxiliary contacts shall be

provided. These MCCBs shall be provided only for power supply feeders in

PANEL. MCCBs to be provided for VFD and soft starter circuits shall be as per

details given under Technical Specification.

Switches

• The switches shall have quick make, quick break, fault make, load break

mechanism operated by an external insulated and earthed handle

complete with ON/OFF position indicator plates.

• The switches shall be

a) AC 23 rated (motor duty) conforming to IS 4064-1978 capable of

interrupting minimum six times the rated current at 0.3 p.f of the switch

for switch ratings up to and including 250 amps.

b) Heavy duty conforming to IS 4064-1978 capable of interrupting three

times the rated current at 0.3 p.f at rated voltage for switches rated

above 250 amps.

c) In case heavy duty switches are offered for (a), then AC-23 rating for the

switch shall be indicated along with test certificate.

• All switch contacts shall be silver plated.

• In combination with series current limiting fuses, the switches shall be

capable of making all currents up to the system short circuit level

specified.

• The load break switch shall be provided with a through door operating

mechanism with visible blades or a visible means of determining the

disconnected position (when the door is opened) and mechanically

interlocked with the door so that switch must be in off-position before the

door can be opened. Provision shall also be there to defeat the door

interlock.



230 | 3 5 9

• It shall be possible to padlock the load-break switch handle in the OFF

position. Integral padlocking discs shall be provided.

• The load break switch shall be TPN.

• Bolted type removable copper links of adequate size shall be provided for

neutral in all incomer feeders and outgoing feeders with TPN fuse switch I

switch fuse units.

• Solid links shall be used for connections between switches and fuses.

Fuses

• All fuses shall be HRC link type (knife edge but not bolted type)

conforming to IS: 9224-1979. The HRC fuses shall be current limiting, non-

deteriorating type having breaking capacity of not less than 50 kA.

• Fuse holders shall be selected based on the highest fuse rating for the

given load break switch and specified lower size fuses shall be fitted by

means of suitable links if required.

• All fuses shall be provided with distinct type operating indicators, to show

whether they have operated or not.

• Fuse holders and fuse bases shall be made of unbreakable non-

inflammable and non-hygroscopic material like phenolic mouldings.

• 3 sets of fuse pullers required for inserting and removing HRC fuses shall

be supplied for each panel.

• Current Vs. time and 12t characteristics of all fuses shall be furnished along

with the tender.

Contactors

Contactors provided for control of motors shall be 3 pole air

breaks,electro-magnetically operated Contactors meant for capacitor



231 | 3 5 9

switching shall have duty corresponding to 150% of rated capacity of bank

at 440V. The contacts shall be made of special silver alloy suitable for

higher switching frequency. The contacts shall have minimum bounce, the

contactor shall have mechanical ON/OFF indication, 2 NO + 2 NC auxiliary

contacts rated at 5A at 440 V. The coil shall be rated at 110 V AC, and

operate satisfactorily from 75 to 110% of rated voltage. Incoming and '

outgoing terminals shall be segregated and terminal capacity shall be

suitable for the type of termination adopted.

Current transformer

Protection and measuring current transformer shall be of cast resin, bar

type primary, with 5A or 1A secondary conforming to IS-2705 -1992 Part

11, Ill and IV. The minimum burden shall be 15 A CT shall be suitable for

415 V +/- 10 %.

Measuring current transformers shall conform to accuracy class 1 of IS-

2705 -1992 and burden of CTs shall be as required by the associated

measuring instruments and connecting leads, The CTs shall have saturation

factor of 5.

Protection current transformers shall have their accuracy and burden as

required by the protection circuit in which they are used and shall have

minimum saturation factor not less than 10.

CTs for restricted earth fault protection shall conform to Class 'PS',

Part IV of IS-2705. All CTS shall withstand without injury dynamic stability and thermal stability currents specified for PANEL.

The current transformer' ratios specified are provisional and are subject to alteration and confirmation later at the time of approval of manufacturer's drawings.

Indicating lamps

In addition to the mechanical indicators on the circuit breaker, each

breaker cubicle shall have cluster LED type indication lamps as Specified.

All indication lamps shall have series resistance for long life maintaining



232 | 3 5 9

visibility. Lamps shall be replaceable from front of the cubicle without

opening the door.

Control switches

Circuit breaker control switches, when provided, shall be of pistol grip,

spring return to neutral type. They shall be arranged to close the breaker

by being turned clock-wise and to trip it being turned antilock wise. The

trip, neutral and close positions shall be clearly located and the switch

cannot be operated inadvertently. It shall be mechanically inter locked to

trim before close. Lost motion contacts shall be provided in these switches.

Cable termination accessories

Undrilled G.l gland plates and compression type brass cable glands shall

be provided for termination of cables. The gland plates shall have gaskets

so that the enclosure conforms to IP-54. . Provision for terminating 1/2

core on to earth bus and neutral bus shall be made. All lugs shall be tined

copper lugs only. All lugs and glands for all power and control cables shall

be supplied with the equipment.

Local Control Stations

All motors for Pumps shall have local control station (LCS) mounted near

driven mechanism, which shall be flameproof located at hazardous area.

These shall be supplied by the Owner and shall be interlocked / connected

to the bidder's equipment for operation of the system.

VFD PANELS

• CONSTRUCTIONAL DETAILS

• Single/Double front design, Non-draw out, free standing,

compartmentalized floor mounting type suitable for both front

and rear access. The panel shall be extendable on both sides at

site.

• Shall have an integral base channel.

• A transport section shall not exceed 3 vertical panels.

Lifting facility shall be provided for each section.



233 | 3 5 9

• Feeder module doors and cable alley doors shall open in opposite

direction for providing more working area for maintenance

purpose.

• Cable alley shall be adequately designed for use of aluminum

conductor power cables. Cable entry shall be from bottom with

undrilled gland plate.

• Neoprene gaskets shall be used for cable alley doors, bus bar

chamber covers to ensure tightness and making it dust proof.

Cutouts in the module door shall have neoprene gaskets ensuring

dust tightness.

• All switches, push buttons etc. shall be capable of operating from

the front. Each feeder module shall have door interlock, defeat

interlock and padlocking facility.

• The panels shall be sheet steel enclosed of minimum thickness 2

mm dust and vermin proof, free-standing, floor mounted type

having Panel illumination lamps, space heaters and sockets for

soldering etc. Base channel of height 75 mm shall be provided.

• Max. height of operating knobs of any device or indicating meters

shall not exceed 1800 mm from floor of room. Minimum height

shall not be less than 450 mm.

• Anti-condensation heaters-of suitable rating with thermostat

cutoff shall be provided in each PANEL.

• The control blocks shall be plug-in type with required/necessary

test sockets. The layout of components shall be such. Designed

that the testing operation & maintenance is convenient. The

panels shall have enclosure with class of protection conforming to

IP-5X.

• Busbars & Supports

• Main busbars shall be made of high conductivity aluminum of

grade E91E (IS-5082/1981), Control bus electrolytic copper as per

IS-1897-1983.



234 | 3 5 9

• Three phase and Neutral bus shall have facility for connection with

earth bus.

• Shall be heat shrinkable PVC shrouded except at the points of

tap-off. The bus bars shall be color coded for phase identification.

• Busbars shall be housed in totally enclosed compartments having

removable type covers for easy maintenance.

• Horizontal power bus bars and control bus bar shall be located at

the top of PANEL.

• Power and control bus bars shall be segregated.

• Main bus bars shall run throughout the length of transport section

and vertical bus bars throughout the height of PANEL. A

continuous earth bus shall be provided for the PANEL at the

bottom with an earthing bolt at each end.

• Busbar joints shall be of bolted type with suitable spring washers

to ensure tight fittings. Bolts and washer shall be galvanized or

cadmium plated.

• Horizontal bus bars shall be extensible on either side of PANEL.

• The earth bus shall be of aluminum having the same size as that

of neutral bus bar at the top. Neutral and earth busbars shall be

connected through a link.

• Provision shall also be made for terminating on earth bus the 4th

core of incoming & outgoing cables. Bolted joints with tooth

spring washers shall be provided for good earth continuity.

• Bus bars shall be sized for the current rating specified (with

temperature derating) to withstand a short circuit of 35kA rms for

1 sec. The current density shall not be more than 0.78

Amps/sq.mm.

• Temperature rise of bus bars shall be limited to 40 Deg. C.

• Bus bar supports shall have adequate mechanical strength, high

dielectric strength, and low moisture absorption characteristics.

Hylam shall not be used.

• Bus bar supports shall be rigidly held to the frame work of PANEL

and shall be so spaced as to ensure rigid support for bus bars.

• Bus bar supports shall be designed to withstand thermal and

dynamic stresses resulting from specified short circuit current.

• Min. clearance between live parts shall be 25 mm and live to earth

19mm.



235 | 3 5 9

• All core type CTs mounted on bus bars shall be supported

separately and not supported on bus bars. CT secondary-

connecting cables shall be properly dressed and clamped such

that these do not hang loose I pass directly over bus bars.

• Wiring & Terminal Blocks

• Suitable provision shall be made to terminate control / power

connections near the respective module. The terminals selected

shall be suitable for the termination of armored cables, as per the

details of cable required. Adequate space shall be kept for

cabling.

• Panels shall be completely factory wired, ready for connecting to

equipment.

• Power circuit wiring shall be with 1100 V grade single core

stranded, PVC insulated copper cable of minimum 4 sq. mm.

• Control circuit wiring shall be with 1100 V grade multi strand, PVC

insulated copper cable of 1.5 sq. mm.

• Internal control wiring shall be laid in PVC ducts with detachable

snap - on covers and there shall be enough length to avoid the

necessity to stretch the cables for door movement connection,

disconnection or changing.

• All terminals, as well as terminations, at various control devices

inside the compartment shall be provided with interlocking type

ferrules having engraved numbers. Terminals having connections

from other modules shall be marked with red ferrules.

• There shall be no joints or tappings between two terminations. No

more than two connections shall be made to any terminal.

• 20% spare terminals shall be provided in each control terminal

block.



236 | 3 5 9

• The wiring shall be terminated in the respective terminal with

suitable crimp type sockets.

• Interlocking type ferrules for identification shall be provided.

• All spare contacts to be wired to terminal block.

• Inter-panel wiring shall be through horizontal bus bar chamber.

• All holes or tubes for wiring runs shall be bushed and shall have

room for reasonable additions.

• All power cable terminal blocks / boards shall be stud and nut

type with phase barriers.

• For higher rated feeders, suitable staggered extension links

shall be provided to permit direct termination of cables.

• Cable supports / clamps shall be provided in cable alley.

• Double compression type GI / brass glands, accessories including

tinned copper lugs to outgoing cable sizes to be supplied loose.

• The color-codes for the wires shall be as follows:

415V, 3phases Red, yellow & blue

Neutral Black

Earth Green Single phase – line Red

110 V AC – line Brown 24V DC +ve Orange

24V DC –ve Black

• Doors & side panels shall be fabricated from cold rolled steel

sheet of minimum 1.6mm thickness. Load bearing parts shall be



237 | 3 5 9

minimum 2 mm thick cold rolled sheet steel. The cable gland plate

shall be 3.0 mm thick.

• Each Panel shall be maximum 2300 mm high (including 75-mm

channel base), minimum 800 mm wide and 800 mm deep, in

general. An anti-vibration pad of 20 mm thickness shall be

provided. Construction shall be modular preferably to

accommodate all components. All cabinets shall be of same

height. Maximum swing out for pivoted card racks, doors and

drawers shall be limited to 600 mm.

• Panels shall be equipped with the front and rear access doors.

Doors shall be equipped with lockable handles and concealed

hinges with pull pins for easy door removal.

• In order to remove dissipated heat effectively from cabinets, vent

louvers backed by wire fly screen shall be provided in cabinet

doors. Further ventilation fans as required shall be provided.

• Each cubicle shall be provided with panel illumination lamp

operated by door switch and 15A, 3 pin socket with switch. 230V

AC supply for this shall be tapped from horizontal bus bars.

• Equipment within the panel / module shall be laid out in an

accessible and logically segregated manner. Cable glands shall be

provided for incoming and outgoing cables to prevent excessive

stress on the individual terminals. All metal parts of the cabinet

shall be electrically continuous and shall be provided with a

common grounding lug.

• CABLE TERMINATIONS

• Cable terminating facilities and terminals shall be suitable for the

specified cable type and conductor size. Contractor shall take

consideration and provision on the equipment design for the use

of cable with aluminum conductors.

• Terminal blocks shall be arranged and positioned for easy access for carrying out external cable termination, testing, inspection and maintenance. There shall be clear space allowed between the



238 | 3 5 9

terminal block and the cable entry for the spreading and termination of external conductors.

• Terminal blocks shall be mounted in a single tier arrangement.

• The panel wiring shall be on one side of the terminal block only.

• All terminal blocks shall be shrouded or provided with transparent covers.

• Terminals for different voltages shall be separated by partition.

• An undrilled gland-plate or entry panel of sufficient dimensions to terminate the specified cables shall be provided. Cable entry shall be from bottom unless specified.

• Positioning of cable terminations shall avoid obstruction of other cable terminations, removable covers, etc. and sufficient space shall be available for maintenance work and cable termination.

• Cable clamping arrangement shall be provided to avoid undue strain on the cable termination.

• ANTI-CONDENSATION SPACE HEATERS

• Thermostatically controlled heaters suitably rated to prevent condensation shall be provided within the distribution board.

• The heater shall be supplied with a double pole isolator

• The heater terminals shall be clearly marked as to their use.

• LABELS

• A main nameplate shall be affixed in a prominent position on the

front of each distribution board giving the following information:

• Manufacturers name.

• Distribution board Tag Number and name.

• System voltage, phase, wires and frequency.

• Year of manufacture.

• Characters shall be of 12 mm height.



239 | 3 5 9

• Labels shall have black characters on a white background and be

made of non-corrodible material. Warning/Danger labels shall

have black lettering on a yellow background.

• Label shall be affixed by screws or rivets.

• Each panel board shall have fitted a circuit directory within-a clear

protective cover located on the inside of the outgoing circuit

compartment door.

• EARTHING

• A continuous earth bus shall be provided for the

VFD/PLC/SOFTSTARTER PANEL at the bottom with an earthing

bolt at each end.

• Provision shall be made for connecting 4th core of incoming and

outgoing cables.

• The earth bus shall be of electrolytic grade copper (E 91E) having

the same size as that of neutral busbar at the top.

• Neutral and earth busbars shall be connected through a link.

• Electrical equipment shall be interconnected with earth grid -

using minimum size 50 x 6 copper.

• Earthing shall conform IS 3043 - 1987, IE rules and statutory

regulation.

• Each cabinet, console and other equipment supplied as a part of

panels shall be provide with an earthing lug. All these lugs shall be

properly secured to the AC mains earthing bus.

• All circuit grounds, shields and drain wires of control cables shall

be connected to the system ground bus which shall be electrically

isolated from AC mains earthing bus. This bus shall be typically of

50 mm wide and 6 mm thick of copper.



240 | 3 5 9

• All barriers, if used, shall be securely grounded. Safety barrier

ground wire shall be capable of carrying a maximum fault level

current of 0.5 A at 250 V r.m.s per barrier.

Following Features shall also be available in the VFD System

a) Shall have Embedded Ethernet port for direct network cable

connections.

b) Battery receptacle for Lithium battery power to the Real Time

Clock.

c) The drive shall employ PI regulation with an adjustable gain for

smooth transition in and out of current limit.

d) Accel/Decel settings shall provide separate adjustments to

allow either setting to be adjusted from 0 to 3600 seconds

e) Software must be available for trending and diagnostics, as well

as online and offline programming functionality.

f) A digital interface shall be used for all set-up, operation and

adjustment settings.

g) All adjustments shall be stored in nonvolatile memory

(EEPROM).

h) No potentiometer adjustments shall be required.

i) EEPROM memory for factory default values shall be provided.

j) Software shall be available for trending and diagnostics, as well

as online and offline programming functionality.

k) The last 10 fault codes shall be stored and time stamped in a

fault buffer.

l) Information about the drive’s condition at the time of the last

fault shall be stored.

m) A power-up marker shall be provided at each power-up time to

aid in analyzing fault data.

n) The last 32 alarm codes shall be stored and time stamped for

additional troubleshooting reference.

o) The drive shall be capable of sensing reference loss conditions.

p) The VFD shall have



241 | 3 5 9

i. Manual Bypass Option:

o Shall provide a means to manually switch a single motor from

drive control to bypass (across the line operation).

o Shall provide separate drive output and bypass contactors. The

contactors shall be electrically and mechanically interlocked.

o Shall provide a Drive/Off/Bypass selector switch, mounted on

the enclosure door, for selection of Drive and Bypass modes of

operation.

o Provide a Class 10 overload for motor protection while

operating in the bypass mode.

ii. Automatic Bypass Option:

o Shall provide a means to automatically (upon a drive fault)

switch a single motor from drive control to bypass (across the

line operation).

o Shall provide separate drive output and bypass contactors. The

contactors shall be electrically and mechanically interlocked.

o Shall provide a Drive/Off/Bypass selector switch, mounted on

the enclosure door, for selection of Drive and Bypass modes of

operation.

q) The VFD system shall capable of providing time stamped

events In the event of loss of the reference signal, the drive

shall be user programmable to the following:

i. Fault the drive and coast to stop.

ii. Issue a minor fault - allows the drive to continue running

while some types of faults are present.

iii. Alarm and maintain last reference.

r) The communications adapter shall have these configurable

responses to network disruptions and controller idle (fault or

program) conditions:

i. Fault

ii. Stop

iii. Zero Data



242 | 3 5 9

iv. Hold Last State

v. Send Fault Configuration

s) At a minimum, the following parameters shall be accessible

through the OIC:

i. Output Current in Amps

ii. Output Voltage in Volts

iii. Output Power in kW

iv. Elapsed MWh

v. DC Bus Voltage

vi. Frequency

vii. Heatsink Temperature

viii. Last 10 faults

ix. Elapsed Run Time

x. IGBT Temperature

t) At a minimum, the following faults shall be accessible through

the System:

i. Power Loss

ii. Under-voltage

iii. Overvoltage

iv. Motor Overload

v. Heat Sink Over-temperature

vi. Maximum Retries

vii. Phase to Phase and Phase to Ground Faults

u) At a minimum, the following predictive diagnostic features shall

be provided:

i. Relay Output Life Cycles based on load type and amps.

ii. Hours of Fan Life based on load and ambient temperature.

iii. Motor Bearing life based on expected hours of use.

iv. Motor Lubrication schedule based on hours of use.

v. Machine Bearing life based on expected hours of use.

.



243 | 3 5 9

v) Shall provide a Auto Bypass/Off/On selector switch, mounted

on the enclosure door, for selection of Auto Bypass mode of

operation.

w) Provide a Class 10 overload for motor protection while

operating in the bypass mode.

APPLICABLE CODES AND STANDARDS

All applicable Indian and IEC codes, regulations and standards shall

govern the work. In the event of the requirements of the specification

exceed the requirements of the corresponding codes, regulations or

standards, the specification shall govern. The applicable standards shall

include standards listed below:

1. IS 2705 Part I 1992 to Part IV: Current transformers,

general requirements.

2. IS 12021 –1937: Control Transformers

3. IS 13947 Part 4– 1993: Contactors

4. IS 13947 Part 3 1993: Specific requirements for the direct

switching of the individual motors,

5. IEC 171: Molded Case Ckt. Breakers

6. IS 2419 – 1979 Reaffirmed 1991: Dimensions for panel

mounted indicating and recording electrical instruments.

7. IS 8197-1976:Terminal markings— Electrical measuring

instruments.

8. IS 8623 Part 2 –1993: Factory built assemblies of switchgear for

voltage up to and including 1000V AC and 1200V DC. Particular

requirement busbar trunking system.

9. IS 13947 Part 1 – 1993: General requirements for switchgear and

control gear for voltages not exceeding 1 000V AC.

10. IS 10118 - 1982: Code of practice for design installation and



244 | 3 5 9

maintenance of switchgear and control gear.

11. IS 13947 Part I - 1993: Degree of protection provided by

enclosure for low voltage switchgear and controlgear.

12. IS 13703-1993: HRC cartridge fuse links.

13. IS 1554 Part 1 1988 & Part 2 1990: PVC insulated (heavy-duty)

electric cables.

14. IS 3043 - 1987: Earthing

15. IS 5578 - 1984: Guide for marking of insulated conductors.

16. IS 13234-1992: Guide for short circuit calculation.

17. IS 2551-1982: Danger boards.

18. IS 3722-1983 : Letters and Symbols used in electrical technology.

19. IS 9676 – 1980: Reference ambient temperature for electrical

equipment.

20. IS 8923 -1978 : Warning symbols for dangerous voltages.

21. IS 5 – 1994: Colour for ready mixed paints and enamels.

22. IS 722: Specification for AC Electricity meters.

23. IS 1248 : Specifications for direct acting indicating analogue

electrical measuring instruments and their accessories.

24. IS 3618: Phosphate treatment of iron and steel for protection

against corrosion.

25. IS 4047: Heavy-duty air break switches and composite units of air

break switches and fuses for voltages not exceeding 1000 V.

26. IS 4064: Air break switches, Air break disconnection, Air break

switch disconnectors and fuse units for voltages not exceeding



245 | 3 5 9

1000 V AC or 1200 V DC.

27. IS 5082: Specification for wrought aluminium and aluminium alloy

bars, rods, tubes and sections for electrical purposes.

28. IS 5578: Guide for marking of insulated conductors.

29. IS 6005: Code of practice for Phosphating of iron and steel.

30. IS 11353: Guide for uniform system marking and identification of

conductors and apparatus terminals.

31. IS 13925: Specification for Shunt capacitors for power Systems

TESTING

Contractor shall provide test certificates for Routine tests carried out on the

equipment / boards. Tests shall be as specified in the relevant standards as

specifically mentioned in the specification

Tests at works and tests at site shall include the following:

a. One minute PF withstand voltage between phases, phase to earth and

between open poles as well as for the auxiliary / control circuit.

b. Insulation resistance test for power, auxiliary and control circuits. c. Physical inspection

d. Operational tests and other routine Tests as per standards/TS.

e. Tests to prove inter changeability of equipment/ components with same

current rating. f. Calibration of meters.

g. Check of control circuits

h. Test to prove operational requirements, programming, monitoring etc.

i. Heat run test on the panels.



246 | 3 5 9

OTHER FIELD EQUIPMENTS

SPECIFICATION FOR DENSITY METER



Qty : Refer BOQ

Service : As given in the design criteria

Working Principle : Direct / Coriolis type

Range : 0.6 to 1.0 gm/cc

Size : Min 10 mm

Accuracy : ± 0.0003 gm/cc over the entire range

Repeatability : ± 0.00005 gm/cc

Location : Open to sky, On the by-pass to the header

line near Gantry

Power Supply : 24 V DC

Temperature Range : As defined in the design parameter

RTD : Built in or separately as per the

specification. Incase provided separately

the same shall be integrated with

densitometer for providing the Standard

Density & temperature locally as well as on

the remote.

Transmitter : Integral

Transmitter Accuracy : Vendor to specify

Pressure : 0 to 10 Kg/ cm2

Protection : IP – 65



247 | 3 5 9

Flanges : SS 316 / SS 316L

Wetted parts : SS 316 / SS 316L/Ni-Span-C

End Connection Min ‘1”

Housing : SS 316 fully welded

Pressure Drop across the main

header

: Less than 0.15 Kg/ Cm2

Vibration effect : Negligible

Communication Interface : HART, Modbus (RS 485), 4-20 mA,

linearised & temperature compensated.

Serial output communication to TAS

System on RS 485. The density details shall

be displayed at the TAS system & shall be

relayed to ERP for printing on the invoice

as per the details given in the functional

requirement

Local Display : Microprocessor based ex proof or IS local

Display of Ambient Density, temperature

and Standard Density. The readings

observed at the local mode & the remote

mode shall be same at uncorrected

temperature

ASTM Table : The densitometer shall have inbuilt latest

ASTM Table 54 B for density correction

suitable for the products used.

Configuration : Via RS 485 communication

Area classification : Class 1, Zone I, Group II A & II B, T3

Certification : CCOE (PESO) Approval is mandatory for

use in hazardous area & any one of the

following FM/UL/ATEX/CENLEC approval.

Ingress Protection : Weather Proof to IP 65



248 | 3 5 9

Other Protection : Circuit shall have protection for surge,

reverse polarity, lightening protection.

Other Requirement Mass Flow meter, if used, shall have

Custody Transfer approval.

Calibration : All densitometer shall be calibrated at FCRI,

Palaghat or any other NABL approved Lab.

Diagnostic Features : Required, Health check up, Calibration

Factors.

Alarm : Alarm shall be generated if the standard

density is beyond tolerance limit as

specified in the functional requirement.

Flow Switch (For Direct

Densitometers only)

: Required at the bypass line. The feedback

shall be available in the TAS to know that

the product is flowing through the bypass

line.

Side Glass (For Direct

Densitometers only)

: Required after the densitometer with

toughened Glass

On Site Verification : Required. By Pycnometer as per API MPMS

Chapter 14 Section 6 or by Digital

hydrometer or any other method as

defined in API Chapter 21 Clause 11.6.3. All

Equipments required for Onsite Verification

& commissioning like pycnometer/ digital

hydrometer , HART Calibrator shall be

brought by the Vendor at no extra cost

during SAT or as & when requested by

HPCL during the commissioning,

Stabilization, warranty, comprehensive

AMC

Material conformity certificate : Required

NOTE: Restriction Orifice to be sized based on the corresponding pressure drop

and flow. Vendor shall calculate the net flow through the main header and shall

size restriction orifice plate as per the net flow and pressure drop (Minimum)

across the density meter. Restriction orifice material shall be SS316.



249 | 3 5 9

SPECIFICATION FOR TEMPERATURE SENSOR (RTD) TRANSMITTER (FOR

DENSITOMETER)


Type : Pt-100, Simplex, 3 wire as per DIN standards

Qty : Refer BOQ

Thermowell : SS 316, barstock

Instr. Connection : ‘1/2" NPT(F)

Immersion length : As required

Range : 0-100deg C

Total length : As required

Mounting : On the Header TLF shed, Incoming lines to

tank


Enclosure : Explosion proof, Class I, Division I, Zone 1,

Gr II A, IIB and weather proof to IP 65

Process connection : Screwed connection 3/4" NPT(F)

Output : 4 to 20 mA signal, HART/ Modbus

Insulation : Mineral Insulated

Accuracy : Accuracy As per DIN 43760

Sheath : Made of SS 316 having 5 mm diameter

Lead wires : Copper

Note: This is required only if the densitometer does not have inbuilt Temperature

sensor



250 | 3 5 9

SPECIFICATION FOR PRESSURE TRANSMITTER FOR WHITE OIL HEADER LINE

Type : Electronic microprocessor based, smart

transmitter


Output : 4-20mA, HART/ Modbus. Pressure readings

shall be communicated to TAS & alarms

shall be generated

Accuracy : 0.07% of Calibrated Span

Principle of operation : Variable capacitance

Range : 0 – 7 bar

Material of construction : SS 316 for wetted parts

Service : Header Pressure Measurement

Process connection : as per OEM standard

Over range protection : 150%

Power : 24 VDC

Element Type : Diaphragm with fill fluid silicon Oil

Area classification : Zone 1, Group II A/II B, T3

Enclosure : Weather Proof to IP 65, Explosion Proof

Protection : Protection required against surges,

lightening, reverse polarity

Zener barrier : Required

Isolation Ball valve : Fire safe, antistatic, Full bore required

Zero & Span Adjustment : Required & shall be carried out at Site as per

the requirement



251 | 3 5 9

SPECIFICATION OF BARRIER GATE

Makes : As per approved vendor list

Quantity : Ref BOQ

Type

: Electrically operated barrier system with

complete drive mechanism box, 4-band circuit

controller, counter balance channel and weights,

control switchgear etc. for 6-meter wide gate.

Construction • Square type boom with 3 mm for 1st

section, 2.5 mm for 2nd Section & 1.9 mm

for 3rd Section with suspended pendent

fringes, painted as per standard Color

combination i.e. yellow & black Color

bands painted alternate, rectangular

target fixed on the boom painted with

“STOP” lettering.

• MS fabricated boom support with rubber

padding.

• Separate wall mounted Local control

panel with 3 nos. push buttons to be

installed on outer face of security room

wall. Job also includes providing

necessary RCC foundation complete with

foundation bolts, etc.

Indicating Lamp : Standalone Non Flameproof Traffic Light shall

be provided which shall be integrated to display

status of the Gate. In closed condition, the Lamp

shall indicate Red Color. Once the Card is shown

& communication is send to PLC, it shall

indicate amber color. When the Gate is in the

transition stage (while opening/closing) it shall

indicate flashing green. When fully open it shall

indicate green color.



252 | 3 5 9

Indicating Box : Non Flameproof box shall be provided near the

card reader with two Lamps (min 1”) for

distinguishing between Authorized &

Unauthorized card

Operating time : Closing/Opening operation within 10 seconds.

In case of card/ Sensor

failure

: Manual(electrical) control available at

Security room

Operating in manual

(electrical) mode

: Remote push button control from Control room

for opening and closing of gates

Operating without power : Manually with hand cranking attachment

Outputs : 2 Nos potential free contact output while

closing position.

Supply voltage : 230 VAC +10% to -15%, 50 Hz +/- 0.5%

Sensor for auto closing : IR sensors with suitable canopy for operating in

sunlight. It shall be provided in inclined fashion

so that the Transmitter & receiver are not in line

for the space between Truck Cabin &

compartment

Motor : Non Flameproof

Warning Sound : Barrier Gate shall have the audible warning beep

while opening & closing o f the gate

Control : Gate Barrier Control shall be through PLC. All

power control & signal cabling, hard wiring of

Barrier gate SPDT contacts to the PLC including

FLP Cable glands is in the vender scope.

Other functional requirements for Gate Barrier Operations: In the event of

showing a proximity card at gate barrier, the card can be valid or invalid. Invalid

card can further be classified as timeout cards , unauthorized cards. The TAS

vendor to install one display box near the card reader ( for each gate) with 4

lights namely Red and Green in first line and second set of Red and Green in

second line. The two set of red and green light shall be separated from each

other by minimum gap of 25 mm. Proper sunshade shall be provided so that the

light is visible clearly from a distance of 3 meter during full sunshine. The lamp

size shall be min 25 mm. First line set of Red and green light shall be for card



253 | 3 5 9

authorization and second set in the second line shall be indicator for power

supply of gate barrier motor. In the event that card is authorized the green light

(in first row) shall glow and in the case card is unauthorized the red light (in first

row) shall glow. TAS vendor needs to check the status of incoming power supply

to gate barrier motor and take the same feedback to TAS system also in events

and in graphics in system health screen. In case of healthy power supply to gate

barrier motor the green light shall continuously glow ( in the second row) else in

case of power failure ( momentarily also) the red light shall glow. The display box

containing these light shall have permanent tag plates indicating individual

headings for each light. The gate barrier provided by the vendor shall have

buzzer which shall give alarm sound and blinking light in center while the boom

is traversing up or down. The gate barrier status shall be taken with the help of

limit switch supplied by vendor. MCB or any other hardware required for

achieving the above functionality and gate barrier installation , panel erection etc

is in scope of vendor.



254 | 3 5 9

DATA SHEET – TRIPLE OFFSET BUTTERFLY VALVE ON HEADER LINE

1 Valve Size As per BOQ

DESIGN PARTICULARS

2 Valve Type Triple Offset high performance , metal to metal

seated, non-rubbing, torque seated, double flange

end, quarter turn, anti-static, anti-blow out stem

arrangement butterfly valve.

3 Mfg. Standard API 609

4 Face to Face As per API 609, Short Pattern

5 Inspection and

Testing

API 598

6 Fire Safe API 6FA/API-607-Vth Edition, Zero leakage before,

during after fire.

7 ANSI Class 150#

8 Rated Travel 90 Degrees

9 Flow direction Bi-directional, tight shut-off in either direction

10 Fire Safe Required

11 Anti Static Device Required

CONSTRUCTION

12 Body Cast

13 Disc Cast

14 Stem Bar-forged (No casting)

15 End Connection Double flanged as per ANSI B 16.5RF

16 Flange & finish 150#, RF, 63-125 AARH, smooth finish

MATERIAL

17 Body ASTM A216 Gr. WCB

18 Disc ASTM A216 Gr. WCB/ASTM A351 CF8M

19 Seal Ring UNS S 31801 Duplex SS+ Graphite

20 Stem A479 UNS 41000/17-4 PH Hard Chrome

21 Bushing UNS S31600

22 Disc Retainer

Flange

ASTM A 516

23 Disc and Bottom

Flange

UNS 31600+ Graphite

24 Seat Stellited Gr. 21 Weld Overlay



255 | 3 5 9

25 Pin/Nut/Washers SS 316

26 Thrust Bearing SS 316/ Hardfaced /Cobalt based alloy

TESTING

27 Body Hydro test 1.5 times the flange rating (30 bar #150)

28 Seat Hydro test 22 bar #150, test duration as per standard

29 Leakage Class

required

Zero Leakage/ bubble tight shutoff

ACCESSORIES

30 Pilot Valve Vendor to specify

31 Make & Model Vendor to specify

32 Weight in kgs Vendor to specify

PROCESS DATA

33 Design Pressure As per #150

34 Design

temperature

65 deg. Centigrade

35 Valve Torque+25%

safety margin

Vendor to specify



256 | 3 5 9

DATA SHEET – ACTUATOR FOR HEADER LINE TOBV

1 Sizing basis 1.25 times the valve torque for shut-off

pressure and less than valve stem shear

torque

2 Actuator Type Electric Actuator with Integral Starter suitable for

quarter turn valves, 2 wire remote control using

communication through Field control unit /

Master control station

3 Electric Supply 415 V AC, 50 Hz 3 Phase

4 Make & Model, Vendor to specify

5 Weight in kgs. Vendor to specify

6 Power

Consumption

Vendor to specify

7 Open/Closing

Time

Vendor to specify

8 Open/Closing

Torque

Vendor to specify

9 Hazardous Area

Protection

Zone 1 Gr. IIA / II B, T3

10 Ingress

Protection

IP 65 as per IEC 529

11 Control Two wire communication - MODBUS RTU

network

12 ESD Command Hardwired command for Emergency

Operation

13 Motor Type Squirrel Cage, induction type

14 Fault Level

Supply system

Fuse protected

15 Rating kW Vendor to specify

16 Speed (RPM) Vendor to specify

17 Direction of

Rotation

Clockwise, Anti Clocwise (Facing Drive End)

18 Cooling Method Air

19 Starter Integral with motor

20 Reduction Integral with actuator



257 | 3 5 9

Gearing

21 Local /Remote

Switch

Required

22 Local On/Off

Controls

Required

23 Hand wheel for

Manual

Operation

Required

24 Open/Close

Limit Switches

Required

25 Local position

indicators/LEDs

Required

26 Cable Entries M12/M25- for control, min. 2nos, M25/M40

for power

Control Status & Alarms

27 Opening & Closing Required

28 Open & Closed Required

29 Stopped Required

30 Torque switch stopped Required

31 Local/Remote & Local Push

Button Pressed

Required

32 Main Power Loss/ Phase

Loss, Control Power Loss

Required

33 Actuator Fault, Field Unit

Fault, Contactor Energising

Fault

Required

34 Thermostat Tripped Required

35 Valve Jammed Required

COMMANDs

36 Open Required

37 Close Required



258 | 3 5 9

SPECIFICATION FOR BULK AIR ELIMINATOR

GENERAL

Air eliminator shall be of horizontal / vertical cylindrical mild steel dished end

tank construction with internal baffles and float operated air release valve along

with supporting steel frame work and anchor bolts. The tank shall have large

cross-sectional area to slow the flow of liquid. The volume of the tank shall be at

least 10% of the flow rate in LPM. The units shall conform to the following

specifications.



Quantity : Ref BOQ

Service : As given in the design criteria Mounting : On Product Header Line near Gantry

Rated flow in LPM : 1200 LPM/Per Point for Main product

& 1200 LPM for Ethanol

Operating Pressure in KG/cm2 : 1.5 Kg-4Kg

Test Pressure : 15 Kg

Inlet & outlet Flange size in mm : As per header line sizes

Allowable Pressure drop in the air

separator at rated flow

: 0.1 Kg/cm2

Weight of BAE : Vendor to specify

Painting : 2 coats of Zinc Phosphate primer(25

microns each) and 2 coasts of

aluminum paint (20 micron each) with

Color bands as per product code of

HPCL Standard

Design : Vendor to submit

Material of Construction

Fabricated Body and baffles : Carbon Steel SA 516 Gr 70/ IS 2002

Gr. 2

Flanges : ANSI B16.5, class 150, A 105, RF



259 | 3 5 9

Pipes : ASTM A 106, Gr. B, SCH-40

Supporting frame : MS IS 2062, Gr. B 99

Drain Plug/socket NPT : ASTM-A-105

Drain : 1” NB 150# with Carbon Steel Ball

Valve. Collecting Sump of size 1m x

1mx0.5m with tiled flooring shall be

made below the drain of each BAE

Vent : ¾” NPT with Carbon Steel Ball Valve

Float & accessories : SS 304

Seals : Nitrile/Viton/ Buna N

Code of construction : ASME Section V III Div. I



260 | 3 5 9

SPECIFICATION FOR THERMAL RELIEF VALVE


Model : Vendor to specify

Quantity : Ref BOQ


Valve Type : Thermal Relief Valve

Bonnet Type : Closed

Conventional/Bellows / Pilot

Operated

: Conventional

Inlet Connection : 1” Flanged / 3/4" NPT(M)

Outlet Connection : 1” flanged / 1" NPT(F).

Cap over adjustment Bolt : Shall be Provided

Applicable Code : API 520, API 526

Material

Body & Bonnet : ASTM A 216 WCB

Nozzle & Disc : SS 316

Spring : Cd Plated CS

Basis of Selection : Liquid Thermal Relief

Required Flow Capacity : Nominal

Operating Temperature : 0C : Amb upto 500C

Back Pressure : Atm (constant)

Set Pressure : 7.5 Kg/cm2g

Orifice Area : As per design



261 | 3 5 9

TECHNICAL SPECIFICATIONS FOR CS SWING CHECK VALVES

GENERAL

1 Type Cast Steel Swing Check valve

2 Manufacturing Standard BS 1868

3 Testing Standard API 598

4 Pressure Rating ASA Class 150

5 Pressure Testing with kerosene or with water mixed with

corrosion inhibitor

6 Test Pressure

A Body

425 psi

B Seat 300 psi

8 Flanged Ends Raised Serrated Finish with holes as per

ANSI B 16.5.

9 Face To Face Dimensions

As per ANSI B 16.10

MATERIAL

MATERIAL

1 Body & Cover Plate ASTM-A-216 GR WCB

2 Seat Rings ASTM A 216 WCB + 13% Cr Hard Facing.

Finished Thickness 1.6 mm min. Hardness

300 BHN minimum.

3 Disc A-217 CA 15/ A-216-WCB +13 % Cr.

Facing - 1.6 mm thk. (300 BHN - Min)



262 | 3 5 9

4 Gasket Corrugated Soft Iron/ Spiral wound SS 304 + CA

Filler

5 Pin AISI -410

CONSTRUCTION

Construction OS &Y

Body Cover connection Bolted Connection

Seats Renewable / Sealwelded

Mounting Suitable for horizontal mounting

SCOPE OF THIRD PARTY INSPECTION FOR VALVES :

All (100 % ) Valves shall be tested by manufacturer's quality control officials,

before offering the valves for third party inspection.

The following will be the scope of inspection :

• Verification of foundry test certificates for all other chemical properties &

correlation of heat numbers for body and bonnet.

• Checking valve manufacturers' certificates for all other materials.

• Checking overall dimensions of the valves for conformity to drawings /

specifications.

• Valve Strip Test : One valve out of ten valves for each size selected at

random, to be stripped open for checking the following to conform to API

600.

Body/Bonnet wall thickness

Stem Diameter

Hardness of wedge/body seat rings, stem, backseat bush



263 | 3 5 9

Wedge wear travel test

Note : At least one valve will be subjected to this test even if the ordered quantity

is less than ten. The strip test results to be recorded & vendor to furnish the same

along with documents.

• Witnessing of Leak tests :

Pressure test with kerosene/ water with corrosion inhibitor for shell and back

seat for 100% valves.

Pressure test with kerosene/ water with inhibitor for seat on 100% valves

selected at random.

Air seat test on 100% valves.

Note: Acceptance / Rejection & also repairs of the valves shall be as per API

standards.

Third Party Inspection agency shall issue a certificate stating that the valves are

conforming to API 600.



264 | 3 5 9

SPECIFICATION FOR CABLES

GENERAL

Design, engineering, supply, laying of Cables suitable for trays, trenches, ducts

and conduits and for underground buried installation with uncontrollable backfill

and possibility of flooding by water & chemicals. Spare core in the existing cable

& JBs may be used to the extent possible if suiting the requirement. Additional

Cables that are required for the newly installed equipment shall be supplied

under the cabling item.

Power Cable shall be heavy duty 1100 V grade & Control cables shall be heavy

duty be 660 V grade, Multi stranded copper conductor. PVC insulated, PVC inner

extruded sheathed, GI wire / Strip armored and FRLS PVC outer sheathed

confirming to IS 1554. The Oxygen Index shall be 29 at 27 +/-2 Deg C. In addition

suitable chemicals shall be added into the PVC compound of the outer sheath to

protect the Cable against rodent & termite attack.

All cables covered in this specification shall be Flame Retardant Low Smoke

(FRLS) unless specified otherwise.. The outer sheath of PVC shall possess flame

propagation properties meeting requirement as per IS 10810 (Part -62) category

AF

OFC cables shall be provided for communication wherever inter-building distance

is more than 100 mtrs.

The overall diameter of the cables shall be strictly as per the values declared by

the manufacturer in the technical information subject to a maximum tolerance of

+/- 2 mm upto overall diameter of 60 mm & +/- 3 mm for beyond 60 mm.

PVC/ Rubber end caps shall be supplied free of cost for each drum. In addition,

ends of cables shall be properly sealed with caps to avoid ingress of water during

transportation & storage.

Sequential marking on outer sheath shall be provided at an interval of 1 M.



265 | 3 5 9

The scope of Cabling shall include supply, laying ferruling, end termination, loop

checking & commissioning for all the equipment included in this Terminal

Automation System which are proposed to be integrated with Terminal

Automation System.

The following Cables shall be considered as a minimum:

• All analog, digital & other signal cables from field to control room.

• All data communication cables including special computer cables, if

required

• Communication cable between MCC room and Control room for data

exchange regarding VFDs, if required.

• All power supply cables to UPS & DG set from MCC & from UPS to all

Instrumentation and Automation equipment.

The Cable shall be laid underground as per the specification & approved drawing

wherever possible & shall be laid on the perforated Cable tray with cover

whenever laid above ground.

Power Cable shall be laid in separate trench and Signal & communication Cabling

shall be laid in different trench. The same may be laid in common trench

provided physical barrier in the form of bricks are provided in such a way that

both are laid min 300 mm apart.

Cable Route marker shall be provided at each 20 m c/c distance & at the turning

whichever is less

Vendor shall submit Cable layout along with the schedule for approval to

HPCL/Project Management Consultant. The Vendor shall also submit cross-

sectional drawing of Cable Trench for approval before proceeding with Cable

trench



266 | 3 5 9

SIGNAL & COMMUNICATION CABLE

Make : As per approved Make

Quantity : Refer BOQ

Type of cable : Single pair/ Multi-pair shielded copper cable

Construction : Min. 1.5 Sq. mm, 7/0.53 strand annealed

electrolytic copper

Primary insulation : PVC compound type ST2 as per IS 5831 type A.

Thickness - 0.7 mm (Nominal)

Pair twist : Two cores of the pair shall be twisted. Ten

number of twist per meter shall be minimum

Shield (Individual Pair) : Each pair shall be shielded with aluminum

backed mylar tape with 100 % coverage and

minimum 25 % overlap.

Shield (Multi-pair) : Same as above for individual pair shielding. Also

the overall shield shall be of aluminum backed

mylar tape with 100 % coverage and minimum

25 % overlap.

Shield thickness : Min. 0.05 mm for individual and overall shielding

Inner Jacket : Extruded PVC, type ST2 ,

Thickness – As per IS 1554, Part -1

Outer Jacket : Extruded PVC, type ST2, FRLS, Blue colour

Thickness – As per IS 1554, Part -1

Pair identification : As per BS:5308 ( Table 11). The number shall be

provided at a distance of not more than 1 mtr

Rip cord : Shall be provided

Drain wire : 0.5 sq. mm multi-strand tinned copper

conductor in a continuous contact with

aluminum side of the shield shall be provided,

Armour : Armour over inner jacket shall be of Galvanized

steel wire as per IS 1554. (Part 1)

Electrical characteristics :

• Maximum resistance (DC) of the

conductor of the complete cable shall not



267 | 3 5 9

exceed 12.3 ohm/Km at 20-deg. C

• Mutual capacitance of the adj. cores or

pair shall not exceed a max. Of 250 pF/M

at a frequency of 1 kHz.

• Capacitance between any core and screen

shall not exceed 400 pF/m at a frequency

of 1 kHz.

• L/R ratio shall not exceed 40 micro

henries per ohm.

LAN Cabling :

Enhanced CAT 6 Cables. The Cabling shall be

structured & factory crimped to the extent

possible.



268 | 3 5 9

SPECIFICATION FOR POWER CABLE



Type of cable : Copper Cable

Voltage Rating : Up to and including 1100 volts

Construction : Min 1.5 sq. mm multi stranded annealed

bare electrolytic grade copper conductor

(7/0.67 mm)

Primary insulation :

Extruded PVC compound as per IS 5831

type C

Inner Sheath : Extruded PVC compound type ST2, min

thickness as per table 4 of IS 1554 Part (I)

Outer Sheath :

Extruded PVC compound, type ST2, min

thickness 1.24mm up to 6 Core & 1.4 mm

above 6 core , FRLS, Black Colour.

Armour over inner sheath :

Galvanized steel wire for UAD less than 13

mm, Galvanised steel strip for UAD

greater than 13 mm Dimensions as per

table 5 of IS 1554 Part

Core Identification :

2 Cores: :

Red & Black

3 Cores: :

Red, Black & Green

4 Cores : Red , Yellow, Black & Green

Note: : Extra core to be considered for purpose

of internal earthing of FLP equipment



269 | 3 5 9

SPECIFICATION FOR CONTROL CABLE



Type of cable : Copper Cable

Construction : Min 1.5 sq. mm , insulated and sheathed as

per IS-8130.. 5 sq. mm multi stranded

annealed bare electrolytic grade copper

conductor

Primary insulation : Extruded PVC compound as per IS 5381

type C. Min thickness as per IS 1554 Part -

1

Inner Sheath : Extruded PVC compound, type ST2, min

thickness 0.7mm as per IS 5831

Outer Sheath : Extruded PVC compound, type ST2, min

thickness as per IS 1554 Part -1, FRLS, Black

Colour

Armour : Shall be provided of galvanized steel

wire/flat strip (Thickness as per IS 1554 Part

-1)

Electrical Characteristics : Max. Resistance (DC) of the conductor of

the cable shall not exceed 12.3 ohm/km at

20 deg. C

Voltage Class : 660 V

Core Identification : Core identification number shall be

provided at a distance of not more than 1

meter

Rip cord : Shall be provided.



270 | 3 5 9

SPECIFICATION FOR RTD CABLE


Quantity : Ref BOQ

Type of cable : Triad cable

Construction : 1 sq. mm cross section, individually shielded

and overall shielded with drain wire

Core : 7 X 0.52 mm nominal stranded ATC wires.

Polyethylene insulated with a nominal min.

insulation thickness of 0.5 mm

Twisting : 3 insulated cores shall form a triad

No of Twists/metre : Min 12 to 20

Drain wire size : 10 strands 0f 0.25 mm ATC

Triad shielding : 100% coverage with Al Mylar tape 0.062 mm

with a Min of 25% overlap along with drain

wire.

Overall taping : 0.015mm thick Polyester taping

Overall outer sheathing : 1.6mm(+/-0.2mm) thick for triad

Drain ire : AWG 20

Voltage class : 600 V

Conductor Resistance : 14 Ohms/Km @ 20 Deg C

Insulation Resistance : As per IS 5831

Mutual capacitance : Between cores with shield grounded shall be

not more than 150pF/Mtr



271 | 3 5 9

Capacitance : Between one conductor and other

Conductors connected to the shield shall be

not more than 250pF/Mtr



272 | 3 5 9

SPECIFICATION FOR CABLE LAYING

Cables shall be laid both aboveground as well as underground. The Cable shall be

laid aboveground/ underground as per the site specific requirement.. All

aboveground cables shall be laid on the Cable tray with cover & underground

cables shall be laid in the trench as per the specification.

Laying of the cables underground shall be in trenches of min. 1 mtr. depth in all

types of soil both hard & soft soil including dewatering, if required. Big boulders,

sharp edges of the steel sections, vegetarian, growth roots etc. if encountered

shall be removed completely. Only soft earth excavated shall be kept for refilling.

Such earth shall be approved by the Engineering-in-charge. Excavated trench

shall be in true straight line as far as possible and bends if necessary shall be

provided. Such bends shall be gradual and not sharp in nature, the excavated

trench shall be approved by the Engineer-in-charge before laying cables In case,

during excavation hard rock is encountered which in the opinion of HPCL EIC/

Consultant cannot be excavated further, then additional sand bedding of 150

mm shall be provided over & above the 150 mm specified for the bedding. The

decision of HPCL/ Consultant is final & binding in this regard. Rate of cable

laying shall include excavation, supply and laying of two layers ( 150 mm thick

each, below and above) of river sand conforming to IS 383 and a layer of good

quality bricks of compressive strength min. 35 Kg/Sq cm. on top of the second

layer of sand & backfilling with good quality excavated earth. Rate shall also

include cutting/excavation of RCC wherever encountered & construction of RCC

culvert/ cable alley in RCC 1:1.5:3 with reinforcement as per design requirement.

All care shall be taken to ensure that no underground utilities like cables,

pipelines etc. gets damaged. However, in case any underground utility like

cables/pipes are damaged, the same shall be repaired/ replaced by the Vendor

immediately at no extra cost. Rate to include backfilling of the excavated earth &

carting away surplus earth within the depot premise as directed by HPCL EIC/

Depot Manager.

Before cutting the cables exact length as per the site conditions shall be

measured and recorded. Cut ends of the cable shall be wound by insulating tape

to protect them from rain water etc. Cable ends shall not be kept open for long.



273 | 3 5 9

Power Cable shall be laid in separate trench and Signal & communication

Cabling shall be laid in different trench. The same may be laid in common trench

provided physical barrier in the form of bricks are provided in such a way that

both are laid min 300 mm apart.

Wherever the cables have to cross the asphalt roads, the rate quoted shall

include cutting of the asphalt and WBM roads including soling and necessary

excavation to the required depth and back filling the trench with river sand and

restoring the asphalt / WBM roads to its original condition including compacting

and rolling the surface.

Road crossing shall be done through the Hume pipe. The existing Hume pipes

may be used in case sufficient space is available for laying the cables. Supply &

laying of the NP2 Hume pipes, if required, shall be in the scope of the Vendor.

Wherever the cables comes aboveground, a suitable size GI sleeve with bend

shall be used. Such pipe shall be laid 150mm below ground level and the

projecting bend shall raise to 500mm above ground level along the

steel/concrete/brick columns. The sleeve shall be neatly clamped by MS clamps

of adequate size and wooden bushes. Necessary precautions shall be taken to

make the opening water tight by wooden bushes.

Whenever, the Cable is laid above ground, it shall be laid on the perforated cable

tray with cover. The cable shall be tied on the GI Cable tray with GI Clamps. No

PVC ties or MS wire shall be used for tying the Cable on the GI Cable tray. The

Cable shall be laid on the tray with min. D spacing (D being the diameter of the

thicker Cable). Bunching of Cables or laying Cable on top of each other is not

permitted.

Separate Cable tray shall be used for laying Power & Signal/ communication/

Control Cables

The perforated GI Cable tray shall be supported at regular interval. The existing

structural support at Gantry, Tanks may be used for supporting the Cable tray. In

case additional supports are required the same shall be supplied & erected by

the Vendor & shall be included in the cost for cable laying.



274 | 3 5 9

Cables shall be taken inside the Control Room through Multi-diameter Cable

Transit Frames & Blocks. MCT shall be supplied and installed by the Vendor.

Multiple MCT blocks of multi-diameter type shall be provided for cable entry to

control room , suitable cutout and structural supports for installation of MCT

frames on the walls / floor of control rooms shall be provided. The MCT Block

system should have only few components for facilitating simple, easy and quick

assembly. The Multi-diameter based cable transits shall be repeatedly re-

openable and re-usable without the need of special tools and discarding the

modules in normal operation. The MCT frame shall be of galvanized steel

material construction having minimum 6 mm thickness. The overall height of

frame should not exceed 450 mm. The supply of frames shall be complete with

multi diameter blocks with center core in all blocks or add-blocks with wraps and

plugs / galvanized steel stay-plates / single piece compression wedge with

galvanized steel bolts from same source. Solid blocks and insert blocks should

not be used.

The sizing of MCT Frame shall be done considering 50% spare for each cable size

/ O.D. All these spares blocks shall be available on the frame as usable Multi-

diameter blocks with center plug or add-blocks with wraps and plugs, so that

these spares blocks in future can be used for wide range of cables also, solid

blocks / insert blocks should not be used at all on frames. Apart from spare if

there is any additional uncovered space left on frame then this uncovered space

should also be filled only with usable Multi-diameter blocks with center plug or

add-blocks with wraps and plugs. The MCT shall be installed as per the

recommended practice of the supplier; The Multi Cable Transits should have been

tested for water tightness gas tightness & fire tests Wherever MCT Blocks are to

be provided in Hazardous area, necessary ATEX certification should be provided.

Stay-plates shall be provided for separating the module layers. Material of the

stay plate should be galvanized steel.

HPCL shall provide cable trench in the control room. The cable trench (length,

width height), flooring modification to suit the erection of panels and consoles

will be in TAS vendor scope. TAS vendor needs to supply and install cable trays

inside the control room Cable trench for taking power and signal cables.



275 | 3 5 9

Necessary loops of min 5 mtr. shall be provided at both ends of the main cables.

Cable shall be laid without any joints.

Cable route markers at 20 m/c and at all the bends/ turnings shall be provided.

Bending radius of cables shall not be less than 12 times O.D. of cable.

All cores of cable shall be identified at both ends by means of PVC ferrule.

Line drivers & all other accessories required in this regard are included in the

scope of work of the vendor.

Cable laying shall also include termination of Cables at both the ends. Cable leads

shall be terminated at both ends by crimped type soldering.

INSPECTION, TESTING AND ACCEPTANCE

The cables shall be tested and inspected at the manufacturer’s works. All the

materials employed in the manufacture of the cable shall be subjected, both

before and after manufacture, to examination, testing and approval by Third

Party Inspection. Manufacturer shall furnish all necessary information concerning

the supply to HPCL/ Consultant. The Third Party inspector shall have free access

to the manufacturer’s works for the purpose of inspecting the process of

manufacture in all its stages and he will have the power to reject any material,

which appears to him to be of unsuitable description or of unsatisfactory quality.

After completion of manufacture of cables and prior to dispatch, the cables shall

be subjected to type, routine, acceptance and special tests as detailed below.

HPCL/Consultant reserves the right to witness all tests with sufficient advance

notice from vendor. The test reports for all cables shall be got approved from the

Third Party Inspection agency before dispatch of the cables.

All routine tests, acceptance tests, type tests and additional type tests for

improved fire performance shall be carried out as listed in IS:1554 (Part I).

The test requirements for PVC insulation and sheath of cables shall be as per

latest revision of IS:5831.



276 | 3 5 9

• Test for Resistance to Ultra Violet Radiation:- This test shall be carried out as

per DIN 53387 or ASTM-G-53 on outer sheath. The retention value of tensile

strength and ultimate elongation after the test shall be minimum 60% of

tensile strength and ultimate elongation before the test. Test certificates with

respect to this test (not older than one year) from recognized testing

laboratory to be furnished for review by Third Party Inspection agency before

dispatch clearance of cables. In case test certificates are not available, test is

to be conducted by vendor at his own cost in any recognized test laboratory

or in house testing laboratory, before dispatch clearance of cables. Sampling

for this test is to be done randomly once for each order, provided outer

sheath remains same.

• Acceptance tests as per IS-1554 (Part 1) and the following special tests to be

performed on the cables as per sampling plan. These tests are required to be

witnessed by Third Party Inspection Agency before dispatch of cables.

a. Accelerated water absorption test for insulation as per NEMA-WC-5 (For

PVC insulated cables). Test certificate with respect to this test (not older

than one year) from recognized testing laboratory to be furnished for

review by Third Party Inspection Agency before dispatch clearance of

cables. In case test certificates are not available, test is to be conducted by

vendor at his own cost in any recognized test laboratory or in house

testing laboratory, before dispatch clearance of cables. Sampling for this

test is to be done randomly once for each order, provided type of

insulation remains same.

b. Dielectric Retention Test:- The dielectric strength of the cable insulation

tested in accordance with NEMA WC -5 at 75 =/- 1 deg C shall not be less

than 50% of the original dielectric strength (For PVC insulated cables).

Test certificates with respect to this test (not older than one year) from

recognized testing laboratory to be furnished for review by Third Party

Inspection Agency before dispatch clearance of cables. In case test

certificates are not available, test is to be conducted by vendor at his own

cost in any recognized test laboratory or in house testing laboratory,

before dispatch clearance of cables. Sampling for this test is to be done

randomly and once for each order.



277 | 3 5 9

c. Oxygen Index Test:- The test shall be carried out as per ASTM D2863 or

applicable Indian Standard Specifications. Sampling to be done for every

offered lot/size as per sampling plan.

d. Flammability Test:- The test shall be carried out on finished cable as per

IS-10810 (Part 61 & 62). Sampling for these tests is to be done randomly

once for each order provided outer sheath remains same. The acceptance

criteria for tests conducted shall be as under:-

Part-61:- The cable meets the requirement if there is no visible damage on

the test specimen within 300mm from its upper end.

Part-62:- The maximum extent of the charred portion measu8red on the

test sample should not have reached a height exceeding 2.5 m above the

bottom edge of the burner at the front of the ladder.

e. Test for rodent and termite repulsion property. The vendors shall furnish

the test details to analyze the property by chemical method. Sampling to

be done for every offered lot / size as per sampling plan.



278 | 3 5 9

SPECIFICATION FOR EXPLOSION PROOF JUNCTION BOX



Quantity : Ref BOQ

Materials

Body & Cover Cast Aluminum Alloy (LM-6); minimum 5

mm thick.

Gasket : Neoprene rubber

Terminals : Clip on type block locked at both ends

suitable for up to 2.5 mm 2 conductor

Tag name plate : Required

Paint : Anti-corrosive epoxy paint, shade light

Grey

JB type : Explosion Proof Suitable for hazardous area

Zone I, Gr. II A, IIB T6

Protection class : Weather Proof to IP 65 as per IS 2147

Earthing : All junction boxes shall be provided with

external earthing lugs.

Cable Gland : Double compression Gland, Nickel plated

brass material, NPT threads, Minimum

engagement of threads shall be as per IS

2148

Other Requirement Explosion proof junction boxes shall have



279 | 3 5 9

detachable cover, which is fixed, to the box

by means of cadmium plated hexagonal

head screws.

Terminal shall be spring loaded, vibration

proof, clip-on type, mounted on nickel

plated steel rails complete with end cover

and clamps for each row.

Sizing shall be done with due consideration

for accessibility and maintenance in

accordance with the following guidelines:

50 to 60 mm between terminals and sides

of box parallel to terminals strip for up to

50 terminals and additional 25 mm for

each additional 25 terminals.

100 to 120 mm between terminals for up

to 50 terminals and additional 25 mm for

each additional 25 terminals.

All junction boxes shall be provided with

20% spare cable entries and terminals.



280 | 3 5 9

SPECIFICATION FOR CABLE GLANDS

Type of protection : Explosion proof suitable for zone 1,group IIA

& II B as per IS 2148

Compression : Double compression type. Single

compression type

Bushes : Neoprene

Threading type : NPT Threads shall be provided. ET threads

will be permitted only if any equipment does

not have provision for NPT threads.

Thread Engagement : As per IS

Material of Construction : Brass-Nickel plated

Tag plate : Shall be provided

Mounting : Suitable for area classified as zone- I, group

IIA and IIB

Protection class : IP-65

Gland Size : As per detailed engineering



281 | 3 5 9

SPECIFICATION FOR CABLE TRAY – GI

Material : GI

Size : As per design

Perforated : Slotted holes

Length : 3 M

Thickness : 2 mm

Height without cover : 50 mm for 150 mm wide trays, 75 mm for

300 wide trays

Cover height : 10 mm cover to be provided for trays

Hot Dip galvanized : According to BS-729-1971 or equivalent

standard, suitable for indoor/outdoor use

having moderate humidity and air pollution.

NOTE : Payment of Junction Box, Cable Tray Cable Glands shall not be done

separately & will be part of Cabling



282 | 3 5 9

SPECIFICATION FOR INSTRUMENT FITTINGS (Carbon steel Fittings)

Nomenclature of all fittings shall be as per ANSI B16.11

Fittings shall be socket-weld type forged pipe fittings of material cadmium

plated ASTM A 105. The minimum rating shall be class 3000.

SS tube Compression Fittings

Nomenclature of all tube fittings shall be as per ISA 42.1

Fittings shall be flare less compression type and of three-piece

construction with ferrule, nut and body suitable for use on SS tube

conforming to ASTM A 269 TP316, hardness not exceeding RB 80.

Hardness of ferrules shall be in the range of RB 85-90 so as to ensure

minimum hardness difference of 5 to 10 between tube & fittings for better

sealing.

Threaded ends of fittings shall be NPT as per ANSI B1.20.1.

Instrument Valves

The impulse line isolation and drain valves shall be forged gate valves with

inside screwed bonnets.

For SS valves body and trim material shall be ASTM A182 Gr. F316.

For CS valves body material shall be ASTM A 105-gr. and trim material

shall be ASTM A182 Gr.F316.

Valve hand-wheel material shall be cadmium or nickel-plated steel.

Impulse pipes

Impulse pipe shall be either Sch. 80 seamless carbon steel pipes as per ASTM A

106 gr. with socket weld fittings or shall be fully annealed, seamless and cold

drawn 316SS tube as per ASTM A 269 with compression fittings. Tube wall

thickness shall be 0.065 unless otherwise specified.



283 | 3 5 9

The process tapping shall be min. 1/2” in dia unless otherwise specified. Root

valves shall be min. 1/2” stainless steel ball or gate valves, suitable to maximum

pressure and temperature. Pressure testing of piping shall be done after

provision of Instrumentation tapping points and closing root valves.

For installation of temperature elements/gauges, suitable tapping on pipeline,

welding of boss with threads or flange shall be arranged by vendor. Pressure

testing of pipelines shall be done by vendor after installation of thermo-wells.



284 | 3 5 9

SPECIFICATION FOR MANUAL CALL POINT & EMERGENCY SHUTDOWN

Manual call points are manually operated devices to initiate an alarm signal and

operate the fire pump. The manual call point & Emergency Shut Down shall be

located at the Gantry. The manual call point shall be painted with fire red as per

IS-5-1994, sheath 536. & ESD hall be grey in color. The manual call point & the

Emergency Shut Down shall be wired to PLC.

Manual call point & ESD shall consist of MS enclosure with a safety glass front.

The front glass keeps the switch in pressed condition. One spare front glass shall

be supplied spare with the MCP & ESD

Manual call point & ESD shall have CMRI certified flame proof enclosure.



285 | 3 5 9

TECHNICAL SPECIFICATION FOR min. 20 KVA or SUITABLE HIGHER

CAPACITY DG SET

It is proposed to install min. 20 KVA or suitable higher capacity CPCB compliant

acoustic DG set to cater to the automation equipment’s load & Two AC in the

control room whenever the Mains power supply is off/ unavailable.

EXISTING SCHEME

At present the location is having State Electricity Board Supply (SEB) & Backup

DG sets for entire loading operation. During normal working day whenever there

is SEB power shut down the existing higher capacity DG set (main standby) is

started for running the Depot/ Terminal normal operation. However, on the non-

working days or in the night during the SEB power shut down, DG set which are

of very high capacity may not be started as there is no loading which may result

in frequent draining of Automation UPS battery. Hence suitable capacity DG set

dedicated for Automation operation is included in the scope of the Vendor.

PROPOSED SCHEME

20 KVA or higher suitable higher capacity DG set with microprocessor / micro

controller based AMF panel shall be supplied, installed & commissioned shall

start automatically the 20 KVA DG set after a lag of 15 min. under no or low

voltage of the Mains (normal) supply. The Vendor needs to design the system &

shall include all items required to complete the job

AMF Panel will have two Incomers (one from Mains supply and the other from

Genset) and one outgoing. The incomers shall be electrically interlocked to avoid

paralleling between the two sources keeping the normal supply as prime power

source and the Genset supply as standby source.

The DG set shall be installed under Canopy. Suitable foundation for the DG set

shall be provided by the Vendor.

SCOPE OF WORK



286 | 3 5 9

Vendor Scope of work for each location shall include but not limited to the

following:

Supply, of min. 20 KVA or suitable higher capacity CPCB compliant DG set

with alternator, engine, AMF Control Panel, Lead Acid Low Maintenance

Battery, Starter Motor, CPCB compliant Acoustic enclosure, integral day

service tank of min. capacity for 10 hrs continuous working, fuel oil system &

its piping, Residential type Silencer with associated exhaust piping with

thermal lagging within the Acoustic Enclosure and reasonable extension

external to the enclosure as per the latest pollution control norms of CPCB /

state PCB’s and complete assembly in RTU (Ready to Use) concept as

specified in the technical specification.

Busbar chamber, TPN 63 A with Copper conductor.

First fill of Lube Oil & charging of battery.

2 Nos. earth pit. ( part of DG scope)

Erection, testing & commissioning

DATA SHEET

------------------------------------------------------------------------------------------------------

SNO. DESCRIPTION HPCL'S REQUIREMENT

-------------------------------------------------------------------------------------------------------

1.0 SCOPE DESIGNING, MANUFACTURING,

TESTING, SUPPLYING, INSTALLATION &

COMMISSIONING OF DIESEL GENERATOR

SETS.

APPLICABLE CODES - BS:5514 (DIESEL ENGINE FOR CONFORM

TO GENERAL PURPOSE); IS:10000 (TYP.

TESTING OF CONSTANT SPEED IC ENGINE

FOR GENERAL PURPOSE) ;IS:10002

(PERFORMANCE OF CONSTANT SPEED IC

ENGINE ) BS 5000/ IS:4722 (ROTATING

ELECTRICAL MACHINES); IS:4691

(DEGREES OF PROTECTION PROVIDED



287 | 3 5 9

BY ENCLOSURES FOR ROTATING ELECTRICAL

M/CS.)

---------------------------------------------------------------------------------------------------

A. ALTERNATOR

---------------------------------------------------------------------------------------------------

2.0 MAKE KIRLOSKAR GREEN / CROMPTON GREAVES

STAMFORD / KEC/ KEL

2.1 MODEL NO. VENDOR TO SPECIFY

3.0 CAPACITY 20 KVA or suitable higher capacity.

4.0 VOLT/PHASE/FREQUENCY 415V / 3-PHASE / 50Hz / 4 WIRE

CONFORMING TO BS 5000/IS 4722

5.0 PROTECTION DRIP PROOF CONSTRUCTION AS

PER IS:4691. VENDOR TO SPECIFY THE

DEGREE OF PROTECTION.

6.0 INSULATION CLASS 'F' OR BETTER

7.0 EXCITATION BRUSHLESS SELF EXCITATION, SELF

REGULATED THROUGH A SUITABLE

ALTERNATOR TERMINAL BOX

MOUNTED AUTOMATIC VOLTAGE

REGULATOR (AVR) WITH +/-1%

VOLTAGE REGULATION COMPLETE

WITH ALL ACCESSORIES

8.0 VOLTAGE REGULATOR SHUNT FIELD & AUTOMATIC

VOLTAGE REGULAT0RS TO BE PROVIDED.

VENDOR TO GIVE ALL DETAILS LIKE MODEL

NO. ETC.



288 | 3 5 9

9.0 SPACE HEATERS -240 V , SINGLE PHASE LOCATED IN THE

LOWER PART OF STATOR FRAME

- SHOULD OPERATE AUTOMATICALLY

WHEN GENSETS ARE NOT IN OPERATION.

- SPACE HEATER AUTO CONTROL

SYSTEM COMPLETE WITH THERMOSTAT,

MCB, INDICATING LAMP, TOGGLE SWITCH,

SEL. SWITCH, POWER / CONTROL WIRING

SHALL BE PROVIDED IN THE AMF CONTROL

PANEL.

10.0 TERMINAL BOX - SUITABLE MOUNTING ARRANGEMENT FOR

TERMINATING THE POWER / CONTROL

CABLES TO THE TERMINALS WITH SUITABLE

BRASS CABLE GLANDS

10.1 GLAND SIZE -TO BE SUITABLY PROVIDED

11.0 OVER LOAD -SHOULD TAKE 10% IN EXCESS OF

THE RATED OUTPUT

- FOR 1 HOUR OUT OF 12 CONTINUOUS

HOURS OF OPERATION

- DURING WHICH TEMPERATURE

SHOULD NOT EXCEED PRESCRIBED LIMITS

OF CLASS 'F' INSULATION

12.0 UNBALANCED LOAD - SHOULD BE CAPABLE OF

CARRAYING LOAD OF 25% WITH OUT

ANY DAMAGE TO ANY PART PROVIDED

RATED CURRENT IS NOT EXCEEDED.

- CORRESPONDING VOLTAGE UNBALANCE

SHOULD NOT EXCEED +/-2% OF AVERAGE

TERMINAL VOLTAGE

13.0 SHORT CIRCUIT - SHOULD WITHSTAND SHORT



289 | 3 5 9

CIRCUIT AT TS TERMINALS FOR 3 SECONDS

WITH EXCITATION ADJUSTED TO DEVELOP

RATED VOLTAGE AT NO LOAD WITH OUT

ANY DAMAGE

14.0 SUB TRANSIENT FAULT SHOULD NOT EXCEED 15 TIMES

THE FULL CURRENT

LOAD CURRENT / AS PER RELEVANT

STANDARDS

15.0 EARTHING 2 NOS. SEPARATE FROM NEUTRAL

TERMINAL

16.0 FIELD WINDING SHOULD BE FULLY INSULATED

FROM CORE.



290 | 3 5 9

------------------------------------------------------------------------------------------------

B. DIESEL ENGINE

--------------------------------------------------------------------------------------------------

SL.NO. DESCRIPTION HPCL'S REQUIREMENT

---------------------------------------------------------------------------------------------------

1.0 MAKE KIRLOSKAR OIL ENGINES /

MAHINDRA & MAHINDRA

1.1 MODEL NO. VENDOR TO SPECIFY

2.0 BHP @ 1500 RPM VENDOR TO SUBMIT THE

CALCULATIONS OF ENGINE TO SUIT THE

ALTERNATOR

3.0 TYPE VENDOR TO QUOTE

4.0 CYLINDERS / ARRANGEMENT VENDOR TO QUOTE

5.0 RPM 1500 RPM

----------------------------------------------------------------------------------------------------

6.0 COOLING SYSTEM

----------------------------------------------------------------------------------------------------

6.1 TYPE JACKET WATER SYSTEM

6.2 RADIATOR WATER COOLED

6.3 FAN FOR RADIATOR COOLING

6.4 SPECIAL COOLANT TO CHECK CORROSION,

RUST, ACIDITY, SCALING & REMOVE

IMPURITIES

7.0 ASPIRATION VENDOR TO QUOTE

8.0 OVERLOAD 10% IN EXCESS FOR 1 HOUR IN

ANY 12 CONTINUOUS HOURS OF

OPERATION

--------------------------------------------------------------------------------------------------



291 | 3 5 9

9.0 FUEL OIL SYSTEM

----------------------------------------------------------------------------------------------------

9.1 FUEL PUMP WITH FILTER

9.2 FUEL TANK

9.2.1 CAPACITY 10 HRS RUNNING CAPACITY

9.2.2 MOUNTING ARRANGEMENT FUEL TANK SHALL BE

INTEGRAL WITH THE ENCLOSURE

WITH ASSOCIATED PIPING

---------------------------------------------------------------------------------------------------

10.0 LUBE OIL SYSTEM AUTOMATIC PRESSURE

LUBRICATION BY ENGINE DRIVEN GEAR

TYPE PUMP

11.0 AIR INTAKE OIL BATH TYPE / DRY TYPE WITH

AIR FILTER

12.0 EXHAUST RESIDENTIAL SILENCER OF MIN.

INSERTION LOSS OF 25 Db(A)WITH

NECESSARY PIPING AND THERMAL

LAGGING WITHIN THE ENCLOSURE AND

OUTSIDE THE ENCLOSURE AS PER

RELEVANT POL. CONTROL NORMS

----------------------------------------------------------------------------------------------------

13.0 STARTING SYSTEM ELECTRICAL STARTING

----------------------------------------------------------------------------------------------------

13.1 STARTER TO BE PROVIDED

13.2 BATTERIES -VOLTAGE TO BE SPECIFIED

-MAKE:EXIDE / PRESTOLITE /

HBL NIFE / AMARON

-LEADS / TERMINALS FOR THE

BATTERY

13.3 BATTERY CHARGER SUITABLE TO CHARGE THE

ABOVE BATTERY WITH ALL

NECESSARY INSTRUMENTS AND

ACCESSORIES (TO BE INTEGRATED

WITH THE AMF PANEL)



292 | 3 5 9

Battery Charger Panel

Function

For functioning of devices in Generator Control Panel, 24V/220VDC battery charger of

suitable capacity along with Lead acid automotive type rechargeable batteries ( as 2 x 12

V DC) shall be used. Charger is fully automatic, with trickle and boost charging facility.

Major Components

Transformer

Electronic controllers

AC/DC ammeter, voltmeter

Metering Devices

Voltmeter (with selector switch) for AC input voltage

Voltmeter for AC /DC output voltage

Ammeter for load and battery current

Indications

Mains supply ON

Float mode / Boost mode

Charger Tripped

Controls possible from Charger

Mains supply ON / OFF

Initial / Normal charging mode selection

Fault reset

Protections provided for Charger

Over load / short circuit / earth fault

Over voltage

Battery reverse

---------------------------------------------------------------------------------------------------

14.0 GOVERNING SYSTEM

---------------------------------------------------------------------------------------------------

14.1 TYPE VENDOR TO QUOTE



293 | 3 5 9

14.2 SPEED DROP -4% TO 4%

14.3 NOMINAL SPEED VENDOR TO QUOTE

14.4 FREQUENCY VARIATION RATE SHALL NOT EXCEED

0.5Hz PER SECOND

14.5 OVER SPEED TRIP MECHANISM - SHOULD CUT OFF FUEL IN

CASE SET REACHES THE OVER

SPEED BETWEEN 110% TO 130% OF

RATED SPEED

-EMERGENCY STOP PUSH

BUTTON SHALL BE PROVIDED

ON THE AMF PANEL

FOR TRIPPING THE ENGINE

----------------------------------------------------------------------------------------------------

15.0 COUPLING FLEXIBLE / FLANGED DIRECT

COUPLING SUITABLE FOR

SINGLE BEARING ALTERNATORS

16.0 INSTRUMENT PANEL TO BE MOUNTED ON

ENGINE AND SHOULD HAVE

- STARTING SWITCH WITH KEY

- ENGINE RPM / HOUR

METER

- LUBE OIL PRESSURE

GAUGE

C. GENERAL

-----------------------------------------------------------------------------------------------


------------------------------------------------------------------------------------------------

1.0 BASE FRAME ENGINE COUPLED WITH

ALTERNATOR SHOULD BE MOUNTED ON A

ROBUST FABRICATED STEEL FRAME

INTEGRATED WITH THE ACOUSTIC

ENCLOSURE



294 | 3 5 9

2.1 ANTI-VIBRATION

MOUNTING PADS TO BE PROVIDED

2.2 MAKE DUNLOP / POLYBOND / EQUIV.

2.3 DUTY VENDOR TO QUOTE

2.4 NO. OF PADS VENDOR TO QUOTE

3.0 DRAWINGS AND DATAS 4 PRINTS OF THE FOLLOWING

( TO BE SUBMITTED IN 4 TO BE PROVIDED.

COPIES AFTER THE

AWARD OF

PURCHASE ORDER)

-OUTLINE DIMENSIONAL DRAWINGS AND

THE GENERAL ARRANGEMENT OF DG AND

CONTROL PANEL SHOWING ALL REQD.

CLEARANCES

-FOUNDATION PLAN DRAWINGS FOR DG

SET AND CONTROL PANEL

-FUEL OIL SYSTEM, LUBE OIL SYSTEM,

JACKET WATER SCHEME WITH

INTRUMENTATION AND CONTROL WITH

WRITE-UP.

- GOVERNOR SYSTEM AND VOLTAGE

REGULATOR WITH WRITE-UP.

- DG SET INSTRUMENTATION AND

CONTROL SYSTEM WITH WRITE-UP.

4.0 INSTRUCTION MANUALS 2 SETS FOR INSTALLATION,

5.0 PACKING PACKING IN A WOODEN CASE IS

NOT REQUIRED.HOWEVER, VENDOR

SHALL SUPPLY A TARPAULIN FOR

COVERING THE ASSEMBLED DG SET.

- CONTROL PANEL TO BE PACKED

SEPERATELY

- BATTERY IN ONE PACK

6.0 PAINTING DG SET TO BE THOROUGHLY

CLEANED AND DEGREASED. ALL RUST

SHARP EDGES AND SCALES SHALL BE



295 | 3 5 9

REMOVED. ALL EXTERNAL PARTS SHALL BE

FINISHED AND PAINTED WITH TWO COATS

OF PRIMER AND TWO COATS OF EPOXY

ENAMEL PAINT.

ACOUSTIC ENCLOSURE SHALL BE POWDER

COATED AFTER REQUIRED 7 / 9 TANK PRE-

TREATMENTS.

7.0 INSTALLATION - BY THE VENDOR

8.0 COMMISSIONING - DG SET TO BE COMMISSIONED

BY THE GENSET VENDOR



296 | 3 5 9

D. MICROPROCESSOR / MICRO CONTROLLER BASED AMF CONTROL

PANEL

---------------------------------------------------------------------------------------------------


---------------------------------------------------------------------------------------------------

1.0 BODY -FABRICATED OUT OF 14 / 16 SWG

CRCA SHEETS

- CUBICLE TYPE

- ACOUSTIC ENCLOSURE MOUNTED

- HINGED DOORS WITH DUST

PROOF GASKET & THUMB KNOB.

- KNOCKOUT GLAND PLATE TO BE

PROVIDED AT THE BOTTOM

----------------------------------------------------------------------------------------------------

2.0 CONTACTORS 2 SETS ( 1 EACH FOR MAINS / GENSET)

SHALL BE RATED FOR 25 A (4 P)

WITH HRC 25 A FUSE BACK UP

TO BE ELECTRICALLY INTERLOCKED

2.1 CAPACITY 25 A, 4 POLE

2.2 MAKE L & T / SCHNEIDER / C&S

2.3 OTHER FEATURES VENDOR TO QUOTE

---------------------------------------------------------------------------------------------------

3.0 KW METER TO BE PROVIDED

3.1 CAPACITY VENDOR TO SPECIFY

3.2 MAKE AE / MECO / IMP / NIPPON

3.3 OTHER FEATURES DIGITAL / VENDOR TO QUOTE

------------------------------------------------------------------------------------------------------

4.0 KWH METER TO BE PROVIDED



297 | 3 5 9

4.1 CAPACITY CT OPERATED / DIRECT

4.2 MAKE ALSTHOM / HAVELL’S / SIMCO /

MAXWELL

4.3 OTHER FEATURES VENDOR TO QUOTE

----------------------------------------------------------------------------------------------------

5.0 AMMETER TO BE PROVIDED

5.1 RANGE VENDOR TO SPECIFY


5.3 SELECTOR SWITCH TEKNIC / MKAY / SALZER / KAYCEE


---------------------------------------------------------------------------------------------------


----------------------------------------------------------------------------------------------------

6.0 FREQUENCY METER TO BE PROVIDED

6.1 RANGE 0-60 Hz.



--------------------------------------------------------------------------------------------------

7.0 VOLTMETER TO MEASURE BOTH LINE &PHASE VOLTAGE

7.1 RANGE VENDOR TO SPECIFY


7.3 SELECTOR SWITCH AE / MECO / IMP / NIPPON

7.4 OTHER FEATURES DIGITAL



298 | 3 5 9

----------------------------------------------------------------------------------------------------

8.0 CURRENT TRANSFORMER TO BE PROVIDED

8.1 CAPACITY VENDOR TO SPECIFY

8.2 MAKE AE / MECO / IMP / INDCOIL

8.3 NO OF CURRENT VENDOR TO SPECIFY

TRANSFORMERS

-------------------------------------------------------------------------------------------------

9.0 SAFETY CONTROLS AUDIO / VISUAL WITH ONE

HOOTER ALARM FOR THE FOLLOWING :

- OVER SPEED

- LOW LUBE OIL PRESSURE

- HIGH WATER TEMPERATURE

- OVER LOAD

Generator Protections

• Differential

• Voltage controlled over current

• Under / Over voltage

• Under / Over frequency

• Earth fault

• Very high Alternator bearing temperature

• Reverse power

• Field failure

• Master trip

----------------------------------------------------------------------------------------------------

10.0 INDICATION LAMPS TO INDICATE :

- 'SUPPLY ON'

- 'LOAD ON'

11.0 PROTECTIONGEAR - 2 O/c + 1 E/F Relay

Make - CSPC / L&T

Type - Micro Controller based CTs

- Dedicated CTs of proper Class

12. BATTERY CHARGER (static) - Rated for 12 V, 10-16 A complete with DC

Ammeter, Voltmeter, Charge Indication,

Bridge Rectifier etc.



299 | 3 5 9

Status Indications

• Low lube oil priming pressure

• DG breaker ON

• DG breaker OFF

• DG breaker Tripped

Alarm Indications

• Low lube oil pressure

• High lube oil temperature

Trip Indications

• Very low lube oil pressure

• Very high lube oil temperature

• Very high water engine outlet temperature

• Engine over speed

• Emergency stop

• Alternator fault

• Under / over voltage

• Under / over frequency

• Voltage controlled over current

• Earth fault

II. SCOPE OF THIRD PARTY INSPECTION.

----------------------------------------------------------------------------------------------------


---------------------------------------------------------------------------------------------------

1.0 AGENCIES AS APPROVED VENDOR LIST

2.0 CODES THAT SHALL BE - ENGINE SHALL CONFORM

CONFORMED TO TO IS 10002(PERFORMANCE

REQUIREMENTS OF DIESEL ENGINE FOR

GENERALPURPOSE - ABOVE 20KW.)

- ALTERNATOR SHALL CONFORM TO IS :

4722 (ROTATING ELECTRICAL MACHINES)

3.0 ACTIVITIES TO BE CARRIED WITNESSING AND CERTIFYING THE



300 | 3 5 9

OUT BY THE THIRD PARTY FOLLOWING :

LOAD TESTS ON THE

ASSEMBLED DG SET

1/2 HOUR AT 50% LOAD

1/2 HOUR AT 75% LOAD

2 HOUR AT 100% LOAD

1 HOUR AT 110% LOAD

- ACTIVATION OF ALL

SAFETY CONTROLS AND CHECKING

WHETHER THE AUDIO / VISUAL

SYSTEM IS FUNCTIONING.

PROPERLY OR NOT

- THIRD PARTY INSPECTION

AGENCY SHALL GIVE A

CERTIFICATE TO THE EFFECT THAT

ENTIRE DG SET ALONG WITH THE

ACCESSORIES CONFORM TO THE

SPECIFICATIONS GIVEN IN THE

PURCHASE ORDER.

ENGINE AND ALTERNATOR SHALL BE

TESTED BY THE MANUFACTURERS

AS PER THE RELEVANT CODES AND

THE CERTIFICATES SHALL BE

PROVIDED TO THE THIRD PARTY

INSPECTION AGENCY DURING THE

INSPECTION FOR THEIR

VERIFICATION AND ENDORSEMENT.

INDIVIDUAL INSPECTION OF ENGINE

AND ALTERNATOR AT

MANUFACTURER'S WORKS IS NOT

INCLUDED IN THE SCOPE OF THIRD

PARTY INSPECTION.

Alternator testing: Following Routine tests (min), shall be conducted on the alternator at Workshop.



301 | 3 5 9

• For generator armature, generator field, exciter armature and exciter field. . Measurement of resistance. . Measurement of insulation resistance. . High voltage test.

• Phase sequence test and voltage balance check. • Open circuit characteristics

With generator line voltage recorded against exciter field current. • Short circuit characteristics

With generator line current recorded against exciter field current. • Voltage regulation test

Conducted with AVR in the circuit with reactive loads up to 25 KVA.

• Control panel test Standard routine tests as per the relevant standard.



302 | 3 5 9

EARTHING SYSTEM

Vendor shall furnish recommendations for the grounding (Earthing) of the system

supplied by him. All the equipment installed in gantry & in the field need to be

earth by flexible 4 sq. mm (min) copper wire of green color of approved make.

The wire from instruments shall be taken inside the existing channel section of

gantry or thru cable tray and hooked up to earthing bus bar on each point. Two

GI Strip ( Min 50 x 6 mm)shall be taken out from each earthing bus bar which

shall be connected to the existing gantry structure earth pits.

All Earth Pits, except for DG sets, will be provided by HPCL

Bus bar MOC shall be of copper with zinc coating and provided with two

insulators . Each bus bar back shall have minimum two insulators. The bus bar of

each point shall be fixed so that the cables are secured and are not prone to

snapping. Mixing of electrical and electronic earthing shall not be acceptable.

No bolting is allowed on the GI Strip. The joints shall be welded and protected

from rusting by treating with Barium chromate. Such welded surfaces shall be

treated with Bitumen paint. TFMS earthing shall be as per OEM recommendations

Vendor shall submit detail earthing scheme to HPCL for approval.



303 | 3 5 9

TESTING, INSTALLATION, COMMISSIONING AND SYSTEM ACCEPTANCE

General

This specification defines the basic guidelines to Terminal Automation System

Vendor for inspection, factory acceptance, installation, commissioning and Site

acceptance of fully integrated system. These guidelines shall also be applicable in

all sub-systems, hardware and instruments bought by Vendor.

On the basis of guidelines specified bidder shall submit their own testing,

installation commissioning and acceptance procedure. For hardware the

procedure shall include purpose of test, test definition of input procedure, results

expected and acceptance criteria. For software it shall include details of the

method, list of tests, sequence of execution, results expected and acceptance

criteria.

The testing and acceptance of the system shall be carried out based on the

mutually agreed procedures and criterion based on this specification and

Vendor’s standard procedures.

SYSTEM ACCEPTANCE TEST

Final acceptance of the System is divided broadly into the following five stages :

• Inspection & Testing at OEMs works by Vendor’s appointed & HPCL approved

Third Party Inspection (TPI)agency

• Factory at Acceptance Test (FAT) at Vendor’s factory & witnessed by the

HPCL/PMC

• Site Acceptance Test (SAT) at the location

• Trial Run

• Stabilization Period & User Acceptance Test ( UAT)

The System shall be accepted after successful completion of all the above five

stages.



304 | 3 5 9

Inspection by TPI Agency

Vendor shall submit the Quality Assurance plan (QAP) to the Consultant along

with the Data sheets for approval. TPI agency shall carry out the inspection as per

the QAP submitted, submit the report to HPCL/PMC both in Hard & Soft Copy

and issue dispatch clearance. HPCL/PMC reserves the right to be involved and

satisfy itself at each and every stage of inspection. HPCL/PMC shall be free to

request specific test on any equipment considered necessary by them although

not listed in this specification, the cost of performing all tests shall be borne by

the Vendor.

Vendor shall note that acceptance of any equipment or the exemption of

inspection or testing shall in no way absolve the Vendor of the responsibility for

delivering the equipment meeting all the requirements specified in this

document.

The inspection and testing shall include but not be limited to raw materials,

components, Sub-assemblies, prototypes, produced units, guaranteed

performance specifications etc. For factory inspection and testing, Vendor shall

arrange all that is required e.g. quality assurance personnel, space, test gear etc

for successfully carrying out the job by the HPCL/PMC and/or his representative

at Vendor’s cost at the manufacturer's works.

Scope of inspection

Scope of Third Party inspection shall be as per the approved QAP unless

otherwise specified in this document. All inspection and testing shall be carried

out based on the following documents:

a) Approved QAP

b) Relevant standards

c) Purchase Order Specifications

d) Approved Data sheets

e) Approved drawings

FAT & SAT are excluded from the scope of TPI & shall be witnessed by HPCL

&PMC.



305 | 3 5 9

As a minimum the following checks shall be included in the inspection

• Conformance to the approved Data sheet.

• Physical verification

• Material Of Construction

• Make, model no verification

• Functional performance checking.

• Hydrostatic tests shall be done for 100 % of items

Third Party Inspection at OEM’s factory shall mandatory include, but not limited,

to the following items:

• Metering Instrument & Accessories as per the inspection scope defined

below

• Batch Controllers

• Densitometer calibration at FCRI or NABL approved lab

• Earthing Relay

• Power, Signal & Communication Cables

• Junction Box

• Bulk Air Eliminator

The inspection for the Metering Instruments & Accessories shall include PD

meters and accessories, set stop valves, and other associated field instruments

and accessories.

The inspection and testing shall be as under :

a) Material inspection including body and internals.

b) Visual inspection checks.

c) Tests for material, welding, leakage (by hydrostatic test) etc.

d) Dimensional inspection.

e) Calibration test of individual instruments / equipment.

f) Meter proving and calibration.

g) Overall batch accuracy test and repeatability tests.

h) Checks for assuring compliance with standards mentioned in the

specifications.



306 | 3 5 9

Vendor shall produce during inspection:

a) Raw material inspection certificate.

b) Manufacturer Test Reports.

c) Statutory certificates as required.

Batch Accuracy Test

• 5 Point Calibration against Weights & Measures certified prover tank in case

of flow-meter

• Generation of pulses per revolution through rotating pulser in case of flow-

meter.

• Testing of randomly chosen Set Stop valves in association with batch

controller and flow meter

• Program checking and relay output checking with simulator in case of batch

controller

• Performance checking of randomly chosen batch controllers in association

with flow-meter & Set stop valve.

The Vendor shall demonstrate the functionality of the system hardware and

software. No materials shall be transported to site until all required tests have

been successfully completed and the material / equipment have been certified

“ready for shipment“ by TPI.

The Metering FAT shall be carried out for 20% of the Metering Units covering all

covering all combination of batch accuracy related equipments randomly picked

up by HPCL/PMC for the purpose of FAT / BAT.

Vendor to note that acceptance of any equipment or the exemption of inspection

testing shall in no way absolve the bidder of the responsibility for delivering the

equipment meeting all the specified requirements.

Delay, if any, for verification and approval by third party inspection agency shall

be on account of vendor and HPCL shall not be responsible for the same.



307 | 3 5 9

Any testing required or recommended by third party needs to be carried out by

vendor in government approved labs or in factory premises at no extra cost to

HPCL.

Vendor may deploy more than one inspection agency for carrying out the above

inspections as per the requirement.

Third party inspection reports and dispatch clearance shall be submitted to

HPCL/PMC in hard copy and soft copy (scanned image) for all the items with back

up test reports.

Approved Third Party Inspection agencies are

BV / EIL /DNV /ICS /Lloyds /IRS

Vendor shall include all incidental charges towards facilitating third party for

inspection like lodging, boarding, travelling etc. and applicable taxes and duties

under respective items. No Separate payment shall be made towards TPI



308 | 3 5 9

Factory Acceptance Test (FAT)

Vendor shall submit the test procedure at least 30 days prior to the acceptance

test to HPCL/PMC for review and modifications, if any. Vendor shall resubmit the

procedure incorporating the revisions for approval by HPCL/PMC.

Factory test shall be conducted at Vendor’s factory/Office. Duration of FAT-

Phase II shall be minimum 3 - 5 days.

Functional Design specification shall be the base of factory acceptance test. All

logics as per approved FDS procedure shall be demonstrated in FAT as minimum.

All system hardware and software used for acceptance testing shall be complete

as specified and shall be with actual equipment to be shipped to the location.

Vendor shall demonstrate functional integrity of the network system hardware

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

tests have been successfully completed and the material/equipment have been

certified' Ready for shipment' by HPCL/PMC

All the graphics user interface/ Man Machine interface shall be approved during

FAT

HPCL/PMC reserves the right to involve and satisfy himself at each and every

stage of testing. They shall be free to request specific tests on equipment

considered necessary by them, although not listed in this specification. The cost

of performing all tests shall be borne by the vendor.

Bidder to note that acceptance of any equipment or the exemption of inspection

testing shall in no way absolve the Vendor of the responsibility for delivering the

equipment, instruments meeting all the specified requirements.

It shall be Vendor's responsibility to modify and/or replace any hardware or

software if the specified functions are not completely achieved satisfactorily

during FAT.

The following minimum equipment, instrument shall be made available by the

Vendor during FAT



309 | 3 5 9

• Entire network equipment

• All servers & Client Machines.

• 4 Nos. Single channel BCU

• 4 nos. of RIT simulator. Simulators to demonstrate complete

loading including Additive & Ethanol blending at 4 Loading points

simultaneously

• 5 nos. of card reader

Detailed list of equipment to be tested as a part of FAT shall be defined in the

FAT procedure for approval of HPCL/PMC

Vendor shall not replace any component/module/subsystem unless it has failed

and a log of such failures shall be maintained during FAT. If a malfunction of

module/component in a subsystem repeats, the test shall be terminated and

vendor shall replace the faulty component/module. Thereafter test shall start all

over again. If a subsystem fails during FAT and is not repaired and made

successfully operational within 4 hours of active repair time after the failure, the

test shall be suspended and restarted all over again only after vendor has

replaced the device into acceptable operational condition.

FAT shall be carried out in two phases. The minimum requirement for testing

during these two phases shall be as follows

Under the first phase, vendor shall perform tests at his works to ensure that all

components function in accordance with the specification for each type of test. A

test report shall be submitted for HPCL/PMC review within two weeks of

completion of this test. All subsystem shall undergo a minimum of 150 hrs burn

in period. Following tests shall be performed by the vendor and reports shall be

forwarded to HPCL/PMC

(a) Quality Control tests shall be carried out to ensure quality of all component

& modules in accordance with the Vendor’s quality control & assurance

procedure.

(b) System pre-test which shall be physical check of all modules, racks, cabinets

etc.



310 | 3 5 9

(c) System power-up test which shall test functionally all hardware, racks,

cabinets etc.

(d) System redundancy checks

(e) All PLC logics

The test log book shall contain the following information for the above tests:

• Date / Time

• Test results and signature of the person who conducted the test

• Action required (if deficiency is detected)

• Action taken, date of completion and signature.

• Special test methods (including special equipment requirement, by

passes used etc.)

If problems or malfunctions develop in any part of the system during acceptance

test period, corrections shall be made at the vendor’s facility at no cost to the

HPCL

The second phase of testing shall systematically, fully and functionally test all

hardware and software in the presence of purchaser representative. All

subsystems shall be interconnected to simulate, as close as possible, the total

integrated system.

The vendor shall depute most competent team including software & hardware

personnel to:

Review acceptance tests Criteria.

Schedule and arrange test facilities.

Arrange the systems according for acceptance test criteria.

Analyze and interpret test results for HPCL/ PMC.

Provide assistance in case of system malfunctions during the

acceptance test period.

Following minimum tests shall be carried out.

(a) Visual and mechanical testing

(b) Functional testing

(c) Hardware test using vendor’s standard diagnostic tests as a basis



311 | 3 5 9

(d) Integrated test

(e) MMI/HMI approvals

(f) ERP/TAS interface

This shall include the simulation of each input and output to verify proper system

response. The testing as a minimum shall include:

• Complete system simulation for T/T Loading

• Demonstration of all PLC system functions including addition/deletion of

an input/output, addition/deletion of a rung or an element in a rung

generation of dynamic graphics and other views, report generation etc.

• 100% checking of logic configured in the PLC by connecting switch/lamp

at input/output.

• Checking of response time as per specification

• System redundancy checks including correct changeover of the back-up

unit in case of failure of main unit. These shall be applicable for

following:

o LRC HSB Test

o CPU Rack to Rack Redundancy.

o Each CPU to host system communication interface &

communication link redundancy

o I/O subsystem to processor system communication redundancy.

o Ethernet Redundancy

o Multiple redundancy Test.

• System diagnostic checking for all subsystems on local level as well as

on console,

• Checking of output status on processor failure

• Checking of alarm generation

• Checking of various reports

Vendor shall provide necessary test equipment and simulation facilities required

for demonstrating Input/ Output points, equipment interface, etc. At any time,

however, any equipment may be checked during the course of the test/



312 | 3 5 9

witnessed test shall consist of a functional check of input points, output points,

alarm points and digital control loops for proper functions and proper display.

After successful completion of FAT, HPCL /PMC shall give authority to supply all

equipment to job site for erection & installation and before commissioning and

start up.

INSTALLATION, TESTING AND COMMISSIONING:

Vendor shall deploy its installation team, which would install the equipment/

instruments, lay the interconnecting cabling, check out, testing and

commissioning the system.

Vendor shall prepare site acceptance test documentation covering hardware,

software, and system functional, testing and submit it three months in advance

for HPCL/PMC review and approval.

All technical personnel assigned to the site by the Vendor shall be fully

conversant with the supplied system and software package and shall have both

hardware and software capability to bring the system on line quickly and

efficiently with a minimum of interference with other concurrent construction and

commissioning activities.

Vendor’s responsibility at site shall include all activities necessary to be

performed to complete the job as per bid documents including, but not limited

to the following:

• Receipt of hardware /software and checking for completeness of supplies

• Installation of the complete system.

• Checking out of the equipment installation.

• Checking of interconnection, hardware and software configuration, overall

system function etc., self-diagnostic test on individual equipment.

• Loop checking.

• Field tests.



313 | 3 5 9

• Commissioning and on-line debugging of the system.

• Performance of final acceptance test.

• Test run.

• Test report

• Supply, installation, commissioning, calibration & testing of all equipments as

per the scope of Vendor.

LOOP CHECKING:

i. Loop check shall be carried out by the vendor for checking the

interconnection, configuration and overall system functioning.

ii. Vendor’s scope of work in loop checking of interconnection

between instrument/equipment, ferruling, tagging of

interconnecting cables up to control room, ferruling of field cables

in control room and performing overall loop performance check.

iii. Loop checking shall be carried out to check the functional

performance of all elements comprising the loop and thereby

ensuring proper configuration functioning and interconnection.

FIELD TESTING:

All the equipment shall be checked thoroughly after its receipt at site. The

tests as a minimum shall include:

i. Visual and mechanical testing.

ii. Complete system configuration loading.

iii. Demonstration of all system functions.

iv. Checking of loop configuration.

v. Checking of OIC displays.

vi. Checking interface with the existing TAS equipment



314 | 3 5 9

vii. Demonstration of all system diagnostics.

viii. Checking of correct changeover of redundant devices.

ix. Checking of proper functioning of printers, sample printing of all

types of logs and reports.

x. Checking of all disc drives, alarm summary and alarm history.

xi. Complete checking of loading operational sequence.

xii. Demonstration of proper operation of system at specified power

supply specifications.

xiii. Loadings of User’s data formats and check out of results.

CALIBRATION OF EQUIPMENT:

Vendor shall make available all consumables, instruments, and equipment

necessary for testing, calibration, maintenance, etc. as required by the defined

scope of works .All instruments and equipment used for the above purpose shall

be of standard make with accuracy better than the accuracy expected from the

calibrated/tested instruments and certified by standard testing agencies. These

instruments and equipment shall be provided as & when required during testing

calibration, maintenance of instrument & equipments in commissioning, testing,

warranty & comprehensive AMC.

All equipments which need calibration either once or on regular periodic or non

periodic time interval shall be calibrated by OEM approved standard guidelines

and procedures. The document specific to project for calibration of the

equipments proposed shall be submitted along with the datasheets. Also the

methodology to verify the calibrated instruments shall form part of datasheets

which shall be submitted for approval. Datasheets of such equipments without

the calibration and verification document shall be not be considered in submitted

category.

TEST RUN / TRIAL RUN:



315 | 3 5 9

Vendor shall conduct trial run of his system for a minimum period of 15 days

after the mechanical completion of job. These trial runs are conducted to verify

the satisfactory performance of the system. In case of major failure in the system,

the trial run shall be repeated for a period of another 15 continuous days. SAT

will be done only after successful Trial run

After trial run site acceptance test (SAT) will be conducted. The project is deemed

to be complete after the compliance of pending pointsof SAT.

In case of non-availability of Ethanol during trial run, the vendor shall

demonstrate performance of ethanol dosing system using MS as an alternate

product. In both the above cases, the Corporation shall make available the

products required for trial run/ commissioning.

QUALITY CONTROL TEST

Quality control tests shall be carried out to ensure quality of all components and

modules in accordance with Vendor's quality controls and assurance procedure.

Vendor shall submit the QAP along with Data sheets of individual equipment.

QAP for site work shall be submitted min 30 days before the start of Site work.

All assemblies shall be aligned and adjusted and all test observations shall be

recorded as per manufacturer published set ups and testing methods.



316 | 3 5 9

SITE ACCEPTANCE TESTS (SAT)

SAT will be conducted at the location for a minimum duration of 3 to 5 days.

Vendor shall submit the common test procedure at least 60 days prior to the

acceptance test to HPCL/PMC for review and modifications, if any, these

procedures. Vendor shall resubmit the procedure incorporating the revisions for

approval by HPCL/PMC. SAT shall be carried out as per the approved procedure.

Any additional tests, though not specifically mentioned in the SAT procedure, but

required by HPCL/PMC shall also be part of SAT.

Vendor shall notify in writing HPCL/PMC minimum 15 days in advance for SAT.

SAT shall include the following minimum tests

o All hardware checks

o All Software checks

o Checking for completeness of supplies for both software and Hardware

o All functional checks individual as well as integrated System checks

o Verification of individual equipment like metering system, Densitometer

etc.

o Verification of Site works like Cable laying

o Verification of all Original licenses

o Verification of all site documents

STABILIZATION PERIOD & USER ACCEPTANCE TEST (UAT)

After successful commissioning of the entire system, the system shall be

observed for faultless working for a period of 90 days. If the following subsystems

remain down for more than 24 hours in a day then the system shall be observed

for a further period of 90 days for stabilization after rectification/ replacement of

the same by the Vendor. These subsystems are;

1 Tank truck loading system

However, during the stabilization period, in case of fault in any individual

equipment which does not result in complete breakdown of any of the above

subsystems or any other subsystems, the same shall be rectified within 48 hrs of

breakdown and restored back to operation and such fault will not be considered



317 | 3 5 9

as major fault & stabilization period will not be restarted. During the Stabilization

period, Tank Truck Gantry operation shall perform as per the accuracy defined

else the same may be extended. Record shall be maintained for at least 50% of

Trucks loaded during this period to establish the same. The stabilization will be

treated as completed after successful User Acceptance Test wherein all

functionality & System accuracy will be re-verified for establishing System

availability & reliability. At the end of stabilization period, vendor shall handover

the entire system in fully working condition with accuracy of flow metering

system as per W&M/ Legal Metrology regulations.



318 | 3 5 9

Failure of equipment

Following action shall be taken in case of failure of listed equipment. For other

instruments failure vendor shall advise the action taken in FDS document for

approval or modification

• DCV failure: Though DVC is fail safe, still the failure may occur due to

diaphragm failure. In such case, the pumps of that particular product &

header line MOV shall be tripped by system with alarm logged in the

alarm section with alarm of DCV and pump tripping specifying the reason.

The method to restart the tripped pump sets shall be submitted by

vendor. Same shall be possible from soft and hard buttons.

• Excess filing above preset quantity : In case of excess filling over the preset

due to failure of DCV, pulsar failure or batch controller or loss of

communication, the said problem clearly identified shall be logged in the

alarms. In case of filled quantity exceeding preset quantity by 10 litres

(Configurable) , the pumps of that particular product shall be tripped by

system indicating alarm “(Product ,specify) pumps tripped ,excess filling

loading point(no, specify)”. In all cases of pump tripping the alarm shall

specify the root cause of pump tripping .

• Card reader: System shall have inbuilt diagnostic tools which shall be put

in system health screen to diagnose health of card reader through

software. The system shall detect the hardware and software( drivers etc)

healthiness.

• Failure of any command: Incase of failure of execution of any command

sent to field devices or control room devices , the same shall be generated

by system on real time basis under system alarm category.

• Low pressure in header line: The system shall stop the loading of product

at all loading points of particular product in case the header pressure falls

below the set pressure. Such set pressure shall be configurable in the

system. Such events shall be captured under events screen. The alarm



319 | 3 5 9

generated shall display loading stopped at (product points, specify

product) due to low pressure in header.

• Batch Controller : whenever any batch controller goes in manual mode the

same shall be advised to user through popup indicating which loading

point has gone in manual.

• Manual loading: Incase manual loading through batch controller needs to

be carried out then the procedure shall be as follows :the batch controller

shall ask for password. Upon successful validation of password the BC

shall read supervisor card no thru card reader. Unless and until the

supervisor card no is read and validates the manual loading shall not

proceed. The successful validation will then advise user to enter truck no.

Upon such validation only then manual loading shall be permitted.

Whenever system comes in remote mode back then data should be

updated automatically without any pressing of button and same shall be

also available in manual load report



320 | 3 5 9

PLANT OPERATION AND MAINTENANCE MANUAL

Vendor shall submit to HPCL for review and approval of the draft of the operating

manual for the facilities as per requirements listed in contract documents. Final

operating manual shall only be issued after approval on draft is obtained. Five

sets of final approved operating and maintenance manual shall be made available

before commencing the commission of the plant.

The operation manual shall have two parts. One shall give the details of the

individual instrument/ equipment. The other part shall contain the system details.

The objective of the manual is to assemble under one bound cover all the

instructions, data and drawings necessary for the operations personnel to start,

operate, control, shut down and maintain the systems under normal and

emergency conditions in a safe manner. It is desired that the instructions to be

written for clarity and simplicity.



321 | 3 5 9

PERFORMANCE GUARANTEE (Defect liability Period)

Vendor shall be responsible for proper design, quality, workmanship, operation &

maintenance of all equipment, accessories, etc. supplied by the Vendor for a

period of 24 months from the date of commencement of Stabilization. In case

commencement of stabilization is delayed due to non-availability of products or

any other reason not attributable to Vendor, then warranty shall be 30 months

from the date of mechanical completion only for that equipment in question.

Further Vendor shall provide written guarantee that the back-up engineering,

maintenance and spare parts shall be available for a minimum period of 8 years

after warranty period for all equipment supplied by the Vendor. In the event of

non-availability of spares due to fast obsolescence of hardware and software, the

vendor shall arrange to upgrade/ replace the equipment with equivalent or

higher hardware and software at no additional cost till end of this 8 year period.

For existing / free issue items, scope of warranty will be limited to the

modification & interface done

It shall be obligatory on the part of the Vendor that during the defect

liability/warranty period, Vendor will take complete responsibility for any defect

observed in the system supplied by the Vendor, any modification and/or

replacement of any hardware from the supplied equipment and attend to the

maintenance of the system, free of cost, during start-up and on-line operation of

TAS. Any emergency requirement shall be attended by Vendor’s Senior Team

within one day notice. The replacement of any sub-system, modules and or entire

system shall be attended within one day.

Cost of all spares, equipment, instruments & services, (be preventive &

breakdown) to take care of the above points has to be borne by the Vendor

during the warranty period In case of failure to attend to these promptly, these

will be attended through alternate agency at vendor’s risk and cost.

All road permits for supply of any spares/ materials during CAMC shall be in the

Vendor’s scope.



322 | 3 5 9

The vendor’s resident engineer will check and service of each equipment &

instrument and its accessories and maintain them in good working condition. Any

consumables required for servicing the equipment shall be arranged by the

Vendor at no extra cost to HPCL during Warranty

Vendor shall maintain minimum consumables for smooth working of equipment/

instrument supplied by them.

Printer cartridge, Stationary papers shall not form part of consumables to be

maintained by the vendor at site.

W&M stamping of the electronic metering system (excluding electronic metering

system) during the warranty period shall be in the scope of Vendor. All incidental

charges for W&M stamping shall be in the scope of the Vendor. Statutory fees

shall be reimbursed by HPCL against submission of Original receipt. The receipt

shall be in the name of HPCL location. Any additional W&M stamping required,

apart from the yearly stamping, due to reasons attributable to automation

equipment like change in calibration, K factors, replacement of pulsars etc. shall

be in the scope of Vendor.

Vendor shall provide Resident Engineer (Min. degree holder) with minimum one

year experience / familiarity in erection/ commissioning/ maintenance of TAS

should be positioned at the location during working hours for taking care of

normal system operation, all Preventive & Breakdown maintenance during the

total warranty period. The Resident Engineer shall submit fortnightly report on

the System operation, preventive & breakdown maintenance carried out. This

includes backup coverage for such engineers for vacations, illness, training etc at

no additional costs.

The Resident Engineer shall assist the Location in verification of metering system,

etc as & when required by the location.



323 | 3 5 9

POST WARRANTY COMPREHENSIVE ANNUAL MAINTENANCE CONTRACT (CAMC)

The system (all equipment supplied by the Vendor including

interface/integration) is to be maintained for a period of five years after expiry of

warranty period. Cost of all spares, equipment, instruments & services,

(Preventive & Breakdown) to take care of maintenance, has to be borne by the

Vendor during the CAMC period. In case of failure to attend within 2 days, these

will be attended through alternate agency at vendor’s risk and cost.

The post warranty comprehensive AMC shall be a separate contract for the 5

years period and shall be signed at beginning of the respective year. The post

warranty Comprehensive AMC rates quoted in price bid for 5 years shall be

included in the evaluation.

6 Nos. normal visits (once in two months) and 4 No. emergency visits per annum

(as & when required) are included in scope of C.A.M.C. (Comprehensive Annual

Maintenance Contract). HPCL will have the right to reschedule the visits and

adjust the total no. of regular and emergency visits.

For existing / free issue items, scope of CAMC will be limited to the modification

& interface done

The vendor’s service engineer will check and service of each equipment &

instrument and its accessories and maintain them in good working condition. Any

consumables required for servicing the equipment shall be arranged by the

Vendor at no extra cost to HPCL during CAMC.

Vendor shall maintain minimum consumables for smooth working of terminal

automation system

Printer cartridge, Stationary papers shall not form part of consumables to be

maintained by the vendor at site.

HPCL can terminate the annual maintenance contract by giving three months’

notice in advance to the vendor.

During the CAMC, Vendor will hold the inventory of minimum spares inventory at

the site required for maintaining the system in operating condition. The vendor

shall ensure availability of spares (at minimum) at all times at the site. The vendor

shall always promptly replenish the spares as & where the same are used. The



324 | 3 5 9

vendor should do proper spares management by carrying out periodical testing

of the spares, safeguards against obsolescence, any up gradation, timely

replenishment, etc.

W&M stamping of the electronic metering system (excluding existing Electronic

Metering System) shall be in the scope of Vendor. All incidental charges for

W&M stamping shall be in the scope of the Vendor. Statutory fees shall be

reimbursed by HPCL against submission of Original receipt. The receipt shall be

in the name respective HPCL location. Any additional W&M stamping required,

apart from the yearly stamping, due to reasons attributable to automation

equipments like change in calibration, K factors, replacement of pulsars etc. shall

be in the scope of Vendor.

Vendor shall furnish Bank Guarantee equivalent to the rates quoted for 5 year

comprehensive Annual Maintenance Contract. This Bank Guarantee shall be

submitted 2 months before the expiry of warranty period failing which retention

money shall stand forfeited. BG for CAMC shall be valid for minimum 62 months

or till the end of 5th year AMC whichever is later.

The vendor shall ensure availability of spares for the Automation System for a

minimum period of 8 years after warranty period. In the event of non-availability

of spares due to fast obsolescence of hardware and software, the vendor shall

arrange to upgrade/ replace the equipments with equivalent or higher hardware

and software at no additional cost till end of CAMC period.

The Vendor must note that all commissioning spares and the spares /

consumables during warranty and comprehensive CAMC shall be supplied by the

vendor free of cost.

All road permits for supply of any spares/ materials during CAMC shall be in the

Vendor’s scope.

Agreement for the Post warranty CAMC shall be entered before the start of each

year. HPCL reserves the right to sign the post warranty AMC for all 5 years or part

of it or none or to extend the contract after 5 years.

The composite rate quoted by vendor for 5 years CAMC period shall be split year

wise in the following percentage for payment purpose



325 | 3 5 9






.



326 | 3 5 9

OTHER TECHNICAL REQUIREMENTS:

Flexibility should be kept in the software to re-designate each tank, pump for a

new product which will in turn maintain the stock accounts as per the change.

The security access for the engineering./configuration database, other terminal

database master maintained in the system, should support additional security

protection other than password protection for the authorized access.

System initialization and setup parameter for entry of the database for tank farm

specifications including system security shall have user friendly interface. System

should have appropriate user interface for data entry of tank calibration charts as

per standard format and bidder shall use the same for tank farm system

configuration.

All commissioning and start-up spares required up to commissioning, system

acceptance and handing over of the system to the HPCL shall be in the Vendor’s

scope.

The Vendor shall be fully responsible for proper selection of equipment,

engineering performance and successful operation of the complete system

including all bought out equipment, subsystems supplied by them when

integrated with the overall Automation System meeting the functional

requirements.

The operational requirements as specified in this tender conditions/specifications

might undergo certain revisions during detail design and engineering. Also there

may be minor variations from depot to depot. The Tenderer must ensure that the

offered system software packages have the capability and flexibility to take care

of these requirements without any major software changes.

The Tenderer has to make his own estimate of quantity of the cables and

erection hardware requirement, based on the layout drawing enclosed and his

own site assessment.



327 | 3 5 9

The system shall be internally protected against system errors and hardware

damage resulting from electrical transients on power wiring and signal wiring

which may be generated by switching large electrical loads or by power line

faults, and connecting & disconnecting devices or removing or inserting printed

circuit boards in the system.

The system design shall permit for future expansion, on line addition of new

systems/ subsystems without any disruption to either the operation or system

communication.

Vendor shall obtain all the required approvals from statutory bodies like CMRI,

CCOE, W & M etc at no extra cost to HPCL. Annual calibration including

coordination with local W & M inspector is included in the scope of the Vendor.

However the stamping charges will be paid by HPCL (Location) on proof and

production of original receipt during Warranty & AMC period.

A corrosion resistant nameplate will be securely fastened to the equipment in a

visible and accessible place. Nameplate shall bear the following data:-

Manufacturer’s Name

Model Number

Serial Number

Size, rating (s) and Range (s)

Electrical data (where applicable)

Approval for Electrical Area Classification (with approving authority's

monogram where applicable)

HPCL’s Tag Number.

Detailed Design and Engineering for various items involved for the total project

for Instrumentation and automation including detailed material specifications /

requisition, project specific drawings, obtaining necessary approvals and

preparation of detailed report is in the scope of the Vendor .

Documentation of the entire system including detailed specification of the

system configuration, system Architecture, technical philosophy, equipment,

detailed drawings, trouble shooting charts, general maintenance guidelines etc

shall be submitted by the Vendor.



328 | 3 5 9

OTHER FUNCTIONAL REQUIREMENT

Trending

The trending feature shall be of various types like Single Bar, Multiple Bar, X-Y,

Numeric, etc. The module shall be able to show at least

Real Time Trending

Historical Trending

Archived Historical Trending

Cursor Read Out

Zoom & Scroll

Trend Comparisons

Trending feature is required for minimum following parameters

Gantry area

Header pressure for all products

Flow rate for individual loading point

Temperature for individual loading points

Each loading point totaliser readings

VFD & energy Management System

Tank farm area

Water level

Oil level

Average temperature of product



329 | 3 5 9

Density of the product for all tanks

Product pumps, (tank truck filling pumps , Additive dosing pumps, ethanol

pumps,)

Each pump running hours

Tank truck loading gantry and various interlocks

• All the Tank Trucks (T/T) will come to the Terminal and report at S & D

counter.

• The load is planned by JDE operator and sent to JDE sever.

• The load is sent from JDE server to TAS LRC through gateway server.

• Once the preload packet is received the LRC displays the truck details ,

customer name and number, and quantity of product to be loaded and

load segregation based on compartment capacity. Compartment

allocation logic and preferred bay configuration logic needs to be part of

TAS software.

• TT is allocated proximity card number. The facility to allocate card shall be

dual i.e. by card reader and through keyboard pads.

• TTES allocates Bay no., based on total no of T/T inside and 1 + 2 criteria

(User Configurable) for TLF bay. TTES operator can override the bay

allocation, if required. Card reader at TTES reads Card number for printing

on FAN (filling advice note). LRC sends a visual communication by means

of display on electronic display unit in T/T parking area, asking T/T to

report for filling bay. FAN is printed by TTES operator and handed over to

the driver along with card and seals. Validity of card vis-a-vis time elapsed

since time of issue & expiry of FAN should also be programmed. The

display to EDU and announcement shall be programmed so that it is in

line with the printing of FAN ie truck whose FAN is printed first shall be

displayed and announced first .

• T/T enters through main Gate of the terminal / depot at TLF entry gate

Barrier.



330 | 3 5 9

• Driver shows the card at barrier gate card reader. Card validation is done

by LRC. Gate opens on command from PLC based on clearance from main

computer of control room, and the T/T enters the licensed premises.

• T/T reports for filling at the allocated bay. The Red lamp in the RIT is ON at

particular TLF bay. T/T driver shows the card at the card reader provided at

the bay. LRC checks its validity, downloads the loading information to

batch controller. If card is not current or valid, Batch controller displays

invalid card or un -authorised card or Go to bay no XXX and RIT will

display steady red lamp. Upon successful completion of identification

sequences, truck registration no is displayed on batch controller.

• Driver connects earthing to the T/T.

• T/T driver inserts loading arm in the first compartment of T/T i.e. Starting

from T/T cabin side.

• Batch controller checks for safety permissive interlocks. RIT lamp

changes from Red to yellow. Batch controller shall simultaneously display

truck no, compartment number and preset quantity. Driver need to

acknowledge once per compartment.

• Driver prepares for loading and acknowledges by pressing yellow push

button on RIT. LRC checks for tank, which is in withdrawal mode to supply

particular product.

• Green lamp on RIT is ON

• Driver presses green PB for actual start of loading operation. Flow of

product should not start unless all the mandatory checks are complied

with.

• (Step 9 to 13 are repeated till the loading is complete for all compartments

of T/T)

• Batch controller uploads all other product meters of the bay and will only

permit flow of designated product. Batch controller continuously updates,

present, remaining & volume loaded during loading operation. If a

multiple load is started on a multiple products bay, the driver may be

allowed to fill both products simultaneously. This should be supported as a

configurable option with LRC, which can be set for only one product active

on bay.

• After the T/T loading is complete, Supervisor at TLF checks sealing of all

chambers of the T/T, signs the FAN. T/T drives out of the bay and moves

towards TLF exit gate barrier.



331 | 3 5 9

• LRC computer will release the bay and meanwhile TDM operator prepares

the challan at the Marketing room

• Supervisors will have unique card, which can be read at the bay reader to

locally load the TT for any given quantity after setting the qty. in batch

controller. All historical data pertaining to such type of fillings will be

recorded in the LRC and at the bay, LRC will generate a report for the

same i.e., the Bill of lading (BOL)

• T/T comes out of licensed premises, goes to security gate. Meanwhile T/T

driver collects the challan from marketing room. T/T driver hands over

Gate pass copy of challan and card to the security , who in turn shows the

card to the exit barrier card reader. LRC checks up in its database, whether

the challan for the particular truck has already been printed from the

Marketing room and all clear signal sent to PLC for opening of the exit

gate at TLF. TT exits through gate barrier.

• Entire system will work on real time mode and will register entry, filling &

exit time of each Tank truck.



332 | 3 5 9

SAFETY PRACTICE

HPCL AUTOMATION OF TERMINALS/DEPOTS

SAFETY / SECURITY OF MATERIALS

The responsibility of safety and security of materials and equipments brought or

installed by the contractors (till they are handed over to us) will remain with

contractor and any claim, of what so ever nature due to any loss or otherwise, will

not be entertained. The contractor will have to hand over completed job in its

entirely as per work order.

SECURITY OF CONTRACTOR’S MATERIALS

HPCL shall not be responsible for the security of Contractor’s materials / equipment.

SAFETY PRECAUTIONS AND HOT WORK

Contractor shall have to take all safety precaution for carrying out hot work in the

premises after obtaining hot work permit from location in charge at his own cost

as directed by the Engineer-In-Charge. Necessary safety equipment such as

safety belts, helmets, etc., and other safety instruments are to be positioned by

the contractor and the same shall be used by the work force as per work

requirement. The contractor has to enforce the same. Safety distance as per CCE Rules and Oil Industry Safety Directorate shall be maintained strictly. Any casualty or damage caused to property or person by any untoward incidents while executing this contract will be at the contractor’s risk and cost.

The contractor shall strictly follow safety practices during construction as per the

copy of OISD 192 enclosed along with the tender document.

HOT WORK PERMIT



333 | 3 5 9

No hot work is permitted without issuance of hot work permit by location in-

charge. The hot work permit will be issued in the HPCL approved format on a

day-to-day basis.

After completion of work, the site should be cleared of all scrap, contractor’s

equipment and machinery used in fabrication. Necessary assistance shall be provided by the contractor at the time of commissioning of the tank / pipelines by providing required manpower / equipment as per the requirement of the site engineer / location in charge.



334 | 3 5 9

HEALTH, SAFETY

AND ENVIRONMENT

REQUIREMENTS



335 | 3 5 9

SAFETY , HEALTH & ENVIRONMENT POLICY

SPECIFICATION FOR HEALTH, SAFETY AND ENVIRONMENT (HSE)

MANAGEMENT

CONTENTS

________________________________________________________________

CLAUSE NO. TITLE PAGE NO.

1.0 SCOPE

2.0 REFERENCES

3.0 REQUIREMENT OF HEALTH, SAFETY AND

ENVIRONMENT (HSE)

3.1 MANAGEMENT RESPONSIBILITY

3.2 HOUSE KEEPING

3.3 SAFETY, HEALTH & ENVIRONMENT

4.0 DETAILS OF HSE MANAGEMENT SYSTEM

BY CONTRACTOR

4.1 ON AWARD OF CONTRACT

4.2 DURING JOB EXECUTION

1.0 SCOPE

This specification establishes the Health, Safety and Environment (HSE)

management requirement to be complied with by the Contractors during

construction.

Requirements stipulated in this specification shall supplement the requirements



336 | 3 5 9

of HSE Management given in relevant Act (s) / legislations. General Conditions

of Contract (GCC), Special Conditions of Contract (SCC) and Job

Specifications. Where different documents stipulate different requirements, the

most stringent shall be adopted.

2.0 REFERENCES

This document should be read in conjunction with following:

- General Conditions of Contract (GCC)

- Special Conditions of Contract (SCC)

- Job Specifications

- Relevant IS Codes (refer Annexure – I)

3.0 REQUIREMENTS OF HEALTH, SAFETY & ENVIRONMENT (HSE)

MANAGEMENT SYSTEM TO BE COMPLIED BY BIDDERS

3.1 MANAGEMENT RESPONSIBILITY

3.1.1 The Contractor should have a documented HSE policy to cover

commitment of their organization to ensure health, safety and

environment aspects in their line of operations.

3.1.2 The HSE management system of the Contractor shall cover the HSE

requirements including but not limited to what is specified under Para

1.0 and para 2.0 above.

3.1.3 Contractor shall be fully responsible for planning and implementing

HSE requirements. Contractor as a minimum requirement shall

designate / deploy the following to co-ordinate the above :

No. of workers deployed Up to 250 - Designate one safety supervisor

Above 250 & up to 500 - Deploy one qualified and experienced

safety Engineer / officer

Above 500 - One additional safety engineer/officer as

above.

(for every 500 or less)

Contractor shall indemnify & hold harmless Owner / HPCL & either representative

free

from any and all liabilities arising out of non – fulfilment of HSE



337 | 3 5 9

requirements.

3.1.4 The Contractor shall ensure that the Health, Safety and Environment

(HSE) requirements are clearly understood & faithfully implemented at

all levels at site.

3.1.5 The Contractor shall promote and develop consciousness for Health,

Safety and Environment among all personnel working for the

Contractor. Regular awareness, programme and fabrication shop / work

site meetings shall be arranged on HSE activities to cover hazards

involved in various operations during construction.

3.1.6 Arrange suitable first aid measures such as First Aid Box, trained

personnel to give First Aid, Stand by Ambulance or Vehicle and

install fire protection measures such as : adequate number of steel

buckets with sand and water and adequate fire extinguishers to the

satisfaction of HPCL/Owner.

3.1.7 The Contractor shall evolve a comprehensive planned and documented

system for implementation and monitoring of the HSE requirements.

This shall be submitted to HPCL/Owner for approval. The monitoring for

implementation shall be done by regular inspections and compliance to

the observations thereof. The Contractor shall get similar HSE

requirements implemented at his sub-contractor(s) work site/office.

However, compliance of HSE requirements shall be the sole

responsibility of the Contractor. Any review / approval by HPCL/Owner

shall not absolve contractor of his responsibility / liability in relation to

all HSE requirements.

3.1.8 Non-Conformance on HSE by Contractor (including his Sub-contractors)

as brought out during review/audit by HPCL/Owner representatives

shall be resolved forthwith by Contractor. Compliance report shall be

provided to HPCL/Owner.

3.1.9 The Contractor shall ensure participation of his Resident Engineer /

Site-in-Charge in the Safety Committee / HSE Committees meetings

arranged by HPCL/Owner. The compliance of any observations shall be

arranged urgently. He shall assist HPCL/Owner to achieve the targets

set by them on HSE during the project implementation.

3.1.10 The Contractor shall adhere consistently to all provisions of HSE

requirements. In case of non-compliance or continuous failure in

implementation of any of HSE provisions; HPCL/Owner may impose



338 | 3 5 9

stoppage of work without any Cost & Time implication to Owner

and/or impose a suitable penalty for non-compliance with a notice of

suitable period, up to a cumulative limit of 1.0% (one percent) of

Contract Value with a maximum limit of Rs. 10 lakhs. This penalty

shall be in addition to all other penalties specified else where in the

contract. The decision of imposing stoppage work, its extent &

monitory penalty shall rest with HPCL/Owner & binding on the

Contractor.

3.1.11 All fatal accidents and other personnel accidents shall be investigated

by a team of Contractor’s senior personnel for root cause &

recommend corrective and preventive actions. Findings shall be

documented and suitable actions taken to avoid recurrences shall be

communicated to HPCL/Owner. Owner / HPCL shall have the liberty to

independently investigate such occurrences and Contractor shall extend

all necessary help and co-operation in this regard.

3.2 HOUSE KEEPING

3.2.1 Contractor shall ensure that a high degree of house keeping is

maintained and shall ensure inter-alia the followings:

a. All surplus earth and debris are removed/disposed off from the

working areas to identified location(s).

b. Unused/Surplus Cables, Steel items and steel scrap lying

scattered at different places within the working areas are

removed to identified location(s).

c. All wooden scrap, empty wooden cable drums and other

combustible packing materials, shall be removed from work

place to identified location(s).

d. Roads shall be kept clear and materials like: pipes, steel, sand

boulders, concrete, chips and bricks etc. shall not be allowed on

the roads to obstruct free movement of men & machineries.

e. Fabricated steel structural, pipes & piping materials shall be

stacked properly for erection.

f. Water logging on roads shall not be allowed.

g. No parking of trucks / trolleys, cranes and trailers etc. shall be

allowed on roads which may obstruct the traffic movement.



339 | 3 5 9

h. Utmost care shall be taken to ensure over all cleanliness and

proper upkeep of the working areas.

i. Trucks carrying sand, earth and pulverized materials etc. shall be

covered while moving within the plane area.

3.3 HEALTH, SAFETY AND ENVIRONMENT

3.3.1 The Contractor shall provide safe means of access to any working

place including provisions of suitable and sufficient scaffolding at

various stages during all operations of the work for the safety of his

workmen, and, HPCL/Owner. Contractor shall ensure deployment of

appropriate equipment and appliances for adequate safety and health of

the workmen and protection of surrounding areas.

3.3.2 The Contractor shall ensure that all their staff and workers including

their sub-contractor(s) shall wear Safety Helmet and Safety shoes.

Contractor shall also ensure use of safety belt, protective goggles,

gloves etc. by the personnel as per job requirements. All these gadgets

shall conform to relevant IS specifications or equivalent.

3.3.3 Contractor shall ensure that a proper Safety Net System shall be used

at appropriate locations. The safety net shall be located not more than

30 feet (9.0 metres) below the working surface at site to arrest or to

reduce the consequences of a possible fall of persons working at

different heights.

3.3.4 Contractor shall ensure that flash back arrester shall be used while

using Gas Cylinders at site. Cylinders shall be mounted on trolleys.

3.3.5 The Contractor shall assign to his workmen, tasks commensurate with

their qualification, experience and state of health for driving of

vehicles, handling and erection of materials and equipments. All lifting

equipments shall be tested certified for its capacity before use.

Adequate and suitable lighting at every work place and approach there

to, shall be provided by the Contractor before starting the actual

operations at night.

3.3.6 Hazardous and/or toxic materials such as solvent coating, or thinners

shall be stored in appropriate containers.

3.3.7 All hazardous materials shall be labeled with the name of the

materials, the hazards associated with its use and necessary precautions



340 | 3 5 9

to be taken.

3.3.8 Contractor shall ensure that during the performance of the work, all

hazards to be health of personnel, have been identified, assessed and

eliminated.

3.3.9 Chemical spills shall be contained & cleaned up immediately to

prevent further contamination.

3.3.10 All personnel exposed to physical agents such as ionizing radiation,

ultraviolet rays or similar other physical agents shall be provided with

adequate shielding or protection commensurate with the type of

exposure involved.

3.3.11 Where contact or exposure of hazardous materials could exceed limits

or could otherwise have harmful affects, appropriate personal protective

equipments such as gloves, goggles, aprons, chemical resistant clothing

and respirator shall be used.

- A Crèche where 10 or more female workers are having

children below the age of 6 years.

- Reasonable Canteen facilities are made available at appropriate

location depending upon site conditions.

3.3.13 Suitable facilities for toilet, drinking water, proper lighting shall be

provided at site and labour camps, commensurate with applicable Laws

/ Legislation.

3.3.14 Contractor shall ensure storage and utilization methodology of materials

that are not detrimental to t he environment. Where required Contractor

shall ensure that only the environment friendly materials are selected.

3.3.15 All persons deployed at site shall be knowledgeable of and comply

with the environmental laws, rules & regulations relating to the

hazardous materials substances and wastes. Contractor shall not dump,

release or otherwise discharge or dispose off any such materials

without the express authorization of HPCL/Owner.

4.0 DETAILS OF HSE MANAGEMENT SYSTEM BY CONTRACTOR

4.1 On Award of Contract

The Contractor shall prior to start of work submit his Health, Safety and



341 | 3 5 9

Environment Manual or procedure and HSE Plans for approval by

HPCL/Owner. The Contractor shall participate in the pre-start meeting with

HPCL/Owner to finalise HSE Plans including the following :

- Job procedure to be followed by Contractor for activities covering.

Handling of equipment, Scaffolding, Electric Installation, describing

the risks involved, actions to be taken and methodology for

monitoring each activity.

- HPCL/Owner review / audit requirement.

- Organization structure along with responsibility and authority records /

reports etc. on HSE activities.

4.2 During job execution

4.2.1 Implement approved Health, Safety and Environment management

procedure including but not limited to as brought out under para 3.0.

Contractor shall also ensure to:

- arrange workmen compensation insurance, registration under ESI Act,

third party liability insurance etc., as applicable.

- arrange all HSE permits before start of activities (as applicable) like

hot work, confined space, work at heights, storage of chemical /

explosive materials and its use and implement all precautions

mentioned therein.

- submit timely the completed checklist on HSE activities, Monthly

HSE report, accident reports, investigation reports etc. as per

HPCL/Owner requirements. Compliance of instructions on HSE shall

be done by Contractor and informed urgently to HPCL/Owner.

- ensure that Resident Engineer / Site-in-Charge of the

Contractor shall attend all the Safety Committee / HSE

meetings arranged by HPCL/Owner. Only in case of his

absence from site that a second senior most person shall be

nominated by him in advance and communicated to

HPCL/Owner.

- display at site office and work locations caution boards, list of

hospitals, emergency services available.



342 | 3 5 9

- provide posters, banners for safe working to promote safety consciousness.

- carryout audits / inspection at sub contractor works as per approved

HSE document and submit the reports for HPCL/Owner review.

- assist in HSE audits by HPCL/Owner, and submit compliance report.

- generate & submit HSE records / report as per HSE Plan.

- appraise HPCL/Owner on HSE activities at site.



343 | 3 5 9

ENCLOSURES



344 | 3 5 9

ATTACHMENT-1



345 | 3 5 9

MINIMUM LIST OF SPARES TO BE KEPT AT THE TERMINAL DURING WARRANTEE &

ANNUAL MAINENANCE PERIOD

S.N ITEMS PROPOSED

SPARES QTY

(NOS.)

1. Batch controller

a. CPU card, motherboard 2

b. Digital Input cards 4

c. Power supply card 2

d. Display board 2

e. Meter Pulse Board 2

f. Keypad assembly 1

g. Analog Input Board 2

h. Digital Output cards 2

i. Cards for ethanol , additive blending 2

2. PD Meter ( 3” )

a. Bearing plate assembly 2

b. Complete Measuring Chamber Set 1

c. Seals 6

d. Pulsar gear assembly 3

e. Pulser card 4

f. Gland packing 4

g. Gasket cover 4



346 | 3 5 9

h. Bearing rotor and blade 2

i. Tri rotor/ Bi rotor (set) 2

j. Timing gear –complete set 1

k. Rotor sub assembly 2

l. Extended spindle 6

m. Rotor gear 2

n. Manifold gasket 6

o. Gasket (outer case) 6

p. Rubber kit of PD meter 6

q. Spindle seal 6

r. Thrust bearing 6

s. Rotor ball bearing 4

t. Spring dowel 6

3 PD Meter (1 1/2 ”)

a. Bearing 1

b. Complete Measuring Chamber Set 1

c. Seals 3

d. Pulsar gear assembly 2

e. Pulser card 2

4 Strainer cum Air Eliminator

a. Strainer Basket 2

b. Gasket / Seals Set 4

c. Float & Reed Assembly 3

d. Differential Pressure Gauge 3

e. O rings set 6



347 | 3 5 9

5 Set Stop Valves/ Digital control valve

a. NO / NC Solenoid Valve (SET) 2

b. Rubber Kit of solenoid Valve 6

c. Springs 6

d. Diaphragm 4

e. O-Ring for outer case 5

f. Seals-set 3

g. Paper gasket for inner capsule 5

6 Earthing Relay

a. Earthing relay board 4

b. Earthing Clamp with cords of 5 m length. 6

c. Lamp cover with lamps (red, green) 2

7 RIT

a. Indicating lamp – RED, GREEN & AMBER – (Set) 2

b. Push Button Set- Red , Amber, Green 2

8 Access Control System

a. Proximity Card 10

b. Card Reader 1

c. Electronic card for card reader 2

d. Power supply module 2

e. Access control unit (incase of Nexwatch system) 2

9 LRC Hardware

a. RS 232 / 485 Converters 2

b. Ethernet Interface card 6

10 PLC / Subsystem

a. DI Modules 2



348 | 3 5 9

b. DO Modules 2

c. AI Modules 1

d. Communication Modules – CPU to I/O rack 1

e. Communication Modules – CPU host system 1

f. I/O rack Interface module 1

g. Barrier for analog I/P 1

11 UPS Subsystem (equivalent as per OEM standard)

a. Thyristor for Charger 1

b. Power Transistor / IGBT 2

c. System manager card 1

d. Buffer card 2

e. Set of Fuses 2

f. Heat sink cooling fan 1

g. Control Transformer 1

h. Thyristor for static 1

i. Regulation and pulse generator module 1

j. PCA rectifier 1

k. PCA power supply 1

l. Control transformer 1

13 Density meter

a. Density meter electronics module 1

b. Pressure Gauge 3

c. Pressure Transmitter for Header 1

14. Electronic Display Board

a. Communication Card 1

16. Isolators ( barriers) for Analogue Input/ Output 4



349 | 3 5 9

17. Barrier gate

a. Motor Contactors 2

b. Limit switch 1

c. Infrared sensor 1

d. MCB 1

e. Clutch liner 1

f. Cam bush 1

g. Springs- complete set 3

18. DG set- mandatory spares recommended by OEM 1 set

Spares indicated above are minimum requirement which shall be maintained at

the Location. Any items other than above required during the warranty and

CAMC period shall also be maintained at site/ supplied by TAS vendor. The

spares shall delivered at the site before the SAT. The spares shall be replaced as

and when it is consumed.

Additional quantity may be kept at the terminal by the Vendor based on OEM

recommendation. Tenderer to specifically indicate the spares / items which are

not applicable to the equipments offered by then in technical bid document.

The above shall be handed over to HPCL at the end of CAMC.



350 | 3 5 9

ATTACHEMENT - III

APPROVED VENDOR LIST FOR HPCL DEPOT AUTOMATION PROJECT

Batch Controller Daniel, Contrec, FMC technologies, Toptech,

Advanced Systek

Positive Displacement Meter IDEX(Liquid Controls), FMC Technologies (Smith),

Brodie

Pulse Transmitter IDEX(Liquid Controls), FMC Technologies (Smith),

Brodie

Strainer cum Air Eliminator IDEX(Liquid Controls), FMC Technologies (Smith),

Brodie, Cryogenic,

Bulk Air Eliminator IDEX(Liquid Controls), FMC Technologies (Smith),

Brodie, Cryogenic, Flash point, Bopp & Reuther

Digital Control Valve for

White oil

Bermad, IDEX(Liquid Controls), Daniel, FMC

Technologies (Smith)

Limit switches Telemechanique, L&T, Siemens, BCH, Honeywell,

Danfoss, Osna, Chemtrol, DAG

Actuator Rotork, Biffi, Auma or Limitorque Triple Offset Butterfly Valve Virgo, Vanessa, Adam, Fouress, L&T

Push Button Station Sudhir, Shyam, Baliga, FCG. Etc.

Solenoid Valve ASCO, ASCO Joucomatic, Rotex, Herion Werke

Proximity Card reader Nexwatch , Daniel, Stahl, FMC

Remote Interaction Terminal Baliga, Teltech, FEPL, Sudhir Switchgear Pvt. Ltd

RTD with Thermowell

General Instruments, Nagman, Altop, Pyroelectric

Earthing Relay Scully, Anderson, Daniel, Baliga, Stahl, Enraf,

Advance Systek, Osna Loading Arm Heatly Gresham, Technica, Associate Engineers,

Woodfield, Emco Wheaton, OPW

Differential Pressure Gauge &

Pressure Gauge

Switzer, Gen. Instruments., Waree, AN Instruments,

Manometer (I) Ltd, Hirlekar, Bourdan, Forbes

Marshall

UPS Hirel, Emerson, DB Power



351 | 3 5 9

Batteries HBL Nife, Exide, Pansonic, AMCO, UPlus

Mobile Prover Tank Flash Point, Teltech, Cryogenic, Liquid Controls,

Toshniwal

Radar Gauge with Tank side

Indicator

Rosemount Tank Radar, Enraaf

Averaging Temp Sensor for

Tanks


Water Interface Measurement

Sensor


Density Probe for U/G Tank Solatron, Lemis Baltic

Pressure transmitters Emerson(Rosemount), ABB, Yokogawa, foxbro

Density meter with

Transmitter/ Mass Flow meter

Solatron, Sarasota, Smith, Emerson, Bopp &

Reuther, E&H, Lemis Baltic

ORIFICE PLATE &

ACCESSORIES

BALIGA/ I.L., PALGHAT/ MICRO PRECISION/ GI/

FMC

Process PLC

Honeywell, Siemens, GE, Schneider, Rockwell, Allan

Bradely, ABB, Yokogawa, Mitsubishi, RTP, Hima

ALARM ANNUNCIATOR IIC/PROCON/ MINILEC/ APLAB

VFD Rockwell/ L&T/ ABB/ Siemens/ Mitsubishi

Control consoles, panels &

Accessories

Chemin, Lotus, Pyrotech, Instrumentation Limited

,Siemens Limited, Rittal

ISOLATOR/ BARRIERS MTL/ STAHL/ P&F

Relays Omron, Tele Mechanique, Honeywell, Allan Bradly,

Paramount, Denki, OEN

Junction Box& Cable Gland

Baliga, CEAG Flameproof control gears, Ex

Protecta, Flameproof eqpt. (p) Ltd, Flexpro

Electricals (P) Ltd, Sterling Switch gears controls

(po) Ltd, Sudhir Switch gears (P) Ltd, Shyam Swich

Gear Pvt. Ltd

Signal cable & Control cable

Delton, Universal cable, RPG, Gemscab, Polycab, ,

Radient cables, Havell, cords, KEI, Thermocables

RTD cable

LAPP, Delton, Universal cable, RPG, Havells,

Gemscab, Polycab

Power cable, earthing cable

Universal cable, Finolex, Fort Gloster ,CCI, Delton,

Cord,RPG, Havell, Gemscab, Polycab, cords,

Thermocables



352 | 3 5 9

MCT Block Roxtec, A B Transits, Brattberg

LAN Cable AMP, Lucent Fiber Optic cable Lucent, Optel, Finolex, Avaya, HCLcomnet, ABB,

Siemens, D-Link, RPG

CABLE TRAY GRAM ENGG./ HOPES METAL/ PREMIER POWER

PRODUCT/ INDIANA/ GLOBE ELECTRICALS / MM

ENGG.

Barrier Gate Heidz India, Technica, Metachem

Pressure relief valve

Instrumentation Ltd., Keystone valves Ltd., Sebim

valves, Tyco Sanmar

Gauge Glass & Cocks

Bliss Anand (P) Ltd., Chemtrols Engg. Pvt. Ltd,

Levcon Instruments

Receiver Instruments

ABB, Instrumentation Ltd., CG-ELSAG Bailey Ltd ,

Rosemount (India) Pvt.Ltd, Seimens Ltd , Honeywell

Automation (I) Ltd., Yokogawa Bluestar Ltd

Alarm annunciator

Electronic corporation of India Ltd, Industrial

Instruments & Controls, Procon Instrumentation(P)

Ltd., Minilec

Pressure Switches

Indfoss (India) Ltd , Switzer Instruments Ltd ,

Bourdan, Asco Joucomatic

Orifice Plates, R.O., Flanges

Baliga Lighting Eqpt., Micro Precision products,

Placka Instruments & Controls (P), Ltd. , Starmech

Controls (I) Ltd. Engineering Specialities Pvt. Ltd.,

Hydropnuematics, Instrumentation Ltd., Mahindra

& Mahindra Ltd.

Instrument Tubing

Apex Tubes Pvt Ltd , Jindal Saw ,Heavy Metals &

Tubes Ltd., Maharashtra Seamless Ltd , Nuclear

Fuel Complex, India, Ratnamani Metal & Tubes Ltd

, ABB , Zenith Ltd, Swagelock

Server system Dell, HP, IBM

Printer Wipro, TVSE, Epson, Panasonic, HP, Epson

ETHERNET SWITCHES AND

TERMINAL SERVERS

IBM/ EMULEX/STALLION/FOXBORO/ D-LINK/

CISCO/ 3 COM/ MOXA/SYSTECH (OEM)/Nortel/L&T

Proximity Switches P & F, Turck, Honeywell, Daniel

Thermal Relief Valve Keystone/Sebim India/ Fainger Leser/Tyco

Sanmar/Instrumentation Ltd./ BHEL



353 | 3 5 9

Ball Valves Audco, Virgo, Flow Chem, KSB, BDR

COMPRESSION FITTING EXCELISOR/ RELIANCE ENGG. / EXCEL HYDRO

PNEUMATIC

Start /Stop switch/ push

button

L&T /Siemens /English electric / Technic/ABB/GE

Isolators, SFU Siemens / L&T / Schiender electric/ GE power

controls/ Indo Asian Fuse Gear Ltd.

AC power contactors Siemens / L&T / Schienderelectric / GE power

controls/ ABB/ Control Switch Gear

Protective relays Alstom India (EE) / ABB

Thermal overload relays Siemens / L&T / Schiender electric/ GE power

controls

Timers, Aux contactor relays Siemens / L&T / Schiender electric/ GE power

controls / BCH

MCB, ELCB,MCCB, MPCB MDS / Indokopp /S&S /Siemens/ Schiender

electric/ GE/L&T/Crompton/Legrand/Havells

ACB L&T /GE/SIEMENS /SCHENIEDER

CONTROL VOLTAGE

TRANSFORMER

SIEMENS/SOUTHERN ELECTRIC / KAPPA/SWAMY

TRADERS

LT BUS DUCT C&S/ BEST&CROMPTON / STARDRIVE / SIEMENS

OVERLOAD RELAYS WITH SPP SIEMENS / L&T/ TELE-MECHANIQUE BCH / ABB

AMMETER AE/IMP/MECO/ R!SHAB

VOLTMETER AE/IMP/MECO/ FZISHA.B

MICRO PROCESSOR BASED

METERS

ADDRESSABLE TYPE ENERGY

METERS

CONZERV/ABB/SIEMENS

PUSH BUTTONS, INDICATION

LAMPS VAISHNO/CONCORD/SIEMENS/L&T/ TT TEKNIC /

SALZER

CT'S SIEMENS/AE/INDCOIUKAPPA/INTRANS

TERMINAL BLOCKS ELMEX / ESSEN /CONNECT WELL / WAGO/

PHOENIX

Indicating meters AE /IMP /MECO

Control/selector switches Siemens/ Sulzer /L&T /Alstom /Kaycee



354 | 3 5 9

Indicating lamps/ Push Button Siemens /L&T /Control Switch Gear/ Schinder-

Electric

Terminal blocks Elmex control / C&S



355 | 3 5 9

ATTACHEMENT- III

LIST OF FACILITIES



356 | 3 5 9

Bay Configuration-Table A (8 Bay Gantry)

Bay no. Type Product

(LP-1)

Product

(LP-2)

5 Top loading BS III MS+ Ethanol+

Additive

BS III MS+ Ethanol

6 Top loading BS III MS + Ethanol +

Additive

BS III HSD + Additive

7 Top loading BS III MS+ Ethanol BS III HSD



10 Top loading BS III HSD BS III HSD + Additive

11 Top loading BS III HSD BS III HSD

12 Top loading SKO BS III HSD

Bay Configuration-Table B (6 Bay Gantry)

Bay no. Type Product

(LP-1)

Product

(LP-2)




16 Top loading BS III MS + Ethanol BS III HSD

17 Top loading BS III MS + Ethanol BS III HSD

18 Top loading BS III HSD BS III HSD



357 | 3 5 9

TLF PRODUCT PUMPS:

S. No Product Pumps

(Nos)

Head of pump

(meters)

Discharge

(LPM)

Rating

(Kw)

Operated

through

1 HSD 5+1 50 4800

55

VFD

2 MS 2+1 50 4800

45

VFD

3 SKO 2+1 50 2400

45

VFD

4 Ethanol 3 75 1200

30

VFD

5 MS 1

50

600

11

MCC

6 HSD 1

50

600

11

MCC

7 SKO 1

50

600

11

MCC

TWD PRODUCT PUMPS:

S.

No Product No. of Pumps

Discharge

(LPM)

Operated through

1 HSD 2 3600

MCC

2 MS 2 2400

MCC

3 SKO

2

3600

MCC



358 | 3 5 9

SCHEDULE OF TANKS

Tank

No

Size Product Capacity Class Remarks

1 14.0DX11.20H HSD 1600 KL B CRV EXISTING

2 14.0D X 11.20H HSD 1600 KL B CRV EXISTING

3 14.0D X 11.20H HSD 1600 KL B CRV EXISTING

4 11.0D X 11.20H SKO 1000 KL B CRV EXISTING

5 11.0D X 11.20H SKO 1000 KL B CRV EXISTING

6 12.0 D X 10.50H MS 1000 KL A FRV EXISTING

7 12.0 D X 10.50H MS 1000 KL A FRV EXISTING

8 3.0 D x 10 LONG MS 70 KL A U/G Tank (Under

Construction)


Construction)


Construction)

12 12.0DX11.0H FIRE WATER 1200 KL -- ORV EXISTING

13 12.0DX11.0H FIRE WATER 1200 KL -- ORV EXISTING

14 25.0DX11.5H HSD 5000 KL B CRV

PROPOSED

15 25.0DX11.5H HSD 5000 KL B CRV

PROPOSED

16 25.0DX14.0 H HSD 6296 KL B CRV

PROPOSED

17 25.0DX14.0 H MS 4000 KL A FRV

PROPOSED

18 4.5DX15.0 LONG ETHANOL 180 KL A UG HORZ

PROPOSED


PROPOSED


PROPOSED

21 16.0DX10.4 LONG FIRE WATER 3010 KL A ORV

PROPOSED

Note : The dimensions of proposed facilities are tentative & may change

during execution



359 | 3 5 9

FIRE ENGINE DETAILS

S.No Description Nos

1 Centrifugal Pumps 3

2 Jockey Pumps 2