tender doc_tas at bhatinda.pdf

8/19/2019 Tender Doc_TAS at bhatinda.pdf

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HINDUSTAN PETROLEUM CORPORATION

LIMITEDTERMINAL 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 DOCUMENT

FOR

TERMINAL AUTOMATION SYSTEM PROJECT

AT

BHATINDA TERMINAL, PUNJAB


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SPECIAL CONDITIONSOF

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 at

his own cost either thru‘ a temporary power connection from the local

Electric Supply Authority or by means of a DG Set of required capacity.

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;


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7.1 For Supply items:

7.1.1 80% 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) Manufacture‘s Guarantee Certificate

d) Inspection Certificate and dispatch clearance issued by the

nominated Inspection Agency and supplier‘s factory

inspection report.

7.2 10% of the quoted rates shall be paid on completion of erection and

successful commissioning (SITE ACCEPTANCE TEST).

7.2.1

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

Stabilisation Period.

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


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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)

7.2.3

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

Stabilization Period

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

be paid on completion of erection and successful commissioning (SITE

ACCEPTANCE TEST)

Successful commissioning is defined as compliance of all SAT punch points

by bidder and accepted by HPCL

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

completion of Training

For Comprehensive Annual Maintenance Contract ( 5 years ): The CAMC

charges shall be quoted in absolute amount (not in %).However the CAMCcharges for 5 years shall be at least 10 % of the total Capital cost to ensure

that the system is maintained throughout the CAMC period as envisaged. If

the Vendor quotes less than 10% as AMC charges, minimum of 10% of the

total capital cost for 5 years period shall be considered as AMC charges,

keeping the total cost (Total capital cost + CAMC) as quoted by the vendor.

In case the vendor quotes higher amount of CAMC, the quoted amount shall

be retained. 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






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

any deviations. In case of deviations, Bidders will be given one opportunityto 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 ― shall mean the Bhatinda Terminal project site.

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

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 fromdate of acceptance of the system (ie date of compliance of punch points

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 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.


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17

The above Special conditions shall be read in conjunction with General

Conditions of Contract and Instructions to bidders. If any provision inthese 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 :

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


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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

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 tomake 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


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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 outof 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

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 orobligated 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


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

including negligence, errors & omissions shall be limited to the totalcontract 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) intent to automate New 8 Bay

Gantry being constructed at Bhatinda Terminal. The Terminal receives, stores and

dispatch various grades of . MS, SKO & HSD etc. Presently Bhatinda Terminal is

operational & has automated operation for Existing 10 Bay Gantry Tank Truck

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

Valve Control logics including module for Management Information System &

Reporting and interface with our ERP. M/s Advanced Systek Pvt Ltd (ASPL) has

done Terminal Automation & provided its software for automated operation of

aforesaid facilities. The New Gantry, VFD & other allied equipment/instrument

proposed to be provided in this tender shall be integrated with the existing

Automation/TAS software. Also existing logics & additional graphics which may

require to be modified/ added due to addition of new Bays, pumps, VFDs etc

shall be suitably modified/ added by the Vendor. 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 which in turn will

control and monitor the entire terminal.

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

the existing scheme of Automation & other aspects of Plant operations for theterminal. 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 Equipments

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

inspection done of the equipments & 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

Site Execution

Commissioning & Trial Runs

Site Acceptance Test including compliance

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 Bay Gantry

b) Product pump operation (All T/T Loading pumps) including supply &

integration of the New VFDs

c) Integration with existing software including logic modification, wherever

required and additional graphics

d) Management Information System & Reporting

All these operations shall be logically integrated through existing Servers,Programmable Logic Controller, other field & control room equipments to ensure

accurate, seamless & secured operation and data exchange.

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. Stabilization period is not included in the completion period.

Control Room location is inside Administrative building.

As Bhatinda Terminal 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

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


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

manager shall be obtained. All hot work shall be planned (min. 21 days in

advance for Gantry/ header job) 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 mechanical job can be carried out during any day/ Sundays/ holidays,

Vendor shall mobilize its mechanical personnel immediately after placement of

order to carry out modification job in such a manner that all jobs like header

modification for BAE installation, are completed by the time supply of these

equipments & instruments are expected. The modification shall be complete in

all respect after providing spool pieces, valves etc. as required so that equipment,

instruments can be mounted immediately on receipt Only those modification like

metering system which may require actual measurement or instruments

/equipments at site may be taken up after receipt of those equipments,

instruments

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


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Trouble shooting for all the individual equipment. Operational &

preventive maintenance of individual equipment & overallsystem(excluding the existing System)

Trouble shooting for all the supplied equipment/instruments under this

tender.

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

equipments 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 Four Major categories viz .Overall Scope of

Work, scope of work for the New 8 Bay Gantry & 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 System to ensure the

deliverables are achieved in line with technical & functional requirement

laid down in this tender document.

Supply, installation, testing & commissioning of all equipment/instruments, material etc complete as stipulated in the schedule of

quantities along with its allied hardware. Balance items which are not

explicitly spelt out in the Schedule of quantities but are required for the

completeness of the work like structural steels, foundation work & other

civil works, fittings, gaskets, nut 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 acceptance of the complete

system.

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

etc.


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Supply, fabrication, welding/ nut bolting, 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 othermaterials for completeness of erection. The erection materials shall also be

suitable to the hazardous area classification.

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

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

mounting or for re-routing the existing pipe in order to facilitate mounting

of the instruments & equipments including fabrication, welding, erection,

hydro testing, painting testing and commissioning. 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 equipments, instruments such aspressure transmitters, density meters etc. Dimension of such canopy shall

be such on all sides of the equipment adequately.

Any modification required in the existing pipeline, loading platform,

loading arms for mounting of instruments & equipments like Metering

system, Header line equipments etc. inclusive of supply of pipes, fittings,


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valves etc. In case it is not possible to modif y 3‖/ 1½― existing pipeline,

Vendor shall fabricate, erect, lay new 3‖/1½ ― pipeline including supply ofpipes, fittings, valves etc & painting from existing tapping onwards at the

Gantry. The limit of modification/laying of new 3‖/ 1½‖ pipeline for

Metering system shall start downstream from the 3‖ / 1½― tapping

provided on the header line inside the Gantry. The vendor scope shall also

include draining & collecting the oil safely from the pipeline, flushing,

degassing, hydro-testing, painting etc. All these modification job,

dismantling, re-installation etc. including supply of pipes, fittings,

consumable, hardware material etc. shall be part of respective instruments

& equipment. No separate payment shall be made for these items.

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

life cycle, his support for Backup engineering & spares

Sealing of cables / tube entries into the control room 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,

Execution of Warranty, Comprehensive Annual Maintenance Contract, etc.

Supply of special tools, test equipments, 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, at each site for all of the following equipment, instruments

o Metering System

o DCV


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o Loading Arm

o Densitometer

o BAE

o VFD

o Batch Controller

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.

Any other instrument/ equipment/ service, which is not explicitly

mentioned in this document or in the Schedule of Quantity/ price bid but

deemed necessary for the successful operation of the system complete in

all respects, shall be in vendor‘s scope.

The functional & operational requirements as specified in this tendermight 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.

Calibration & Verification of all equipments & instruments

W&M Stamping of the Electronic metering system. Any other instruments,

equipments which may require stamping as per statutory law shall also be in


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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, equipments & materials as per the

approved QAP.

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

B.

Scope of Work in the New 8 Bay Gantry & existing Gantry shall include butnot limited to the following:

Supply, installation, testing & commissioning of the Electronic Metering

System, RIT, Card Reader, earthing relay, RTD, Loading arms, JBs, Cables,

all allied hardware, instruments equipment etc complete required for

Gantry Automation


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Supply, installation, testing & commissioning of Online Densitometer on

the product header line.

The existing header line of the existing gantry (HSD-10‖, MS & SKO-6‖) will

be dismantled by HPCL & new line of size HSD-14‖, MS-10‖ & SKO-8‖ will

be laid by HPCL independently for both new & existing Gantry. It is

tentatively planned to use existing 10‖ HSD BAE for new 10‖ MS line,

existing 6‖ SKO BAE for new 8‖ SKO & existing 6‖ MS for new Ethanol line

along with other header line equipment like PT, DT, TRV etc. The

dismantling of the header line equipment & re-installation on the new

header line will be in the scope of the vendor along with required fittings

like bends, flanges, expander reducer etc, gaskets, nut-bolts etc completerequired for successful erection of the equipment. Foundation for

equipment as per the requirement shall be in the scope of Vendor. New

Triple offset Butterfly valve (TOBV) with electric actuator shall be supplied

& installed with the existing BAE & the same shall be part of re-installation

item. TRV shall be provided on the BAE & on the downstream of TOBV.

TRVs shall be connected to the U/G Tank through 1‘‘ line or shall be

connected to the unloading line, if available, with NRV or shall be

connected at the pump house on the suction line with NRV. All

modification in the pipeline as per the requirement including supply of allrequired hardware, fittings like valves, expander, reducer, flanges etc &

pipes.

Rerouting of cables, JBs, providing additional cables, cable tray etc for

reinstallation of header line equipment. This will be part of cable item.

Rerouting & realignment of existing SS additive line over the proposed

trestle up to the existing Gantry along with supply of required SS Pipe,

bends fittings, gasket nut bolts etc. No separate payment will be made for

this item

Supply & installation of new BAE along with TOBV, DT, PT, orifice plate etc

on the header line including modification in the pipeline required for

installation of these equipments. Supply of all required hardware, pipes,

fittings like valves, flanges, bends etc.

Earthing of all the equipment, instruments to the existing earth pit.


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The existing Fire Engine Automation shall be extended to include One No

ESD & One No MCP shall be provided at the New Gantry.

As the pipeline is being laid new, the layout shall be made to facilitate

installation of TAS equipment. However any further modification required

in the existing pipeline from the existing tapping onwards available at the

Gantry for both Main product & secondary product to suit mounting of

Automation equipment. Supply if pipes, fittings, gaskets, nut bolts & all

allied hardware etc shall be included in the scope of Vendor‘s job.

Dismantling & reinstallation of any Valve, hardware etc. if required shall be

included in the scope of work.

C.

Integration with the existing Terminal Automation System : The existing System

is supplied & maintained by M/s Advanced Systek Pvt Ltd, Vadodara. Vendor

shall get the access authority required for modification/ up-gradation of the

existing TAS (hardware and software) from M/s Advanced Systek Pvt Ltd,

Vadodara. Vendor to submit the same to HPCL in un-priced bid along with

undertaking from TAS integrator regarding non- dilution of warranty of

existing TAS system.Scope of Work for integration with the existing TASshall include but not limited to the following:

o Modification, up-gradation, additional graphics as required in the existing

TAS software to seamlessly integrate the new system.

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

material or any hardware including all supplies as required for seamlessly

interfacing with the existing Terminal Automation System to meet the

specified technical & functional requirement.

o

Integration of header line TOBV to the existing TAS including modificationin the logic & allied graphics

o The MMI/ GUI for all the new items, equipment, instruments shall be same

as the existing one.


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o All the existing reports shall be modified to include the reports required

for the new equipment, instruments & shall be available to the user in acombined format.

o All alarm, events etc available in the existing system shall be extended for

the new system.

o Any change in the existing TAS logic due to inclusion on new Gantry like

Bay allocation logic, EDU logic etc

o The Spare DI, DO, AI, AO available in the existing PLC may be used. Any

additional I/Os required for integration shall be supplied along with itsallied hardware. Change in ladder logic shall also be incorporated to suit

the requirement of the new equipment/ instruments.

o The spares available in the existing networking component like Terminal

Server etc may be used. In case the same is not sufficient, new networking

components in same configuration along with all its allied hardware shall

be supplied, installed, commissioned integrated by the Vendor

o All the newly supplied equipment/ instruments shall be powered through

the existing parallel redundant UPS. In case the existing UPS capacity is notsufficient to power up the new equipment/ instruments then same

specification UPS of suitable capacity shall be supplied by the Vendor to

power up the new equipment/ instruments at no extra cost. Any cabling,

hardware etc required powering up the new equipment shall be included

in the cabling item & will not be paid separately.

o Modification/ Up-gradation of the existing Power Distribution panel shall

or alternatively supply of New MCB panel for supply of Power to the new

equipment/instruments. 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 existing Product pumps are either controlled though Motor Control

Center (MCC) or through Variable Frequency Drive (VFD) or combination


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25 | 2 3 8

of MCC & VFD. These are currently integrated with the TAS such that the

pumps are started based on the Pump demand & are run based on thepressure on the header line. Because of new Gantry, the existing pumps

are being upgraded to higher capacity pumps by HPCL along with new

VFDs which are part of this tender. These new Pumps & VFD shall be

integrated with the existing TAS by the Vendor so that the new as well as

existing Gantry comes in the purview of the Pump automation & the

pumps are operated automatically based on the pump demand. HPCL

scope will be limited to providing the Pumps & MCC in working condition.

Any changes required in the ladder logic or TAS software shall be

developed & incorporated to complete the VFD Interface with the existing

TAS. All software, hardware etc. required for VFD interfacing with the

existing TAS including development of graphics, modification in the logic

will be in Vendor‘s scope. Existing cables hardware etc available at site may

be utilized, if suitable.

o

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

o Any licenses required for due to up-gradation/ modification in the existing

system shall be provided by the Vendor

o

All items required for integration, though not specifically mentionedabove, of the new equipment/ instruments are deemed to be included

under integration item only unless otherwise specified.


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HPCL’s SCOPE OF WORKS.

HPCL shall provide the following to the successful vendor:

o Gantry Structure for installation of metering system

o Existing Terminal Automation System in proper working condition.

o Cable trenches, Hume pipes if available & having sufficient space

o Cabling from Pumps to the MCC.

o All free issue items in standalone working condition.


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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

Products Characteristics:

As given below

Flow rate:

Normal flow rate 150 to 1200 LPM at each

Loading point. Maximum Header Flow Rate

will be when all the pumps for that particular

product are operating & minimum Headerflow 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


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

For BATCH Controller and RIT communication with LRC : 2 Sec

Time taken between card flashing & corresponding

batch controller message appearance

: 4 Sec

Other system responses required for driver interaction

such as card validation, RIT lamp sequences, down

loading of data etc.

: 4 Sec


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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 forPainting.

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


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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 systemCode / Standard Description

AMSE B1.20.1

AMSE B16.5

AMSE B16.20

ASME SEC VIII

Pipe thread

Steel Pipe flanges and flanged fittings

Ring-Joint gaskets and grooves for steel flanges

Boiler & pressure vessel code rules.

ANSI/ISA 575-01 Control valve sizing , capacity test procedures, face to face


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dimensions, leakage

RP 520 Fire sizing of safety and control valveRP 598 Control valve leakage

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 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

OISD

recommendations

For storage, handling and safety systems and

transportation

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 liquid in

fixed storage tanks.

IS 2801 PD meter Accuracy

BASEEFA/PTB/KEM

A/FM/ATEX/ TUV/

PESO/CMRS/ IBR/

RDSO/W&M

Statutory standards

BS 5308 Part-I Instrumentation Cable

ISA –S5.1 Instrument Symbol & Identification

ISA- S 5.2 Graphical symbol for Process Operators

IS 2148 Flame proof , enclosure for electrical apparatus

IS 3043 Cod of Practice for Earthing


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DESIGN CRITERIA FOR TANK TRUCK LOADING FACILITIES

Tank Trucks are loaded on a volumetric basis in the filling Gantry. New 8 Bay

Gantry is constructed to load MS & HSD at each bay which shall be filled

simultaneously, if required, through two different loading arms. Each loading

Point shall be capable of filling multiple variant of the same product

depending on the infrastructure available.

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‖ 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.

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 &


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DCV. The pressure drop will be required to be demonstrated during SAT.

Necessary arrangement on the metering assembly/ piping to be provided bythe vendor. After successful demonstration of the pressure drop, the same to

be plugged.

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 the case may be) as per the requirement

RTD shall be provided at each loading point .

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.

Intrinsically safe proximity card reader shall be provided at each bay

Each bay shall be provided with Earthing device which shall be interlockedwith the manual earthing, apart from other suitable interlocks as defined in

the technical specifications.

Each product pipeline entering into TLF shall be provided with a densitometer

with Orifice plate arrangement for measuring ambient & standard density of

product. 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 be modified to monitor

& record density for each truck compartment and communicate it to ERP for

printing on the invoice. Orifice plate shall be designed to ensure that theproduct 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

Pressure transmitters shall be installed required to be installed in all the

delivery header lines to TLF. The pressures in the header lines are to be


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transmitted to PLC / LRC. If pressure in the delivery pipeline header exceeds

specified value or reduced below specified value, alarm should be transmittedto PLC panel from pressure transmitter for stopping the Batch Controller or

starting/ stopping the pump.


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DOCUMENTATION

LEGEND : I – Information ,A- Approval F – Final delivery of equipment,

SN Description For

Information

Approval

Final Docu -

mentation

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 Functional Design Specification A F

1.5 Procedure for dismantling existing

instruments, equipments, cabling,

structure etc. wherever applicable

A

1.6 Operational Philosophy A

1.7 Progress report (Fortnightly) I

1.8 Safety Report ( Fortnightly)

1.9 Document Control Sheet (Fortnightly) I

1.10 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

A F

2.7 SYSTEM CABINETS

a. Arrangement of modules I F

b. Structure, dimension, construction, etc. I F

2.8 AUXILIARY CABINETS


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36 | 2 3 8

a. Arrangement of modules A F

b. Structure, dimension, construction etc. I F2.9 Power supply distribution diagram A F

2.10 Cable layout A F

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 A

2.15 Software Design Manual A

2.16 Interfacing scheme A2.17 MIS Formats A

2.18 Interconnection diagram I F

2.19 Earthing System A F

2.20 As built drawing 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,

Loading Arms, by the respective OEM

I F

4.0 INSPECTION AND TEST

4.1 Inspection and test report from

Vendor‘s quality control department

F

4.2 Imported shipping documents alongwith test certificate F

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


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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 F

5.4 Maintenance manual F

5.5 HOTO Report covering all the details

of the Project( to be submitted in both

hard form & CD)

A F

7.0 QULAITY ASSURANCE PLAN A FNOTE :

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 - 4 sets

- Final -4 sets

c. DVD – 2 sets (soft copy)

d. As built drawings shall be laminated and properly bound with index sheet for

preservation and future reference.

(1) All drawing which are submitted for approval, shall be submitted on DVD as

a final document (after approval) along with HOTO Report


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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 toachieve the desired functions.


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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 equipments, shall be +/-0.05% of the Batch. The metering system shall

be checked with reference to the existing Calibrated Mobile Prover Tank of

capacity 2 KL

o Electronic Metering System for primary product (MS, HSD etc) 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 for each Bay.

o

Calibration & Weights & Measure (W&M) Stamping : The existing Mobile

Prover Tank is already calibrated & stamped by Weights & Measure

(W&M) Department. The Calibrated & W&M stamped Mobile prover tank

shall be used for calibrating the Flow metering system as per the

Calibration procedure given in this document. W&M stamping shall be

done by the Vendor for the Flow metering system used for the Main

product, Secondary product if the tapping is downstream of the flow


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40 | 2 3 8

metering system of the main product i.e. Ethanol Product is blended in

the main product without flowing through the main metering system. ThusW&M Stamping may not be required for Secondary product if the tapping

is upstream of the Main metering system and if such an arrangement is

permitted/approved by statutory rules/Local W&M Department. Batch

Controllers shall also be stamped by W&M & the meter factor/‘K‘ Factor

for all the Products ( Main, Secondary) shall come under W&M

configuration parameter such that these cannot be altered after providing

the W&M sealing. Stamping of these newly supplied equipments, by state

W&M Department & the entire coordination shall be in the scope of the

Vendor during execution as well as in Two 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 equipments can be mounted on the Gantry Platform

with suitable foundation/ Structural Steel support. Supply, installation &

re-routing of the 3‖ pipeline/ 1.5‖ pipeline and or laying of new 3‖/1.5‖

pipeline including all associated hardware, fittings, gaskets, jumpers

required for mounting these equipments from the header line tapping

onwards at the Gantry shall be in the scope of the Vendor. The new/

modified pipeline shall be painted as per the color coding of HPCL. All

these hardware shall be supplied as per the specification given in the

tender document.


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41 | 2 3 8

o All Structural Steel like angles, flats channels beams, brackets etc required

for mounting/ supporting these equipments or any existing equipmentsshall be in the scope of the Vendor.


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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


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43 | 2 3 8

additive injection system.

Pump Demand contacts for MainProduct 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 SecondaryProduct

Over Blending of Secondary Product

Auto deletion of memory

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%

Data entry : Alpha numeric entry pad


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Online Self diagnostics : Required

Memory capacity & backup : Non Volatile RAM capable of retainingdata. 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

memoryScan 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

Electromagnetic Interference


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Protection

Electrical Transient Suppression onall 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

communication is established)


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47 | 2 3 8

password shall be available for any

basic database configurationaffecting 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 belogged 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


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48 | 2 3 8

shall also be captured

All such changes in Shall begenerated as exception reports.

Keyboard Type : Touch Sensitive

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/StopButton

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 Mode Change from Auto to Manual

(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 aposition 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


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49 | 2 3 8

along with Truck Number. Provision

shall be available in the BatchController 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

Mode Change from Auto to Manual

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


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50 | 2 3 8

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 etc.

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

Outer Housing : Carbon steel

End connection : 3", class 150#, RF serrated ANSI B 16.5

Flange : RF Serrated ANSI B 16.5MOC 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


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Calibration : Meter shall be factory Calibrated & also at

the Location. Weights & Measure stampingis 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

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.


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SPECIFICATION FOR DUAL PULSE TRANSMITTER FOR MAIN PRODUCT

Make : As per approved vendor list.

Qty : Refer BOQ

Application : To convert volumetric flow to pulse

Operating Range : Upto 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 of the

Calibrator output shaft for pulse security

conforming to Level A as per IP 252 / 76.

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

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


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: 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


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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


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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 1kg/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‖.


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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 pointersConnection

: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


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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) ,200-1200 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)


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Tubing & Pipe : SS 316

Diaphragm material : Viton/ NBR-LSTrim : SS 316

Seals : Viton

Body type : Inline

Solenoid Valve

Type : 1 No. Normally Open (NO) &

1 No. Normally Close (NC)

SOV Make : ASCO

Body : Stainless Steel

Trim : SS 304Mounting : On Digital Control valve

Max. working pressure : 15 Kg/sq. cm

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 65Power Supply : 230V +10% to -15% AC , 50 Hz +/-5%

Coil Insulation : F Type

Approval/Certification for

Digital Control Valve

: CCOE

Features Required : Fail Safe

Bubble Tight Shut off

No reverse flow

Valve close on Power Failure

Adjustable rate of opening &

closing of Valve.

Low Pressure Drop


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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, 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 LP