(a.govt of india undertaking) chainsa – jhajjar pipeline ... · (a.govt of india undertaking)...

GAIL (INDIA) LIMITED (A.GOVT OF INDIA UNDERTAKING)

CHAINSA – JHAJJAR PIPELINE PROJECT

BID DOCUMENT FOR

SCADA VOL II OF II – TECHNICAL

(BID DOCUMENT NO 11/0230/JPK/GAIL/10-R0)

DOMESTIC COMPETITIVE BIDDING

ISSUED BY

GAIL (India) Limited

CHAINSA-JHAJJAR-BAMNOULI PIPELINE PROJECT

CLIENT JOB NO. 0230 TECHNICAL SPECIFICATION FOR RTU/SCADA

TOTAL SHEETS 19

DOCUMENT NO 11 0230 00 11 2 017

C 21/02/09 CLIENTS COMMENTS INCORPORATED MS AKA AKA

B 06/01/09 CLIENTS COMMENTS INCORPORATED MS AKA AKA

A 24/07/08 ISSUED FOR CLIENTS COMMENTS MS AKA AKA

REV DATE DESCRIPTION PREP CHK APPR

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TECHNICAL SPECIFICATION FOR RTU PAGE 2 of 19

CONTENTS

1.0 INTRODUCTION

2.0 SCOPE OF SUPPLY AND SERVICES

3.0 RTU SPECIFICATIONS

4.0 SERIAL LINK REQUIREMENTS

5.0 FACTORY ACCEPTANCE TEST (FAT)

6.0 VENDOR DATA REQUIREMENT AND DOCUMENTATION

7.0 SPARES

ANNEXURE-1 INPUT/OUTPUT LIST.

2.P&IDS.

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1.0 INTRODUCTION 1.1 GENERAL GAIL (India) Limited is in the process of laying a new pipeline from Chainsa to jhajjar of approx. 85 Km

length & approx. 18 Km length spur line from Bamnouli to PPCL power plant, as an extension of existing pipeline network of GAIL. For effective control, operation, monitoring, management and maintenance of the pipeline, the exisisting SCADA system at NOIDA has to be extended to this new section of pipeline.

1.2 BRIEF DESCRIPTION OF THE PROJECT

The purpose of SCADA system is to ensure effective and reliable control, management and supervision of pipeline from centralized location using remote terminal units located at suitable locations along the pipeline. The exisisting SCADA system will be connected through optical fiber link (OFC) to the remote terminal units (RTUs) located along the pipeline. The following pipeline locations have been considered for telemetry operations. 1. CHAINSA DISPATCH STATION 2. SV-2

3. SV-3 4. SV-4 & BAMNOULI 5. PPCL POWER PLANT 6. JHAJJAR.RECEIVING STATION In above locations new RTUs are required (TOTAL 6 Numbers of RTUs). RTUs will be used for control and monitoring of pipeline parameters like flow, pressure, temperature, valve open/close status, pig arrival indication through pig signaler,CP parameters, electrical parameters etc and update the master /emergency scada stations. The scada station will be used for remote opening /closing of Gas operated valves/sectionalizing valves. As it is considered extension of exisisting SCADA system (OF INVENSYSY MAKE) ,the new RTUS have to be effectively and properly integrated with this existing SCADA system on DNP-3 protocol.Vendor to furnish details of integration already done with INVENSYS FOX SCADA system or services tied up with M/s INVENSYS to ensure proper integration with scada system at NOIDA.

1.3 GENERAL SITE INFORMATION AND ENVIRONMENT CONDITIONS All the equipments supplied under contract shall be suitable for continuous operation under the environmental conditions prevailing at site. The equipments shall be suitable for transportation under proper packed conditions by road, air, sea.conforming to standards. The equipments shall also be resistant to termite, fungus, rodents and salty environment. The equipment shall withstand ambient temperature up to 50 deg. Centigrade, and humidity from 5 to 95%.RH. All enclosed equipment shall be constructed to allow free air flow for proper heat dissipation, and ventilation grill shall not obstruct operation and maintenance of equipment. All equipments shall withstand international standards for vibration under industrial operation.

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2.0 SCOPE OF SUPPLY & SERVICES

1. Vendor’s scope of supply and services shall include ,but not limited to all the activities of project management ,design,engineering,factory testing,supply,installation of RTUs & other equipments,integration with exisisting SCADA system,commissioning,site testing, test run,packaging,forwarding,transportation ,insurance, port handling, custom clearance, inland transportation etc, receipt &storage at site,warranty,quality assurance and quality control of the system and documentation with the turnkey responsibility and meet the requirements described in the specifications and taking care of complete requirements of tender specifications.

2. Vendor shall undertake full responsibility of supply of equipments and integration of the same with

exisisting SCADA system on DNP-3 protocol meeting the objectives and specific project requirements. 3. The scope of supply and services shall also include fulfillment of complete telemetry requirements for

monitoring and control as per various P&IDs, list of I/O parameters. And project requirements detailed in tender specifications.

4. Engineering, supply, installation, commissioning, integration with existing SCADA sustem of M/s

INVENSYS. 5. Supply of all items/equipments including cabinets etc, special tools & test equipments (if any), software,

installation materials etc, required to integrate and execute the SCADA systems complete in all respects. However if any additional items are required to integrate the new RTU with exisisting SCADA system, vendor shall supply the same without any cost and time implication.

6. Supply of loose mandatory spares as given below (for each type of RTU)

a. Power supply module : 1 no. b. DI module : 2 nos. (With LEDS cards, if any) c. DO module : 2 nos.(with relays as per cards capacity) d. AI module : 2 nos. e. CPU master processor module : 2 nos. f. Serial port module : 2 nos.

7. Further following services/works shall be carried out by vendor: Configuration /augmentation in master stations & in new RTUs, database updation/preparation, graphics

updation/preparation, other modifications/changes etc, required for integration of new RTUs. a. Development, testing and commissioning of necessary software for RTUs to interface with flow

computers (FCs)/ Gas chromatographs (GC) as per P&IDs.through serial link (RS485/RS232)The FC/GC make and model and protocol shall be provided by consultant/owner.

b. Supply of hardware / software for reading Customer Flow computer parameters and writing GC analysis data to customer flow computers using GSM dialup / GPRS. GSM Modem to be supplied by the vendor as per the scope requirement (Mentioned in Annexure I). Vendor shall take full responsibility for programming and integrating of customer flow computers using either GSM dialup or GSM GPRS. Also owner should be able to add / remove and change customer detail (like telephone number, register address etc) in future. Technical detail /manual/ training for adding and modifying register, read write operation etc in future to be provided by the vendor to the owner. Also if any additional software is required for doing the programming, the licensed copy of the same to be provided by the vendor to owner.

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c. Program for read and write the gas chromatograph energy data from RTU to multiple flow

computers using dialup/GSM/leased line. d. Any other work as per instruction of consultant/owner. e. Performing all works required for designing,engineering,testing,supply,installation,interfacing with

communication channel,IED’s, and instrumentation and electrical systems etc,commissioning (with supply of commissioning spares including consumables),site testing, test run and putting into commercial operation of the system complete in all respects.

f. Furnishing all documentation, drawings and other information required including user, operation &

maintenance manuals, and handbook of inventory of all the equipments supplied and installed in (hardcopy and softcopy). Furnishing as built documents, drawings and CDs of the complete system as per tender requirements.

g. All cables between respective equipments, telecom cables, power supply & power distribution cables, earthing cables/strips etc. covering the complete requirements as specified are in vendor’s scope. In addition supply of cables, glands and interconnection of cabling and accessories including cable routing between the following cabinets/equipments are also included in vendor’s scope, and to be carried out by the vendor. The activities of signal identification at site, cable laying routing, cable termination, ferruling, glanding, dressing at TIC/FC/GC end, RTU end, telecom rack end etc,are in vendor’s scope.

a. Between RTUs & telemetry interface cabinets/metering panel. b. Between RTUs & telecommunication equipments. c. Between RTUs & FC/GC (serial link interface). d. Between CLS to telecommunication equipments in MS (Noida) and EMS(Noida).

All cables between TIC/metering panel and RTUs shall be PVC insulated, single pair (1.5 mm2)/multipair (0.5mm2), twisted in pair individually (individual pair shielded applicable for analog input and output signal only ) and overall shielded with aluminium mylar tape.Seperate cables for analog and digital signals to be used. Each pair of multipair cable would be identified by the pair no./colour code identification. Notes: a. Distance between TIC/Metering panel &RTU shall be tentatively considered as 15 mtrs. However

these distances shall be firmed up during detail engineering. b. Distance between FC/GC and RTU shall be tentatively considered as 25 mtrs.However these

distances shall be firmed up during detail engineering. c. Distance between Telecom. Panel and RTUs shall be tentatively considered as 15 mtrs..However

these distances shall be firmed up during detail engineering. h. Coordination with instrumentation vendor/contractor during installation & commissioning phase of

the project. i. The civil works associated with the installation of supplied equipments at all stations. j. The electrical works associated with the installation and commissioning of the equipment, earthing

of equipments at all sites. Powering of equipment at all sites, termination of cables as required. k. Coordination with electrical vendor/site installation contractor during installation and

commissioning. l. Coordination with telecom vendor/site installation contractor for SCADA and telecom

interconnection during engineering phase and also during installation and commissioning phase. m. Vendor to consider I/O counts at various stations as per annexure-1.

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n. Distance Between SCADA CLS and Telecom equipment at telecom room at Master Station(Noida)

will be considered as approx. 15 mtrs and for EMS(Hazira) will be approx. 100 mtrs. However these distances shall be firmed up during detail engineering.

o. Based on the details, vendor to prepare IO list as per GAIL format for each station and submit the final list to GAIL after commissioning.

p. For all hardwired analog inputs –Engineering range along with units of measurement shall be provided to vendor during detail engineering.

2.1 PANEL DESIGN CRITERIA.

POWER SUPPLY UPS power supply for various locations will be provided as a. CHAINSA DISPATCH STATION : 150 W,24 V DC b. SV-2 : 150 W, 24VDC. c. SV-3 : 150W, 24 V DC. d. SV-4 &BAMNOULI : 150W, 24 V DC. e. PPCL POWER PLANT : 150VA,230V AC. f. JHAJJAR RECEIVING STATION : 150W,24 V DC. No separate power supply shall be given for various equipments, it shall be responsibility of vendor to convert to various/levels types of power required for his equipments. Reliable &rugged SMPS to generate isolated and stabilized voltage levels required for equipment operation will be supplied by vendor. THE power supply equipments shall be protected against short circuit, over voltage, under voltage and transients. Power supply units shall not generate excessive vibration or acoustic noise. The heat generated by the units shall be kept to the minimum.

2.1 Surge protection, transient suppressors,RFI filters Protection devices shall be provided in all the equipments to guard against the effects of lightning stikes and induced high voltages. Card level transient suppressors shall be provided wherever necessary.

2.2 Earthing Earthing of all electronic equipments is required to reduce the effects of interference and personal safety of operation and maintenance personal. Each panel, cabinet and individual equipment shall be equipped with continuous lugs/strips. All these lugs/strips shall be properly secured to the AC mains earthing bus. Separate earthing shall be provided for system grounding and frame main grounding.Seperate earth pits shall be provided for electrical and instrument earth at each station.

3.0 RTU SPECIFICATIONS 3.1 GENERAL SPECIFICATIONS

a) The RTU shall be a powerful Intelligent Device specifically designed for Integrated Control System applications where, in addition to the traditional RTU functions, enhanced communication capabilities mixed with high performance control strategies are required.

b) The RTU shall be designed to monitor and control process instruments /gas or gas over oil actuated valves, metering stations, etc. It shall process the analog data for high-low limit violations as per stored

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limit tables and communicate same to master station. Linear conversion to engineering units and input filtering (conversion of raw data to normalized value (e.g. to 0 to 1.0) for communication shall also be acceptable.

c) RTU shall comprise of following subsystems: d) Central processor with system software. e) Analog input modules f) Digital input modules g) Analog output modules h) Digital output modules i) Communications j) Serial ports k) SMPS power supply l) Diagnostic tools.

3.2 RTU TO SCADA SYSTEM

a) The data transfer scheme employed between RTUs and SCADA Master station should conform to DNP3 Protocol Standards resulting in transfer of the Time-Stamped instrument

b) Parameter values from RTU to SCADA System. c) The scheme employed should result in availability of all the Point / Parameter values in SCADA d) System at a time resolution of 1 Seconds. e) It shall be possible to integrate the RTUs through serial & Ethernet port. Communication of RTU with

serial port and Ethernet port shall be tested during FAT. f) It should be possible to integrate the RTUs to SCADA system through various communications g) Links such as TDMA Radios, Fiber Optic, Microwave and Satellite. However in present case Fiber Optic

system shall be used. h) The data transfer between RTU and Third Party Equipment like Flow Computers should be based on

Modicon Modbus RTU Standards/protocol where the values of Computed Flow & other parameters from Flow Computer are made available to RTU.

i) Vendor shall interface RTUs with MS/EMS in the existing Foxboro SCADA along with generation of necessary graphics screens for view of SCADA data of CJBPL pipeline in the MMI. Vendor to configure RTU/SCADA system for read/writing of GC data to flow computers through communication connection.

3.2 RTU DETAILED TECHNICAL FEATURES

a) The RTU shall be a single microprocessor based modular electronic control device equipped with I/O terminals suitable for connecting directly to the field wiring of analog & digital devices. Galvanic isolated IS barriers will be incorporated wherever necessary in instrumentation panel.

b) The following features shall be provided as a minimum: Multiple (min. 4) RS-232C & RS-485 serial ports capable of each carrying a different Communication protocol. c) Act like a data concentrator for the local Intelligent Electronic Devices (lED). d) Minimum two (2) Ethernet ports encapsulating TCP/IP network compatibility to IEEE 802.3 10/100 Base - T specifications. e) Communications management over redundant multiple links. f) Local data archiving & processing. g) Time synchronization via SCADA master with a resolution of 100 msec. h) Time stamping to 1 second or better resolution for all digital, analog and pulse accumulator inputs & exception reports. i) Multi loop control, logic control and sequencing. j) Remote loading of configuration, parameters and application SW onto RTU flash memory (e.g. addition,

deletion, modification and reassignment with different range, limits etc. from workstations to avoid local engineering at RTU level. The remote configuration w.r.t. following parameters for the points defined in RTUs shall be done from master station:

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k) Analog alarm limits l) Analog scaling factor for engineering unit conversion m) Threshold value n) Smoothing factor (filter time constant) o) Directly handle standard I/O modules and perform intelligent process control functions for applications requiring highly accurate measurement of process variables, closed loops control, logic control and sequences, sophisticated algorithms, easy programmable through user friendly sequences configuration. p) Redundancy should be achieved at the following levels: CPU, Power Supply and Communication modules. q) Shall be scalable to 25% of the built up capacity for future expansion. r) Fault detection and Auto-diagnostics (both local and remote). s) Single 32-bit CPUs with minimum 166 MHz system clock. 32 M byte SDRAM (up to 64 M byte

expansions piggyback). t) Local LCD display panel as an integral part of the RTU. u) Low power consumption typically not more than 40W. v) Certified for industrial environments (according to CE). w) Field terminations incorporating scaling resistors test and isolation links. x) Removal and replacement of I/O modules and communication modules without powering down the RTU. y) Optical/galvanic isolation on all digital inputs. Digital bounce elimination circuits. z) Masking of selected inputs should be under the master’s control. aa) It should have the feature of derivation of calculated Analog Point based on +, -, *, /, and

square root. Calculation shall be performed in RTU in engineering units with 16 bit floating point accuracy, required in case engineering conversion is being done at RTU level.

bb) Field inputs initiated discrete control action. cc) Discrete control action corresponding to remote control command reception. dd) Operator initiated discrete control action with check before execute and time out feature. ee) Operator initiated discrete control with sequencing and interlocking. ff) Derivation of counter values using integration of hardware and software generated analog points. gg) RTU resident accumulator points driven by analog points. hh) Flow computers, CP Panel & Gas chromatographs interfacing through RS485/RS232 ports for serial

data. ii) RTU should have the feature of Derivation of calculated digital point based on AND/OR/NOT etc. jj) Integration of Hardware and Software generated points. These calculated Analog and Digital points is given same treatment as the acquired point for setting limits, generating alarms, and reporting to SCADA master. kk) Power failure and restoration should not result in Malfunctioning/Accidental activation of controls. ll) Select-Check-Execute and Time-Out features for operator controls. mm) SCAN disable / enable facilities for a selected single point, group of points under a defined process and an RTU.Fast scanning of selected I/O points. It is expected that scan rate shall not

exceed 100 msec. The scan rates for individual I/O modules shall be such that time-tagging resolution and system performance requirements are achieved. The consideration of scan times shall include the acquisition of data, processing and updating of RTU database. The overall RTU local scan shall be defined as the time required to acquire field data and update the RTU database and the same shall be much faster than RTU poll time by master station.

nn) Add/delete a RTU, event logger in online mode without disturbing the SCADA facilities. oo) Should support various schemes for data transfer to SCADA systems such as Polling from Master/EMS SCADA system, RBE (Report by Exception), Request and Fast-update of some configured selected parameter. It should be possible to configure RTU so that only fast changing / critical parameter or only those parameters which have changed beyond dead band are transferred to master station to suit the limited bandwidth availability.

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pp) Scan and acquire the data (single bit / two bit data) on continuous basis at 1 second or less interval from the field instruments. qq) RTU shall be capable of updating process parameters data and configuration data in its own built-in-

memory. Time stamping of all field values at RTU shall be required. In the event of failures or break of communication link, the RTU shall continue to scan all parameters and update its database. RTU shall retain its database till it is completely read by master station in order to take care of no loss of data on failure of master station. The RTU shall scan the field and the memory buffer is to be sized to store all the changing data (i.e. new exception report for the data every poll time) and master station receive the same without any loss of data and alarms in the SCADA system to take care of channel, SCADA server switchover times

rr) Further to take care of long term communication outages with master station the RTUs shall be designed to also scan the field and store in the memory upto 1000 field exception reports during period of communication outage for retrieval by master station subsequently.

ss) The RTU system shall have the facility to attach to digital event signal a time tag generated by RTU local clock to enable the occurrence to be recorded and transferred with a resolution of 100 msec.

tt) It shall be possible to have highest priority for alarms, in order for the same to be sent to master station. uu) Every control associated with RTU shall report the status of the point after control execution. In case the

status has not changed within specified time it shall be reported to master station for not having executed the control.

vv) RTU shall not generate any false control signal due to power supply on-off conditions. ww) It shall have feature of connecting pluggable programming diagnostic test unit (PDT)/Local craft terminal

with keyboard &monitors diagnostic and programmable aid to trouble shoot and configure tool for RTU and I/O modules. It shall be possible to exercise all the functions of RTU without disconnecting the RTU from process.Vendor shall supply the programming diagnostic test unit loaded with all the softwares for programming /configuration of RTUs along with all accessories i.e, keyboard,monitor,cables ,connectors,power supply unit,charger etc;

PROGRAMMING DIAGNOSTIC TEST UNIT(PDT)/LOCAL CRAFT TERMINAL(LCT) : PDT/LCT shall have following minimum specifications: INTEL centrino core 2 Duo processor (1.66 Ghz/2MB Cache/667 Mhz fsb),2 GB DDR2 SDRAM expandable to 4GB,160 GB SATA Hard Disk Drive,DVD-R/RW (Dual layered Super DVD drive) 15.4” WXGA TFT Display 3Xusb 2.0 ,Bluetooth,serial port ,SD Media Slot Intel Graphics Media accelerator X 3100,Gigabit Ethernet,TPM,56 K Modem,battery,charger,carry case,installed with all programming/configuration/diagnostic/maintenance softwares. The RTU configuration software shall support latest Windows OS and licensed software of RTU software, Windows OS and any other software needed for RTU programming to be provided by the vendor along with all the drivers. xx) It shall be possible to off-scan complete RTU individually in addition to off-scan RTU points. In case of

failure of complete RTU or off-scan of complete RTU only one alarm shall be generated and the RTU analog and digital points shown in various graphics and printed in reports shall have data integrity qualifier flag.

yy) RTU shall be able to store the configuration data and the process database upon power failure for at least one month on continuous basis. Upon restoration of power, RTU shall resume the normal operation automatically.

zz) RTU shall operate from power supply level of 24V DC.Separate on/off power supply switch and fuse shall be supplied with each RTU. Vendor shall indicate power consumption for all RTUs.Adequate isolation of input, output and power supply circuits shall be provided along with over voltage and short circuit protection. Terminations for connections of power supply should be of standard industrial type. Vendor shall supply PDT as diagnostic tool to RTU and shall be a notebook (laptop) with proper enclosure and shall operate on integral battery, which shall be rechargeable type. The battery shall be able to supply power as a minimum for 8 hours before requiring recharging action. Also PDT shall operate on

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230VAC/24VDC power supply. PDT supplied by vendor shall be loaded with all the software’s’ for programming/configuration of RTU along with all cables and connectors. aaa) Adequate isolation, over voltage and short circuit protection. bbb) Should work with any type of grounding (Negative, Positive or Floating grounding as per the ccc) field requirement). ddd) Cut-off the power as and when the input power goes out of range (18 to 36 VDC) and switch on automatically when input voltage returns to the normal range.

eee) Each enclosure will incorporate the specified RFI/EMI shielding control requirements by meeting latest

standards of IEC-801, MIL, and VDE etc; fff) RTUs shall communicate with MS/EMS vide telecom system over optical Fiber cable. ggg) The RTU shall be configured such that failure of any part an RTU subsystem (module) except the CPU,

power supply module shall not directly affect the integrity of the unit as a whole. hhh) It shall be possible to output any AI (including serial data from IEDs) &DI point value available in real

time data base at master station as AO (including serial data to IEDs)&DO to any RTU respectively. The relay contact configuration shall be provided upto the RTU terminal block. The DO command contact closure duration shall be configurable. It shall be possible to configure DO contact closure duration open or close for a long duration as per the DI status. Non-availability of any one of two communication channels should not hamper the functioning of the other RTUs multidropped on the pair of channels.

iii) Vendor to ensure that open/close status of valves (open state first wired and thereafter close state) be wired consecutively in the RTUs.

jjj) At the RTU failure of a module in a subsystem shall be identified by an individual LED display. kkk) Each I/O shall be protected against reverse polarity of the power voltage to I/O. lll) All data shall be available in engineering units in the RTU DATABASE.

mmm) RTU scanning times of Input and Output points shall be as specified earlier. All Analog and Digital

input points shall be time stamped to a time resolution as specified earlier. The actual time stamp for each point shall be reported to the SCADA Master station/EMS when the RTU is polled. For digital points the time stamp shall occur when the change of state is first noted before the de-bounce timer starts. For analog and pulse accumulator points the time stamp shall be the time when the RTU analogue point is polled.

nnn) RTU shall be capable of interfacing both 4-20 mA and 0-5 V signals.

3.3 RTU COMMUNICATION FEATURES

The RTU shall support both internal and external communications functions. The communications network internal to the RTU shall be designed and implemented in such a way that the passing of data and commands between modules shall not be prevented by the failure of any module not directly involved in the communication exchange. In addition, the network shall not become overloaded under the heaviest traffic possible in RTUS ultimate expansion configuration. The master station shall initiate communications with a selected RTU by addressing function. Each RTU shall recognize its own unique address and shall have the capability of being assigned any address within a range of possible addresses (256 minimum). LED indication shall be provided in the RTU to check the health of RTU communication. RTUs shall be multidropped on a pair of communication channels. Upon failure of primary channel, RTU shall respond to master station requests/interrogation on secondary channel automatically without any loss of data &operation. System shall provide status on availability of each of channels. The RTUs shall support 100 Mbps redundant Ethernet communication speeds. The RTU shall be designed to build up hierarchical data transport networks on diversified transmission media,

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supporting multiple communication protocols. The RTU shall be equipped with asynchronous and synchronous serial communication channels that can be connected to a wide range of different communication media, in single or redundant configuration:

a) 2/4 wires analog/ digital dedicated communication lines, in point-to-point or multi-drop b) modes. c) Dedicated RS-232/RS-485 . d) Fiber optic links. e) LAN (Ethernet) interface.

Protocols to be supported by the RTU shall be:

a) SCADA/RTU PROTOCOL: - I) DNP3 (PRESENTLY TO BE USED FOR INVENSYS SCADA)

II) IEC-870-5-101 Iii) TCP/IP

b) FIELD PROTOCOLS: MODICON MODBUS RTU

3.4 RTU CONFIGURATION

a) The RTUs provided shall be self -contained units capable of collecting data from dry contacts, current or voltage signals, and contact-making pulsing devices.

b) All RTUs shall include the following features: c) The RTU configuration shall support latest Windows OS . d) Auto configuration on ‘Power up’, not requiring any external RTU configurator. e) No false outputs shall occur during power up or power down f) A minimum of 256 unique I/O addresses g) Selection interlock to prohibit more than one control selection at a time at the RTU h) No single component logic failure shall result in a false output operation. The failure of the first component, which in conjunction with a second component failure could cause a false command, shall be detectable in the course of normal RTU operation. i) Remote down loading of configuration, parameter changes and application SW onto RTU memory from the Master and the sub-master j) Remote diagnostic capability from the Master and the sub-master.

k) The RTUs shall have self diagnostic feature and software watchdog timer devices to monitor & report the

healthiness of CPU, memory, power supply, comm. Interfaces and I/O modules at the local level. Further RTU shall support remote diagnostics from master station and displayed in RTU status graphic.

l) The analog input card shall generate an event, if it is out of calibration, which shall be sent to master

station. Further if analog output card is not self calibrating type then all analog outputs shall be wired back as analog inputs and calculations performed on each channel to detect AO card out of calibration. This out of calibration shall be available as part of RTU status graphic along with set point vale displayed in the graphic, next to the corresponding controller symbol.

m) The bidder shall supply all required support equipment for future reprogramming of the RTU by the Owner.

n) The following are preferred methods of programming tools:

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o) Program loader; handheld, capable of minor modification to software, plus Software packages for programming of the RTU on a compatible laptop / notepad PC & on SCADA server. p) The final application programs shall reside on EPROM or a similar component. It q) Enter program titles, comments, and I/O lists r) Produce documentation, including cross-reference lists s) Modify the program off-line, whilst the system is on-line. The changes made must be saved permanently and not lost when the RTU does a reboot. t) Modify the program on-line, whilst the system is on-line. The changes made to be stored permanently and not lost when the RTU does a reboot. u) Store input values as discrete identities in an event of loss of communication and to be transferred to the master when normalcy is restored. v) RTU should be wired and ready for expandability by 25% over and above the configured I/O count estimated for each type. However the RTUs shall also be scalable up to 25% of the engineered capacity including the built up spare capacity for future expansions. The scalability shall be achieved by adding relevant I/O module/Data base configuration and should not require any hardware change in terms of additional memory or changes in internal wiring. w) Installation tools, tackles and accessories, cables, marker ferrules, lugs, cable ties, cable glands, gland

hoods, conduits, trays etc., shall be provided by the bidder. x) The system should be designed by selecting high grade components of proven quality and

a. proper design of system electronics. Due considerations should be given to the specified b. environmental conditions and temperature conditions.

3.5 ENCLOSURES

The bidder shall supply the RTU and all associated hardware mounted inside a suitable enclosure as specified herein. The enclosures provided shall accommodate the full extent of the future expansion (sufficient power supply capability, rack space, termination space, cabling space, bus slots, etc) for the RTUs as defined in the bid. The enclosures should have proper lifting arrangements. Cabling. Fasteners. Fittings, screw-heads, nuts and bolts shall be compliant with relevant International standards. All Enclosures and equipment within it should have identification to be finalized during detail engineering. The RTU shall be mounted in IP 52 carbon steel freestanding cabinets (frame minimum thickness shall be 1.6 mm) with lockable front and rear doors and bottom cable entry and with gaskets and fittings to keep out moisture, corrosive, salts, dust and gases. All doors, drawers, trays and other weight supporting parts shall be fabricated of metal adequately reinforced to limit vibration and ensure plane surfaces and shall be well-housed and tidy in appearance. The cabinets [minimum 1100mm height (1000mm height+100mm base plate), 1000mm width and 800mm depth ] self standing type,with bottom entry for cable connections, fitted with concealed hinges with pull pins for door removal shall be provided for RTUs at all stations.This is approx. dimension,vendor to size the cabinet after taking into account ease of operation and maintenance of RTUs.The dimensions will be finalized during detail engineering. A document pocket shall be provided in each cabinet for storage of documentation The configuration of all enclosures, electronic chassis, modules and cabling shall permit ease of access to all serviceable equipment. Test equipment connections shall be adequately labeled and shall be readily accessible without the need to remove any board or portion of the equipment or power supply. All cabling, fastenings, fittings, screw heads, nuts and bolts shall be International Standard sizes suitable for prolonged use .The equipment and all modules therein shall be clearly labeled in English for ease of recognition without module removal.

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Power cables shall enter the bottom of the cabinets via suitable termination assembles and internal power distribution wiring shall be installed in separate conduits. Signal cables shall enter though the bottom of the cabinets via suitable termination assemblies. No opening other than cable entry points through glands shall be provided at bottom of cabinet. The exposed surfaces of equipment enclosures shall exhibit a uniform finish and appearance. The colour and finish texture of the equipment enclosures shall be subject to approval. All metal parts shall be treated to prevent corrosion. Painted surfaces shall be cleaned, primed and undercoated prior to painting to ensure a wear resistant finish. A preparatory powder coating process is preferred. For adequate light inside the cabinet tube shall be provided which shall operate on 24 V DC.Exhaust fans shall be provided to remove heat and provide ventilation and these shall operate on 24V DC.

3.6 INSULATION AND ISOLATION REQUIREMENTS

The RTU, including all Status inputs, control outputs analog inputs, power supply inputs and Communications inputs/outputs shall meet the following insulation and isolation levels specified in IEC 255. Insulation: The RTU shall be designed to withstand a Power withstand test voltage of 1.5 KV rms and shall conform to IEC 255-5 test standards.

Isolation: The RTU shall have an isolation resistance of more than 5 Megohms. It shall also pass an impulse withstand test of 5 kV and shall conform to IEC 255-4 test standards. High Frequency Disturbance: The RTU shall be designed to pass a high frequency disturbance test to a 5 kV impulse test voltage and shall conform to IEC 255 test standards.

3.7 LABELING

The bidder shall supply and install labels to identify all equipment in accordance with the equipment identification on the Drawings finalized during detail engineering. Each site cabinet shall have a site name label mounted on the door. All labels shall be manufactured from SS or similar material with black lettering engraved on a white background and secured using rivets. All engraved letters on labels shall be in block capitals, with black letters on white background. RTU card files, power distribution boards, terminations etc complete in all respects properly correlating with drawings is to be ensured by the vendor.

3.8 TERMINATIONS AND INPUT/OUTPUT WIRING

The Vendor shall ensure clear and adequate segregation between terminals and cables in the Following categories:

a) Analog b) Digital c) Intrinsically Safe d) High Level (above 50 V)

Vendor shall supply, terminate,test all required cables,ferrules,cable glands from telemetry interface cabinet to RTU at all the stations (vendor to carryout termination of cables at both ends) Terminal protection is to be provided as required by statutory regulations. The RTU shall contain Terminal facilities for connection of field wiring. The terminations shall provide a means of circuit isolation and test access without the need for disconnection of wires.

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Captive screw and saddle compression connections made from parts that are suitably treated to resist corrosion shall be used. The terminations shall be segregated according to signal type. Each terminal shall be clearly marked using a permanent marker to provide for its unique identification. I/O board termination assemblies shall be of the plug-in variety using a suitable modular plug and socket arrangement. It shall be possible to remove and replace a faulty board without the need to individually unmake and remake each circuit connection. Ribbon cable connectors shall not be used at the I/O termination boards. The equipment shall make extensive use of plug in modules. Input and output modules shall be capable of being removed from or inserted into a fully powered and operational rack without risk of damage. Failure and subsequent replacement of an input or output module shall not effect other modules or cause a system failure. Modules shall be arranged so that they may be removed without unsoldering or unscrewing wires or breaking any other kind of permanent fastening. The hardware shall be modular in construction and replacements and adjustments can be made as far as possible with the system on-line. The bidder shall deploy means to ensure that the wrong cards cannot be put into card frame slots. Sufficient space for terminations shall be provided within the enclosure to support the maximum possible required capacity and future capacity as nominated elsewhere in the bid. A single point earth shall be provided in the RTU in the form of a bolt compression type earth lug capable of accommodating a standard stranded earthing cable. Wiring within the enclosure shall be protected from wear and tear, against accidental cuts, and from contact with enclosure parts or surfaces. The design, wiring and layout of the RTU enclosures shall be subject to review and approval. No more than two wires to be connected to one terminals and only wire to be connected to each side of the terminal block, except for terminal jumpers, provided they are crimped together by the same cable lug or wire pin.

3.9 I/O CONNECTIONS

The bidder shall include schematic diagrams showing proposed connection arrangements at the I/O modules for analog input signals, MODBUS/digital input voltage-free contacts and digital output circuits (both DO and AO). Module power supply and communication connections shall also be shown.

3.10 STATUS INPUT REQUIREMENTS Visual indication by means of LED shall be provided for each input to indicate the condition of the input. A lit LED shall indicate that the external contact is closed. Each status input shall be isolated from high electrical noise and properly filtered for contact bounce such that contact transitions must last for a minimum of time to be specified before a change is reported. The time of the change is at the initial contact. The bid shall describe the use of the digital inputs as pulse counting accumulators and detail the maximum contacts repeat rate, maximum number of counts before rollover of the counting register or buffer, and the process of reporting accumulator values to the Station RTU. The RTU shall provide necessary voltage for the status input contacts.

3.11 DIGITAL INPUT MODULE:

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a) Ability to sense change of state of volt - free dry contact (min.32 Volt free contacts-2 wire isolated). The contact bounce suppressor and high noise immunity circuit shall be employed.

b) Internal voltage shall source power to convert contact state of volt-free dry contact into logic level signals. c) Ability to register single momentary change of state (less than 5 msecs.) until it has been read d) and reset by data processing system e) At least 1.5 KV RMS isolation between input lines and the system /circuit ground. f) All inputs should have galvanic isolation with opto-isolators. g) The card shall have loop & state LEDs for each input. h) Contact wetting shall be 2-4 mA per input at 24 V DC. i) Resistance recognized shall be I) not exceeding 1 kilo ohms as a closed contact and II) not less than 50

kilo ohms as an open contact. j) Insulation resistance 20 M ohms at 500 V DC inputs. k) Mixing of NO/NC contacts shall be possible in the same card. NOTE: - Internal voltage of the system to be used for sensing plant dry contact (as said above) shall be isolated power w.r.t. the system input power.All the digital input parameters shall be NC (Normally closed type)

3.12 DIGITAL OUTPUT MODULE:

a) Output type – Min. 12 relay contacts b) LED indication for each DO point shall be provided. c) Miniature power relay shall be provided. d) 1 NO+NC relay contacts configuration to be provided upto the RTU terminal block. e) Potential free contact rating of output interposing relay for each DO point (contact rating 48 f) V DC, 2 A; 230 V AC, 5 A) g) Isolation shall be 2 KV RMS Contacts to logic. h) DO command activation shall be configurable pulse duration. The contact output subsystem shall

provide momentary 2 sec closure of potential free contact relay output for operation of valves. It shall be possible to configure DO contact duration for a longer duration and all contacts shall be voltage free. It shall not be possible for RTU to energise an output that has not been selected for control. An RTU start, following power failure shall not reset the output circuits, shall not generate false control signal and shall cancel any pending control selection.

i) Output contacts shall be monitor via opto-isolators, shall be shot circuit proof and protected by suitable mechanism like fuse with suitable fuse blown indication provided.

3.13 ANALOG TO DIGITAL CONVERTOR:

a) Resolution 16 bits. b) Linearity + or - 1 LSB. c) Repeatability + or - 1 LSB. d) Accuracy: +/- 0.2% of full scale over operating temperature range. e) Cross-talk better than 120 dB. f) Input shall be guarded two wire differential. g) Zero offset temperature co-efficient less than +-50 microvolt per Zero Deg. C. h) Provision for a high accuracy reference voltage shall exist on the board and shall be used for i) checking the accuracy of conversion, linearity, Zero drift, Zero adjust and gain.

3.14 PULSE INPUT MODULE:

a) Suitable for accepting through switch select either of the following inputs: b) Voltage free dry contact relay operation (Max.25 contact closures per second). Contact c) bounce shall be suppressed. d) Magnetic pick-up coil of 1500 ohms impedance and output voltage and frequency (up to 5 e) KHz) proportional to the flow rate, Voltage output varies from 250 mV to 25V. Suitable f) sensitivity and dynamic signal range shall be incorporated. g) Suitable galvanic isolation for inputs to be provided.

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h) Counters shall accumulate pulses and transfer the same to microprocessor in a predetermined i) manner.

3.15 ANALOG INPUT MODULE:

a) Input type = Min. 16 isolated, current inputs b) Range= 4-20mA DC,0-5 V signals. c) Mux shall be vendor standard. d) Serial mode rejection-greater than 30 dB AT 50 Hz. e) Common mode rejection-greater than 100 dB at 50 Hz. f) Roll over bit= 1 bit. g) Temp. coefficient= 0.005% per degree C h) Accuracy= +/- 0.1% of range including drop in resistor.

3.16 ANALOG OUTPUT MODULE: a) Output shall be 4 to 20 milli-amps DC source to drive up to 1K Ohms load.Min. 4 completely b) isolated current (4-20 mA) outputs c) DAC type 12 bit binary (exclusive of sign bit) d) DAC span = 10V or 5V e) Isolation= each output shall be isolated from logic and the others to 500 Volts. f) Differential linearity= ½ L.S.B. g) Temp. coefficient=0.01% FSD per degree C. h) Retentivity= Set point value to be held by AO card till updated by new set-point value from Master

station. i) Output will be floating with isolation to Ground. j) Overall accuracy shall be better than +/- 0.1% of the full scale. k) The output shall withstand indefinite open circuit. l) Output resolution shall be better than 0.5% over the range and the temperature linearity shall be m) better than 0.3%.

3.17 POWER SUPPLY MODULE:

a. Power supply available at various stations shall be:- b) CHAINSA,SV-2,SV-3,SV-4/BAMNOULI,JHAJJAR :-SOLAR POWER 24 V DC. c) PPCL:-230 V AC d) Vendor shall convert to suitable power supply source (redundant) as required for their system from above

available supplies level. e) It should be capable of converting 18 to 40 VDC to required output voltages for various RTU f) modules. g) It should support a load of at least 150 Watts. h) A provision for display and monitoring of input and output voltages with the help of onboard LEDs and

test points respectively. i) It should support any type of grounding. j) It should have hot standby redundancy.

3.18 SET-POINT CONTROLS:

All analog output control functions shall utilize the select-check-operate control sequence associated with set point control.

3.19 INTERLOCKING LOGIC:

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The means to minimize the risk of incorrect operation or incorrect sequence of operations can be included within RTU as a logical interlocking function.

4.0 SERIAL LINK REQUIREMENT:

Vendor shall develop, configure and establish the communication for retrieval of data from the flow computers/CP panels/gas chromatographs. Vendor shall be provided with make, model no. and protocol details of flow computers, gas chromatograph during detail engineering or prior to FAT. Vendor to simulate the above devices using protocol analysers/PC/other means to demonstrate during FAT. Vendor shall provide all software tools and programs (source code) used to interface RTUs with flow/computer/gas chromatograph/any other IEDs.It shall be possible to integrate other IEDs with RTU in future. To achieve the same RTUs shall have provision for integrating IEDs. Mapped contiguous modbus register shall be provided by IED vendors,details of same shall be provided during detail engineering. The alarms for power supply /serial link failure/flow computer, CP Panel &gas chromatograph malfunction through serial link shall be implemented. The RTU memory sizing shall be adequate for required numbers of flow computers/gas chromatographs serially connected with RTU. The flow computer/gas chromatograph data shall be scanned by RTU much faster than RTU poll time by master station. It shall be possible to program the RTU to gather IED/Flow computer/GC data using dial-up mode and the necessary program along with source code is to be provided for one flow computer using MODBUS protocol as part of the project. The details regarding the same will be finalized during detail engineering.

5.0 Factory Acceptance Test (FAT) Fat shall be carried out at Bidder’s factory and include all material and equipment delivered and software pertaining to the system, including the equipment, material and software supplied by sub-vendor. Tests shall be performed as per the procedures described in the FAT document and observation will be recorded and signed by representative of Bidder as well as purchaser. The tests shall be performed to represent working conditions as closely as possible. These will comprise of two types: a) Routine tests- These tests are to be carried out on all items of equipment and are to prove that all

components work, all wiring is correct and the functional requirements are complied with. b) Acceptance tests- These tests are to prove that the design and quality of components are such as to

ensure the equipments will work over the full range of conditions. These tests need only be carried out on one piece of equipment of each type.

In order to successfully conduct the FAT, it is advisable that the Bidder conducts a PRE-FAT test to ensure that the system performs in compliance with the specification requirements .These tests shall enable the Bidder to detect and correct most design, integration and performance problems before FAT. The signed and approved PRE-FAT reports shall be submitted to the purchaser. Based on these reports the clearance for conducting FAT shall be given by the purchaser. The Bidder shall invite purchaser well in advance with minimum 1 week notice of the date on which the system shall be ready for FAT. The Bidder shall functionally test all the hardware and software in the presence of Purchaser’s/consultant’s inspectors in order to ascertain compliance with the contract document and approved drawings and documents. The equipment shall be dispatched from the factory only after the purchaser based on successful completion of factory acceptance test (FAT) issues dispatch instructions. The Bidder shall provide to the purchaser’s representative with all reasonable facilities necessary to inspect the equipment as per specification requirements. The Bidder shall provide all assistance,instruments,specialists,labour and materials as required for conducting the tests.

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The Bidder to note that acceptance of the equipment or the system or exemption of inspection and testing shall in no way absolve the bidder of the responsibility to deliver the equipment meeting all the requirements specified in the specification. All the tests considered necessary for successful execution of the works shall be mutually agreed upon. Bidder shall submit detailed FAT procedure for approval by purchaser/consultant, prior to start of FAT. After installation at site bidder shall carry out SAT(site acceptance test) which will comprise of all the functional tests carried out during FAT, including integration/configuration job done at site.

6.0 VENDOR DATA REQUIREMENT AND DOCUMENTATION: Six sets of documentation shall be submitted with each submission. All documents shall be in English language only. Bidder shall provide six sets of folders containing all drawings, tests records, catalogs, maintenenace manuals in hard copies, in addition four sets of soft copies in CD-ROM form shall be provided.

7.0 SPARES:

Vendor to supply RTUs fully wired upto terminals for 25% of all types of I/Os counts (necessary cards shall be supplied) designed as spares.

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ANNEXURE-1. Input/Output list. Sl. No.

Location Analog Input(AI)

Analog output(AO)

Digital Input(DI)

Digital Output(DO)

Serial Ports.

“No of consumers to be polled through GSM(dialup/GPRS)”

1 CHAINSA 42+(5*) NIL 60+(14*) 12+(4*) 6 (RS232:-4,RS485:-2 +(1* RS 232)

2

2 SV-2 15 NIL 30 4 NIL 2 3 SV-3 15+(8*) NIL 30+(10*) 4+(4*) 2(RS232:

-1 RS485:-1)

(10*)

4 BAMNOULI-SV-4

66+(5*) 2 64+(10*) 8+(4*) 6(RS232:-4, RS485:-2)

(10*)

5 PPCL 23 NIL 35 6 NIL 2 6 JHAJJAR 24+(36*) NIL 35+(35*) 6+(16*) 6(RS232:

-4, RS485:-2

5

*----Vendor to provide indicated inputs/outputs additionally and these shall be configured/integrated by vendor later on as per owner’s time schedule and guidance. ANNEXURE-2 P&IDS:-

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