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Tender Doc TAS at Bhatinda PDF
Tender Doc TAS at Bhatinda PDF
LIMITED
TERMINAL AUTOMATION PROJECT
TENDER DOCUMENT
FOR
AT
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HINDUSTAN PETROLEUM CORPORATION
LIMITED
TERMINAL AUTOMATION PROJECT
SPECIAL CONDITIONS
OF
CONTRACT
(SCC)
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TERMINAL AUTOMATION PROJECT
1. Completion period: 7 months from the date of issue of LOI / Work order .
This excludes the stabilization period.
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.
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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7.1.1 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;
7.2 10% of the quoted rates shall be paid on completion of erection and
successful commissioning (SITE ACCEPTANCE TEST).
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
d) Wage Sheet
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7.2.2 10% of the quoted rates shall be paid on completion of erection and
successful commissioning (SITE ACCEPTANCE TEST)
8 For Testing and commissioning Items : 100 % of the quoted rates shall
be paid on completion of erection and successful commissioning (SITE
ACCEPTANCE TEST)
8.2 For Training Items : 100 % of the quoted rates shall be paid on
completion of Training
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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 opportunity
to withdraw the same without any revision in prices failing which the offer is
liable to be rejected.
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.
13 Form C/D, Road Permits, Entry Permits etc. will not be issued by HPCL.
In addition to clause No.11 & 5n of GTC, the entire system including all
supplied materials shall be warranted for another 12 months. Thus the
total period of warranty/guarantee will be for 24 months starting from
date of acceptance of the system (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.
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19. CONFIDENTIALITY:
18 General :
No idle time charges shall be payable by HPCL ,in any case what so ever.
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Successful Bidder will be wholly and solely responsible and liable for all the
jobs carried out by them / services provided by them. HPCL acceptance
having signed off a particular milestone will not exonerate the Successful
Bidder from his prime responsibilities to have done a correct job as per the
requirement of the job/contract and as per international practices in the
first instance itself. If required, Successful Bidder will be required to revisit
those milestones which are already signed off and will be required to
make suitable corrections at no extra cost to HPCL.
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SPECIFICATIONS
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INTENT OF SPECIFICATIONS
Before submitting techno commercial bids, bidders are required to visit and study
the existing scheme of Automation & other aspects of Plant operations for the
terminal. Any job, material, equipment, instrument etc not explicitly mentioned in
the Schedule of quantity but required to be provided to meet the functional &
technical requirement as mentioned in this tender shall be in the scope of
Vendor.
M/s HPCL may appoint Project Management Consultant (PMC) on their behalf for
execution & implementation of the entire TAS including Data Sheets approval,
Site Supervision, Bills Certification, Project monitoring etc. & all related activities
of automation as covered under this tender. However, inspection of 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
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.
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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 the
operation 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:-
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The above training shall be conducted at the site during handing over of the
system & during the Warranty period. Two such trainings shall be held every year
in the Warranty Period. Each training module shall be of minimum 2 days.
The TT crews are also required to be familiarized with the operation of the TLF
equipments for which HPCL shall organize the program and the vendor shall
demonstrate the T/T operation.
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SCOPE OF WORK
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.
Third party inspection of the bought out item, Trial run of the system, Site
acceptance test, system stabilization and acceptance of the complete
system.
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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
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valves etc. In case it is not possible to modify 3‖/ 1½― existing pipeline,
Vendor shall fabricate, erect, lay new 3‖/1½ ― pipeline including supply of
pipes, 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.
Sealing of cables / tube entries into the control room after laying and
testing of all tubes, cables etc.,
Providing training to HPCL operation team and T/T Crew member as per
the scope defined in the tender,
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
Drilling holes on all panels, power distribution panel, control panels, etc.
for cables / glands.
All mechanical, electrical jobs required for TAS shall be in Vendor‘s scope.
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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.
B. Scope of Work in the New 8 Bay Gantry & existing Gantry shall include but
not 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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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 complete
required 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 all
required 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.
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.
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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.
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 TAS
shall 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 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 a
combined 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 its
allied hardware. Change in ladder logic shall also be incorporated to suit
the requirement of the new equipment/ instruments.
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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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 the
pressure 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.
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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:
PRODUCT CHARACTERSTICS
PARAMETERS MS SKO HSD
Specific Gravity 0.7-0.75 0.75-0.8 0.8-0.9
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SYSTEM RESPONSE TIME: Vendor shall design the System so as to have the
following minimum response time.
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The equipment shall also conform to the latest Indian Electricity Rules, OISD,
PESO & petroleum rules as regards safety, earthing and other essential
provisions specified there in for the installation and operation of electrical plants.
The equipment in the hazardous area shall have CMRI, CCOE approvals. OEM
shall have BIS approval.
All painting shall be done in accordance with the General Specification for
Painting.
All equipment shall comply with the statutory requirements of the Government
of India and the State Government of respective states.
The Vendor shall execute the job to comply with the requirements of the
relevant regulations or acts in force in the area together with design
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dimensions, leakage
RP 520 Fire sizing of safety and control valve
RP 598 Control valve leakage
OIML standard R (Measuring systems for liquids other than water)
117
ISA RP SS-1 Instrument Society of America standard and codes
S 62-01, S82-02
S8-03, S18.1
IEC 801/EN Electromagnetic compatibility
50081/82
IEC 79.10/BS 4683/ Hazardous area classification
IS 2148
IEC-529/IS 2147/ For execution of Inst. Enclosures
NEMA
OISD For storage, handling and safety systems and
recommendations transportation
API MP MS Ch 21 Flow measurement using Electronic Metering System
ISO/TC28/Section Terms relating to calculation of oil quantity
3
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 Statutory standards
A/FM/ATEX/ TUV/
PESO/CMRS/ IBR/
RDSO/W&M
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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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
eliminator and digital control valve shall be provided for Ethanol blending. All
o Base product
o Base product with blending.
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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
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.
Each bay shall be provided with Earthing device which shall be interlocked
with the manual earthing, apart from other suitable interlocks as defined in
the technical specifications.
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 the
product flow through the densitometer all the time during loading of that
particular product. In case the product is not flowing through densitometers
during loading of that particular product then ―Error‖ message shall be
displayed instead of last healthy reading
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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DOCUMENTATION
LEGEND : I – Information ,A- Approval F – Final delivery of equipment,
SN Description For Final Docu -
Information mentation
Approval
1.0 GENERAL
1.1 Vendor engineering and service I
personnel organization chart including
set up for this project.
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 A
instruments, equipments, cabling,
structure etc. wherever applicable
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 F
a) Flow metering system
b) Densitometer, PT
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a. Arrangement of modules A F
b. Structure, dimension, construction etc. I F
2.9 Power supply distribution diagram A F
2.10 Cable layout A F
2.11 System drawing (loop A F
diagrams,reports)
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 A
2.17 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 F
Ex-Proof, IS, Weather Proof ( shall also
be submitted along with Data sheets
for approval)
3.2 Vendor‘s guarantee /warranty F
3.3 Original Software Licenses F
3.4 Certification of Installation for I F
Metering system, Densitometer,
Loading Arms, by the respective OEM
4.0 INSPECTION AND TEST
4.1 Inspection and test report from F
Vendor‘s quality control department
4.2 Imported shipping documents along F
with test certificate
4.4 Factory acceptance tests procedure for A
Batch accuracy tests
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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TECHNICAL SPECIFICATION
TECHNICAL SPECIFICATIONS SUPPLY OF NEW INSTRUMENTS/EQUIPMENT
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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 RTD shall be provided at each loading point & its input shall be taken in
the Batch Controller.
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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o All Structural Steel like angles, flats channels beams, brackets etc required
for mounting/ supporting these equipments or any existing equipments
shall be in the scope of the Vendor.
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Protection
Electrical Transient Suppression on
all power, communication and data
input & output to provide
protection from transient over
Voltage.
Approvals /Certification : PESO(CCOE) approved
Ex Proof to Zone-1, Gr II A & II B
Weather Proof to IP 65
W&M Model Approval : OIML approval as
per R 117 for Custody Transfer
Batch Accuracy of the : Shall be 0.05% of batch over the full flow
Electronic Metering system 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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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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Materials :
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Size : 3‖
Mounting : Pipeline
Materials :
Seal : Viton/Buna N
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End Connection :
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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
: SS 316, diaphragm /Piston
Element material & Type
:
Socket material SS 316
:
Zero Adjustment Micrometer pointers
:
Connection ½‖ / ¼ ―NPT (M), 2 nos.
:
Connection location Bottom
:
Accuracy ± 2% of FSD
:
Over range protection As per IS 3624
:
Blow out protection As per IS 3624
:
Range 0-2 Kg / Sq.Cm
:
Maximum Static Pressure 15 Kg / Sq.Cm
:
Accessories 3 way manifold- SS 304
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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
Service : Ethanol
Accuracy : +/-0.5%
Linearity : 0.15%
Repeatability : 0.05%
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Seals : Viton/Buna N
NOTE: Batch Controller shall control the Blending proportion based on recipe &
product code
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Dial : Aluminum
Accuracy : ± 2 % of FSD
Materials
Movement : SS 316
Element : SS 316
Socket : SS 316
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Standard : IS 3624
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Mesh Size : 60
Vent : Required
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TAPPING
General
Service : ETHANOL
Size : ‗1/2‖ to 1 ½‖
Cover : Bolted
Seat
Material :
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THERMO WELL
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(X)-Axis
: 1 ½ ― ANSI 150# RF 125 AARH Flanged
Process Connection
: ½ ‖ NPT (F)
Instr. Connection
: To suit element
Bore Diameter
: 1.5 max operating pressure
Hydro test
: STS
Make/Model No.
: RTD Pt 100 to DIN 43760
Signal Source
: Alphanumeric LCD Display
Local Display
: +/- 0.15% of Input
Accuracy
: Threaded connection on main pipeline header
Mounting
going to TLF.
: 4-20 mA signal proportional to temperature.
Output
: RTD linearisation, upscale or downscale for open
Functions
circuit / short circuit sensor-Smart transmitter
: Circuit protected against surges, lightning,
Protection
reverse polarity, reverse insertion
:
Enclosure IP-65,
:
Execution Intrinsic safe with active barrier in control room
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inhibition.
Lamp Housing & clear lens shall protrude
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Tank truck loading shall be interlocked with earthing and bonding . The earthing
relay shall have two probes in minimum. One probe shall be used for earthing of
TT and the other probe shall be used for bonding of TT. The earthing relay shall
be combined unit for earthing and bonding. Apart from the earthing and
bonding clamps of new earthing relay, the existing earthing wire needs to be
integrated. The system shall also detect that the clamps are attached to tank
truck earth only and shall not give green indication if they are attached to
existing MS structures like catwalk, gratings, gantry structure etc. The system shall
also monitor at each loading point level the value of resistance of each earth
pit/earthing grid to which the earthing relay is connected. The system shall be
designed such that when all the three clamps ( one clamp for earthing of new
earthing relay, one clamp for bonding of new earthing relay, one clamp of
existing earthing) are put and all are found to be healthy and resistance of
earthing grid is less than 1 ohm ( incase the existing earth pits are not in grid
then individual earth pit reading to be checked and shall not exceed 2 ohm ),
then loading of particular compartment shall start.
In case of failure of any of the contacts or the earthing resistance going beyond
the cut off value ,then loading shall stop immediately
NOTE : A 16 sq mm cross-section braided copper strip of 3 m length shall be
provided with each earthing relay.
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Sensing Distance : 25 mm
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Inlet Flanges : Raised face serrated finish, ASA class 150, with
material
Seals : Viton
mtr.(Vertical)
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Loading Arm type : Self supported Top Loading. Quantity for Left
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DESIGN REQUIREMENT
1. Loading Arm shall be self supported type. Extra bearing support which
creates obstruction to the movement of manpower & other equipment
should not to be required by the Loading Arm i.e. Design of Loading arm
should be such that it do not require any extra Bearing support.
2. Base swivel joint should be capable of taking bending load of the loading
arm. Loading shall be checked of bending load by applying 40 Kg weight
at the end of inboard arm and will be checked for smooth rotation.
4. The swivel joints shall be designed to make the loading arm maneuverable
with minimum effort. All swivel joint should be of split type design and
have minimum type rows of chrome steel hardened balls fixed in suitably
hardened carbon steel guide ways. Material conforming to ASTM A 106
Gr. B/A-105 having HCS Balls, ball races are to be hardened to 500 BHN,
seal of VITON / PTFE. Sealing surfaces of Swivel Joint should have overlay
with SS material. Aluminum swivel Joint shall be Aluminum Alloy.
Aluminum swivel joint should be hardened Ball races to achieve longer lift.
All Swivel joints of steel or Aluminum should be of Split type design.
Swivel joint made of Aluminum should have replaceable snap type ball
races in which balls moves.
The quantum of force required at the end of outboard arm to move the
outboard arm in horizontal place and in vertical plane and the complete
loading arm from the base swivel joint in horizontal plane without fluid &
checked on shop floor will be as below:
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5. Seals of swivel shall be of Metal inserted Viton material. Swivel joints shall
be completely leak proof under operating pressure and vacuum. The
tightness of seal shall not hinder the easy operation of swivel joint.
The Outboard arm and drop pipe shall counter balanced by spring
balancing Mechanism will be of Helical Compression spring type
with totally enclosed cover design. Spring box should be such that,
setting of the spring tension can be done by any one [person at site
without any special tools, Helical spring assembly.
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a) Balancing Test:
This is conducted in Loading arm to demonstrate that the arms are
mechanically counterbalanced. Test under no hydrostatic pressure.
Quantum of Check : 100%
Rotate the swivel joints for three cycles in forward & three cycles in reverse
Direction to demonstrate that swivel joints can be easily operated and
operating torque required are in following range.
The loading Arm is pressurized to 15 Kg/cm2 using water as test fluid &
pressure Held for 15 minutes. Requirement : No leakage is allowed.
Quantum of check: 100%
d) Radiography:
10% of all the carbon steel butt weld joints in a loading arm shall be
radiographed.
Quantum of check : 10% quantity
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f) Life cycle testing of swivel joint of each type shall be done & the
certificates shall be offered for verification during inspection.
Additionally Aluminum swivel joint shall also be tested for endurance test
for 20,000 cycles, which will be witnessed by TPIA.
g) Bending moment test for springs & base swivel joint shall be done & the
certificates shall be offered for verification during Inspection. Additionally
Bending moment test shall be done for split flange type of Swivel joint &
witnessed by TPIA.
j) Vacuum test: Closing inside and inlet side. The loading arm assembly to
be tested at (-) 0.15 BAR vacuum condition inside and hold for 15 minutes
(no drop at vacuum gauge permitted).
PAINTING
Loading arm and the accessories shall be painted one coat anticorrosive
paint and two coats of enamel paint of colour code shade as given below :
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The colour code shall be given with a spray gun to get a shining finish.
Aluminium nozzle shall not be painted.
NOTE:
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Vendor shall submit the elaborate calibration procedure based on the following
general guidelines:
Existing 2KL Mobile prover tank stamped by W&M shall be used by the
Meter linearization shall be done at multiple flow or single flow as per the
Engineer-In- Charge.
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Size : Min 10 mm
Protection : IP – 65
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Pressure Drop across the main : Less than 0.15 Kg/ Cm2
header
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size restriction orifice plate as per the net flow and pressure drop (Minimum)
across the density meter. Restriction orifice material shall be SS316.
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Range : 0-100deg C
tank
Note: This is required only if the densitometer does not have inbuilt Temperature
sensor
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CONSTRUCTION
12 Body Cast
13 Disc Cast
14 Stem Bar-forged (No casting)
15 End Connection Double flanged as per ANSI B 16.5RF
16 Flange & finish 150#, RF, 63-125 AARH, smooth finish
MATERIAL
17 Body ASTM A216 Gr. WCB
18 Disc ASTM A216 Gr. WCB/ASTM A351 CF8M
19 Seal Ring UNS S 31801 Douplex SS+ Graphite
20 Stem A479 UNS 41000/17-4 PH Hard Chrome
21 Bushing UNS S31600
22 Disc Retainer ASTM A 516
Flange
23 Disc and Bottom UNS 31600+ Graphite
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Flange
24 Seat Stellited Gr. 21 Weld Overlay
25 Pin/Nut/Washers SS 316
26 Thrust Bearing SS 316/ Hardfaced /Cobalt based alloy
TESTING
27 Body Hydro test 1.5 times the flange rating (30 bar #150)
28 Seat Hydro test 22 bar #150, test duration as per standard
29 Pneumatic Seat NA (6 bar # 150)
Test
30 Leakage Class Zero Leakage/ bubble tight shutoff
required
SPECIAL REQUIREMENTS
31 Safety Integrity SIL 2 capable for actuated valve when it is Type A
Level Device
32 SIL Certification IEC 61508
Std.
33 Third Party TUV/Exida
Certification
ACCESSORIES
34 Dust Excluder N.A.
35 Quick Exhaust N.A.
Valve
36 Fire Safe Box N.A.
37 Volume/ Buffer N.A.
Tanks
38 Port Protector N.A.
39 Pilot Valve Vendor to specify
40 Make & Model Vendor to specify
41 Weight in kgs Vendor to specify
PROCESS DATA
42 Design Pressure As per #150
43 Design 65 deg. Centigrade
temperature
44 Fail Action Fail to Close
45 Valve Torque+25% Vendor to specify
safety margin
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Rotation
18 Cooling Method Air
19 Starter Integral with motor
20 Reduction Integral with actuator
Gearing
21 Local /Remote Required
Switch
22 Local On/Off Required
Controls
23 Hand wheel for Required
Manual
Operation
24 Open/Close Required
Limit Switches
25 Local position Required
indicators/LEDs
26 Cable Entries M12/M25- for control, min. 2nos, M25/M40
for power
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Air eliminator shall be of horizontal / vertical cylindrical mild steel dished end
tank construction with internal baffles and float operated air release valve along
with supporting steel frame work and anchor bolts. The tank shall have large
cross-sectional area to slow the flow of liquid. The volume of the tank shall be at
least 10% of the flow rate in LPM. The units shall conform to the following
specifications.
Material of Construction
Fabricated Body and baffles : Carbon Steel SA 516 Gr 70/ IS 2002
Gr. 2
Flanges : ANSI B16.5, class 150, A 105, RF
Pipes : ASTM A 106, Gr. B, SCH-40
Supporting frame : MS IS 2062, Gr. B 99
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Material
Spring : Cd Plated CS
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GENERAL
Design, engineering, supply, laying of Cables suitable for trays, trenches, ducts
and conduits and for underground buried installation with uncontrollable backfill
and possibility of flooding by water & chemicals. Spare core in the existing cable
& JBs may be used to the extent possible if suiting the requirement. Additional
Cables that are required for the newly installed equipment shall be supplied
under the cabling item.
Power Cable shall be heavy duty 1100 V grade & Control cables shall be heavy
duty be 660 V grade, Multi stranded copper conductor. PVC insulated, PVC inner
extruded sheathed, GI wire / Strip armored and FRLS PVC outer sheathed
confirming to IS 1554. The Oxygen Index shall be 29 at 27 +/-2 Deg C. In addition
suitable chemicals shall be added into the PVC compound of the outer sheath to
protect the Cable against rodent & termite attack.
All cables covered in this specification shall be Flame Retardant Low Smoke
(FRLS) unless specified otherwise.. The outer sheath of PVC shall possess flame
propagation properties meeting requirement as per IS 10810 (Part -62) category
AF
The overall diameter of the cables shall be strictly as per the values declared by
the manufacturer in the technical information subject to a maximum tolerance of
+/- 2 mm upto overall diameter of 60 mm & +/- 3 mm for beyond 60 mm.
PVC/ Rubber end caps shall be supplied free of cost for each drum. In addition,
ends of cables shall be properly sealed with caps to avoid ingress of water during
transportation & storage.
The scope of Cabling shall include supply, laying ferruling, end termination, loop
checking & commissioning for all the equipments included in this Terminal
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All analog, digital & other signal cables from field to control room.
required
Communication cable between MCC room and Control room for data
Automation equipment.
The Cable shall be laid underground as per the specification & approved drawing
wherever possible & shall be laid on the perforated Cable tray with cover
whenever laid above ground.
Power Cable shall be laid in separate trench and Signal & communication
Cabling shall be laid in different trench. The same may be laid in common trench
provided physical barrier in the form of bricks are provided in such a way that
both are laid min 300 mm apart.
Cable Route marker shall be provided at each 20 m c/c distance & at the turning
whichever is less
Vendor shall submit Cable layout along with the schedule for approval to
HPCL/Project Management Consultant. The Vendor shall also submit cross-
sectional drawing of Cable Trench for approval before proceeding with Cable
trench
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No of Twists/metre : Min 12 to 20
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Laying of the cables underground shall be in trenches of min. 1 mtr. depth in all
types of soil both hard & soft soil including dewatering, if required. Big boulders,
sharp edges of the steel sections, vegetarian, growth roots etc. if encountered
shall be removed completely. Only soft earth excavated shall be kept for refilling.
Such earth shall be approved by the Engineering-in-charge. Excavated trench
shall be in true straight line as far as possible and bends if necessary shall be
provided. Such bends shall be gradual and not sharp in nature, the excavated
trench shall be approved by the Engineer-in-charge before laying cables In case,
during excavation hard rock is encountered which in the opinion of HPCL EIC/
Consultant cannot be excavated further, then additional sand bedding of 150
mm shall be provided over & above the 150 mm specified for the bedding. The
decision of HPCL/ Consultant is final & binding in this regard. Rate of cable
laying shall include excavation, supply and laying of two layers ( 150 mm thick
each, below and above) of river sand conforming to IS 383 and a layer of good
quality bricks of compressive strength min. 35 Kg/Sq cm. on top of the second
layer of sand & backfilling with good quality excavated earth. Rate shall also
include cutting/excavation of RCC wherever encountered & construction of RCC
culvert/ cable alley in RCC 1:1.5:3 with reinforcement as per design requirement.
All care shall be taken to ensure that no underground utilities like cables,
pipelines etc. gets damaged. However, in case any underground utility like
cables/pipes are damaged, the same shall be repaired/ replaced by the Vendor
immediately at no extra cost. Rate to include backfilling of the excavated earth &
carting away surplus earth within the depot premise as directed by HPCL EIC/
Depot Manager.
Before cutting the cables exact length as per the site conditions shall be
measured and recorded. Cut ends of the cable shall be wound by insulating tape
to protect them from rain water etc. Cable ends shall not be kept open for long.
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Power Cable shall be laid in separate trench and Signal & communication
Cabling shall be laid in different trench. The same may be laid in common trench
provided physical barrier in the form of bricks are provided in such a way that
both are laid min 300 mm apart.
All the cables inside tank farm area shall be laid through class B GI pipes buried
underground not less than 1000mm deep. 25mm dia. pipe to be used for one
cable & 50mm dia. pipe to be used for two cables. Power & Signal/
communication/Control cables shall be laid thru‘ separate GI pipes.
Wherever the cables have to cross the asphalt roads, the rate quoted shall
include cutting of the asphalt and WBM roads including soling and necessary
excavation to the required depth and back filling the trench with river sand and
restoring the asphalt / WBM roads to its original condition including compacting
and rolling the surface.
Road crossing shall be done through the Hume pipe. The existing Hume pipes
may be used in case sufficient space is available for laying the cables. Supply &
laying of the NP2 Hume pipes, if required, shall be in the scope of the Vendor.
Wherever the cables comes aboveground, a suitable size GI sleeve with bend
shall be used. Such pipe shall be laid 150mm below ground level and the
projecting bend shall raise to 500mm above ground level along the
steel/concrete/brick columns. The sleeve shall be neatly clamped by MS clamps
of adequate size and wooden bushes. Necessary precautions shall be taken to
make the opening water tight by wooden bushes.
Whenever, the Cable is laid above ground, it shall be laid on the perforated cable
tray with cover. The cable shall be tied on the GI Cable tray with GI Clamps. No
PVC ties or MS wire shall be used for tying the Cable on the GI Cable tray. The
Cable shall be laid on the tray with min. D spacing (D being the diameter of the
thicker Cable). Bunching of Cables or laying Cable on top of each other is not
permitted.
Separate Cable tray shall be used for laying Power & Signal/ communication/
Control Cables
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The perforated GI Cable tray shall be supported at regular interval. The existing
structural support at Gantry, Tanks may be used for supporting the Cable tray. In
case additional supports are required the same shall be supplied & erected by
the Vendor & shall be included in the cost for cable laying.
Cables shall be brought inside the control room through the trench. All the cables
shall be brought inside the control room through various sizes of GI pipes . These
GI pipes shall be encased in brick structure which shall be provided by vendor on
the entry side of the trench. GI pipes supply and fixing is in vendor scope. The
mixing of power , signal or communication cables inside GI pipes shall not be
allowed. The cables which can cause interference of any type shall be separated
apart by min 300 mm and shall enter cable trench inside control room by
separate GI pipes. Once all the cables are laid through GI pipes, both ends of GI
pipe shall be sealed by cable sealant compound so as to prevent entry of any
creeping creatures, water inside control room. Selection of pipes and bunching
of cables shall be done in such a way that it shall be possible to replace the cable
, if required in future date. The cable trench shall be sealed perfectly once all the
cables are laid so that the ingress of water, dampness or any creature is totally
restricted.
HPCL shall provide cable trench in the control room. The cable trench (length,
width height), flooring modification to suit the erection of panels and consoles
will be in TAS vendor scope. TAS vendor needs to supply and install cable trays
inside the control room Cable trench for taking power and signal cables.
Necessary loops of min 5 mtr. shall be provided at both ends of the main cables.
Cable shall be laid without any joints.
Cable route markers at 20 m/c and at all the bends/ turnings shall be provided.
Bending radius of cables shall not be less than 12 times O.D. of cable.
All cores of cable shall be identified at both ends by means of PVC ferrule.
Line drivers & all other accessories required in this regard are included in the
scope of work of the vendor.
Cable laying shall also include termination of Cables at both the ends. Cable leads
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Rate shall also include megger test by 1000V megger for establishing the
healthiness of cable in the drum before removing the same, unwinding and
straightening the cable & after laying of cables.
The cables shall be tested and inspected at the manufacturer‘s works. All the
materials employed in the manufacture of the cable shall be subjected, both
before and after manufacture, to examination, testing and approval by Third
Party Inspection. Manufacturer shall furnish all necessary information concerning
the supply to HPCL/ Consultant. The Third Party inspector shall have free access
to the manufacturer‘s works for the purpose of inspecting the process of
manufacture in all its stages and he will have the power to reject any material,
which appears to him to be of unsuitable description or of unsatisfactory quality.
After completion of manufacture of cables and prior to dispatch, the cables shall
be subjected to type, routine, acceptance and special tests as detailed below.
HPCL/Consultant reserves the right to witness all tests with sufficient advance
notice from vendor. The test reports for all cables shall be got approved from the
Third Party Inspection agency before dispatch of the cables.
All routine tests, acceptance tests, type tests and additional type tests for
improved fire performance shall be carried out as listed in IS:1554 (Part I).
The test requirements for PVC insulation and sheath of cables shall be as per
latest revision of IS:5831.
Test for Resistance to Ultra Violet Radiation:- This test shall be carried out as
per DIN 53387 or ASTM-G-53 on outer sheath. The retention value of tensile
strength and ultimate elongation after the test shall be minimum 60% of
tensile strength and ultimate elongation before the test. Test certificates with
respect to this test (not older than one year) from recognized testing
laboratory to be furnished for review by Third Party Inspection agency before
dispatch clearance of cables. In case test certificates are not available, test is
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Acceptance tests as per IS-1554 (Part 1) and the following special tests to be
performed on the cables as per sampling plan. These tests are required to be
witnessed by Third Party Inspection Agency before dispatch of cables.
c. Oxygen Index Test:- The test shall be carried out as per ASTM D2863 or
applicable Indian Standard Specifications. Sampling to be done for every
offered lot/size as per sampling plan.
d. Flammability Test:- The test shall be carried out on finished cable as per
IS-10810 (Part 61 & 62). Sampling for these tests is to be done randomly
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once for each order provided outer sheath remains same. The acceptance
criteria for tests conducted shall be as under:-
e. Test for rodent and termite repulsion property. The vendors shall furnish
the test details to analyze the property by chemical method. Sampling to
be done for every offered lot / size as per sampling plan.
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Materials
mm thick.
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Material : GI
Length : 3M
Thickness : 2 mm
NOTE : Payment of Junction Box, Cable Tray Cable Glands shall not be done
separately & will be part of Cabling
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Instrument Valves
The impulse line isolation and drain valves shall be forged gate valves with
inside screwed bonnets.
For SS valves body and trim material shall be ASTM A182 Gr. F316.
For CS valves body material shall be ASTM A 105-gr. and trim material
shall be ASTM A182 Gr.F316.
Impulse pipes
Impulse pipe shall be either Sch. 80 seamless carbon steel pipes as per ASTM A
106 gr. with socket weld fittings or shall be fully annealed, seamless and cold
drawn 316SS tube as per ASTM A 269 with compression fittings. Tube wall
thickness shall be 0.065 unless otherwise specified.
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The process tapping shall be min. 1/2‖ in dia unless otherwise specified. Root
valves shall be min. 1/2‖ stainless steel ball or gate valves, suitable to maximum
pressure and temperature. Pressure testing of piping shall be done after
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GENERAL
The product pumps for which the VFD/ Soft Starters/DOL feeders etc are
covered in the specifications are under various stages of tendering and
placement of order. As such the ratings indicated are tentative and may be
subject to changes depending upon the mechanical equipments supplier.
Besides HPCL reserves the right to vary the ratings, quantities while placing the
order on the successful bidder or during execution of the work. For all such
changes the prices quoted for the components by the bidder and agreed by the
HPCL shall be applicable. However the changes will be limited to +/- 10% of the
rating given.
Detail specification
2. VFD/Soft Starters for Tank Truck loadings pumps (VFD: 1 No, Soft Starter: 7 Nos)
a) No. of Centrifugal Pumps: 7 (Seven)
b) Power : 75 kW (Motor Rating)
c) Discharge Rate : 4800 lpm
d) Product to be pumped : HSD
3. VFD/Soft Starters for Tank Truck loadings pumps (VFD: 1 No, Soft Starter: 3 Nos)
a) No. of Centrifugal Pumps: 3 (Three)
b) Power : 37 kW (Motor Rating)
c) Discharge Rate : 2400 LPM
d) Product to be pumped : SKO
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For each product group of drives, there shall be preferable two sets of
panels adjacent to each other as follow:
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product group of pumps), energy meter and energy data acquisition and
transmission system, programming interface, displays, lamps, MCCBs/
switches, auxiliary contractors, MCBs etc. I/Os from following interlocking
panels shall also be wired to the above PLC. Central Interface Unit (CIU)
and RS-485 to Ethernet converter with built-in power supply unit as may
be required for energy meter data acquisition and transmission shall be
located in this panel. This panel door shall have provision to connect PLC
programming terminal for programming and monitoring as only one
programming terminal shall be supplied.
Interlocking control panel (may have number of vertical panels as per
requirement) shall consist of Soft Starters (With control and programming
unit on panel door with associated switch gear (MCCB,CTs, Contactors
(VK-1,2 etc and SK-1,2 etc) for VFD connection and Soft Starter
connection to each motor of the groups of pumps, thermistor relay units
for motor (30 KW and above) for over temperature monitor and
protection, one Digital Speed indicator for VFD driven pump, energy
meter and energy data acquisition and transmission system for each soft
starter, displays, lamps, switches, auxiliary contactors, MCBs etc.
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command from TAS PLC in desired format and also transmit the energy
consumption data and other information about the status/ operation of
the drives and starters to TAS PLC. The communication format for the
required exchange of information / data for desired controls, reporting
and monitoring system of the bidder shall be submitted by him during
detailing.
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4.1 The main objective of the control system is to provide facility to start any
pump of the group with one VFD and run the same on VFD to control the
required set pressure in the line by switching in other pumps (one by one) on
their respective soft starters. At any time during control if two or more
pumps of a group are to be operating then it shall be assured that soft
starter driven pumps must run at rated load and VFD driven pump can be
lightly loaded. Both VFD and soft starters work for energy saving while
controlling/ maintaining the set header pressure.
Two modes of control are envisaged for operation and maintenance of the
pumps. The mode of operation – LOCAL OR REMOTE – is selected at local
control station of the respective pumps.
Remote mode of the operation is the normal mode of the operation and
control for group of the pumps. All the pumps are selected in REMOTE
mode from their LCS. The operation shall be carried out from existing TAS
PLC.
For group the set point, start command and stop command will be provided
by TAS PLC to Group PLC on ETHERNET and TAS PLC will monitor drives
and their energy consumption and further generate necessary reports
including energy consumption reports –pump wise and product group wise.
The group PLC will provide the set point to the group VFD drive and
provide start command when the system is ready and healthy.
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A PID loop is envisaged in each PLC to control the pumps to maintain the
header pressure for proper loading. First one of the selected pumps of the
group is started and allowed to run. The group PLC shall monitor the VFD
run pump speed and as soon as the speed rises above the set speed a
command is generated by PLC to start the next pump with its soft starter
and at the same time control speed of the VFD run pump speed. Even after
the start of the second pump the VFD run pump increases then the
command is given to third pump. Under all the condition the VFD run pump
is controlled and monitored continuously. All the pump control work
independently to conserve/ save on energy consumption. From VFD there
shall be continuous feedback of VFD driven pump speed for the above
purpose. 4 – 20mA feedback shall also be envisaged to indicate the speed
of the VFD controlled pump on the digital indicator with motor ID and
speed in RPM. However there shall be provision to alternatively execute the
PID in VFD drive in case of emergency and bidder shall include all hardware/
software also.
There shall be provision to record the date, time and the number of times
the system is run on soft starter.
All the addressable digital energy meters and group PLCs shall be
connected on 10/100 MBPS Ethernet bus with existing TAS PLC for
integrated operation.
All meters shall have digital indications but the energy meter (as per IEC-
1248) shall have RS-485 port to communicate energy consumption and
other data to central interface unit (CIU). The CIU shall have digital display
and built-in soft keys for parameter setting/ selection and monitor the data
from CIU shall be taken to TAS PLC through convertor (RS-485 to Ethernet
10/100 MBPS ). Energy transducer shall have accuracy as per IEC 687/1036.
The CIU at a location shall have connections to energy indicator cum
transducer installed in motor soft starter circuit and VFD circuits so that
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motor data collected by transducer are read by CIU periodically and displays
the same on its indicator and transmit data (real time
KVA/KW/PF/AMP/VOLT and KWh for selected time interval) to TAS PLC with
motor ID.
VFD unit shall mainly consist of a three phase twelve pulse rectifier
bridge with necessary three winding transformer, D.C link with
reactor and capacitors, inverter bridge, control system
(microprocessor based). The VFD unit shall have cooling fan and
this shall be controlled based on heat sink temperature.
The VFD shall be pulse width modulation (PWM) type with flux
vector control for closed loop speed control with pump header
pressure feedback for high accuracy and good dynamic
performance. Pressure shall be maintained at set value by speed
control of the motor operating on VFD and switching motors
operated on soft starters.
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minimum. For the inverter unit IGBT‘s shall be used. The outgoing
of the unit shall include reactor, contactor and thermal over load
relay with (1NO + 1NC) contacts. The unit shall also be equipped
with thermister relay also for motor ratings 30 KW and above. But
these contactors, thermistor relay & over load relay shall be
located in interlocking panel.
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1. START PB
2. STOP PB
3. Fault reset PB
4. LED indication lamp for power on (R,Y,B), Drive ready
drive on, drive fault, off, overload trip etc.
Abnormal conditions shall initiate alarm and shut down drive based on the
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Instruments
o Digital speed indicator.
o Digital Energy meter (accuracy class 0.5 0r better)
o All meters shall have digital indications but the energy
meter (as per IEC-1248) shall have RS-485 port to
communicate energy consumption and other data to
central interface unit (CIU).
DESIGN CRITERIA
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phase
Output frequency : 0-60 Hz, 3 phase as required.
Resolution : 0.01 Hz
Inputs and outputs : Analog I/Os: 3 on board inputs
(Minimum) & 2 programmable outputs.
Digital I/Os: 9 inputs & 4
programmable outputs.
Communication for which : RS-485, Ethernet (10 or100
Hardware provided in MBPS )
Equipment
TESTS
Factory test:
Insulation resistance
Light load test
Checking of auxiliary devices
Control system test.
Efficiency test.
Site Test:
Insulation resistance
Light load test
Rated current test
Checking of auxiliary devices
Control system test.
Efficiency test.
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SPARES
One module of each type (viz. CPU card, Ethernet card, memory card,
Ethernet switch, Power supply unit/card, FO connectors, Digital Input and
output card, Analog Input and output card, Signal isolator etc) shall be
supplied to enhance the system functional requirement for future.
20% spare slot for installing I/O modules of each type in future.
The processor and memory shall have spare capacity to execute logic, PID
function for additional 20% I/Os spares and I/Os installed in spare slots.
Whenever relays are used to interface process inputs/outputs with PLC
10% additional relays shall be provided.
SELF DIAGNOSTICS
The system shall have an extensive set of self diagnostic routines which
shall be able to identify the system failures at least upto module level
including redundant components and power supplies.
Al the local level, failure of a module in any sub system shall be identified
by a individual LED.
SOFT STARTERS
Selection Criteria
Soft starter shall be provided for the pumps. Design and selection of soft
starters shall be done taking into consideration the fact that the soft
starters are to operate continuously (without bypass contactor) and with
all reasonable precautions and provisions for the safety of operating and
maintenance personnel. The soft starter rating shall be at least equal to
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motor KW rating at 50°C for continuous operation and other specified site
conditions.
For the motor, the incoming AC voltage to soft starter shall be 415V, 3
phase, and 50 Hz neutral earthed system.
All the busbar works of soft starter system shall be of copper only.
The soft starters have digital control using microprocessor based digital
regulation & control. This shall be provided with six thyristors in power
circuit and shall have all controls suitable for energy saving also.
Individual soft starter module for each motor shall be with MCCB with
built-in releases, 3 core CTs for connection to energy meter, Energy Meter,
surge suppressor, soft starter, Contactors and Overload relay. The digital
regulation and control system shall be compatible for operation from PLC
provided in VFD panel.
5Salient Features
1) The other protective features for the Soft starter shall include
following:
Harmonic filters
2) Suitable for soft start I current limit I full voltage mode of operation.
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The regulation equipment shall be able to carry out all the control
functions including following important features.
Ventilation failure
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All meters shall have digital indications but the energy meter (as per
IEC-1 248) shall have RS-485 port to communicate energy
consumption and other data to Central Interface Unit (CIU).
• Main power ON
• Control supply ON
• Phase loss
• Microprocessor healthy
• System faulty
Motor Faults
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• Over current
• Over voltage
• Earth fault
• Readiness
• Fault
• Run
Control Transformers
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The transformer shall be double wound, dry type with class E insulating
materials.
The control supply for the motor feeders shall be fed through suitable
rated MCBs in the modules.
The control bus of the PANEL shall be electrolytic grade copper only and
will be designed to carry the transformer rated secondary current as well
as withstand the available short circuit level.
The MCCB rating shall be as per SLD. Adjustable inverse time overload
and I or instantaneous magnetic releases shall be provided suitably.
Operating handle, door interlock and padlocking at ON/OFF position shall
be provided. Symmetrical breaking capacity shall not be less than the
system short circuit level. At least 1 NO and 1 NC auxiliary contacts shall
be provided. These MCCBs shall be provided only for power supply
feeders in PANEL. MCCBs to be provided for VFD and soft starter circuits
shall be as per details given under Technical Specification.
Switches
The switches shall have quick make, quick break, fault make, load break
mechanism operated by an external insulated and earthed handle
complete with ON/OFF position indicator plates.
The switches shall be
a) AC 23 rated (motor duty) conforming to IS 4064-1978 capable of
interrupting minimum six times the rated current at 0.3 p.f of the switch
for switch ratings upto and including 250 amps.
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c) In case heavy duty switches are offered for (a), then AC-23 rating for the
switch shall be indicated along with test certificate.
The load break switch shall be provided with a through door operating
mechanism with visible blades or a visible means of determining the
disconnected position (when the door is opened) and mechanically
interlocked with the door so that switch must be in off-position before the
door can be opened. Provision shall also be there to defeat the door
interlock.
Bolted type removable copper links of adequate size shall be provided for
neutral in all incomer feeders and outgoing feeders with TPN fuse switch I
switch fuse units.
Solid links shall be used for connections between switches and fuses.
Fuses
All fuses shall be HRC link type (knife edge but not bolted type)
conforming to IS: 9224-1979. The HRC fuses shall be current limiting, non-
deteriorating type having breaking capacity of not less than 50 kA.
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Fuse holders shall be selected based on the highest fuse rating for the
given load break switch and specified lower size fuses shall be fitted by
means of suitable links if required.
All fuses shall be provided with distinct type operating indicators, to show
whether they have operated or not.
3 sets of fuse pullers required for inserting and removing HRC fuses shall
be supplied for each panel.
Current Vs. time and 12t characteristics of all fuses shall be furnished along
with the tender.
Contactors
Current transformer
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11, Ill and IV. The minimum burden shall be 15 A CT shall be suitable for
415 V +/- 10 %.
CTs for restricted earth fault protection shall conform to Class 'PS',
Part IV of IS-2705. All CTS shall withstand without injury dynamic stability
and thermal stability currents specified for PANEL.
The current transformer' ratios specified are provisional and are subject to
alteration and confirmation later at the time of approval of manufacturer's
drawings.
Indicating lamps
Control switches
Circuit breaker control switches, when provided, shall be of pistol grip,
spring return to neutral type. They shall be arranged to close the breaker
by being turned clock-wise and to trip it being turned antilock wise. The
trip, neutral and close positions shall be clearly located and the switch
cannot be operated inadvertently. It shall be mechanically inter locked to
trim before close. Lost motion contacts shall be provided in these switches.
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Undrilled G.l gland plates and compression type brass cable glands shall
be provided for termination of cables. The gland plates shall have gaskets
so that the enclosure conforms to IP-54. . Provision for terminating 1/2
core on to earth bus and neutral bus shall be made. All lugs shall be tined
copper lugs only. All lugs and glands for all power and control cables shall
be supplied with the equipment.
All motors for Pumps shall have local control station (LCS) mounted near
driven mechanism, which shall be flameproof located at hazardous area.
These shall be supplied by the Owner and shall be interlocked / connected
to the bidder's equipment for operation of the system.
CONSTRUCTIONAL DETAILS
Single/Double front design, Non-draw out, free standing,
compartmentalized floor mounting type suitable for both front
and rear access. The panel shall be extendable on both sides at
site.
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Neoprene gaskets shall be used for cable alley doors, bus bar
chamber covers to ensure tightness and making it dust proof.
Cutouts in the module door shall have neoprene gaskets ensuring
dust tightness.
All switches, push buttons etc. shall be capable of operating from
the front. Each feeder module shall have door interlock, defeat
interlock and padlocking facility.
The panels shall be sheet steel enclosed of minimum thickness 2
mm dust and vermin proof, free-standing, floor mounted type
having Panel illumination lamps, space heaters and sockets for
soldering etc. Base channel of height 75 mm shall be provided.
Max. height of operating knobs of any device or indicating meters
shall not exceed 1800 mm from floor of room. Minimum height
shall not be less than 450 mm.
Anti-condensation heaters-of suitable rating with thermostat
cutoff shall be provided in each PANEL.
The control blocks shall be plug-in type with required/necessary
test sockets. The layout of components shall be such. Designed
that the testing operation & maintenance is convenient. The
panels shall have enclosure with class of protection conforming to
IP-54.
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Control circuit wiring shall be with 1100 V grade multi strand, PVC
insulated copper cable of 1.5 sq. mm.
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All holes or tubes for wiring runs shall be bushed and shall have
room for reasonable additions.
All power cable terminal blocks / boards shall be stud and nut
type with phase barriers.
Doors & side panels shall be fabricated from cold rolled steel
sheet of minimum 1.6mm thickness. Load bearing parts shall be
minimum 2 mm thick cold rolled sheet steel. The cable gland plate
shall be 3.0 mm thick.
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Panels shall be equipped with the front and rear access doors.
Doors shall be equipped with lockable handles and concealed
hinges with pull pins for easy door removal.
CABLE TERMINATIONS
Cable terminating facilities and terminals shall be suitable for the
specified cable type and conductor size. Contractor shall take
consideration and provision on the equipment design for the use
of cable with aluminum conductors.
Terminal blocks shall be arranged and positioned for easy access
for carrying out external cable termination, testing, inspection and
maintenance. There shall be clear space allowed between the
terminal block and the cable entry for the spreading and
termination of external conductors.
Terminal blocks shall be mounted in a single tier arrangement.
The panel wiring shall be on one side of the terminal block only.
All terminal blocks shall be shrouded or provided with transparent
covers.
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LABELS
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Each panel board shall have fitted a circuit directory within-a clear
protective cover located on the inside of the outgoing circuit
compartment door.
DRAWINGS
EARTHING
A continuous earth bus shall be provided for the
VFD/PLC/SOFTSTARTER PANEL at the bottom with an earthing
bolt at each end.
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All circuit grounds, shields and drain wires of control cables shall
be connected to the system ground bus which shall be electrically
isolated from AC mains earthing bus. This bus shall be typically of
50 mm wide and 6 mm thick of copper.
PAINTING
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All applicable Indian and IEC codes, regulations and standards shall
govern the work. In the event of the requirements of the specification
exceed the requirements of the corresponding codes, regulations or
standards, the specification shall govern. The applicable standards shall
include standards listed below:
1. IS 2705 Part I 1992 to Part IV: Current transformers,
general requirements.
2. IS 12021 –1937: Control Transformers
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13. IS 1554 Part 1 1988 & Part 2 1990: PVC insulated (heavy-duty)
electric cables.
25. IS 4047: Heavy-duty air break switches and composite units of air
break switches and fuses for voltages not exceeding 1000 V.
26. IS 4064: Air break switches, Air break disconnection, Air break
switch disconnectors and fuse units for voltages not exceeding
1000 V AC or 1200 V DC.
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TESTING
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Manual call points are manually operated devices to initiate an alarm signal and
operate the fire pump. The manual call point & Emergency Shut Down shall be
located at the Gantry. The manual call point shall be painted with fire red as per
IS-5-1994, sheath 536. & ESD hall be grey in color. The manual call point & the
Emergency Shut Down shall be wired to PLC.
Manual call point & ESD shall consist of MS enclosure with a safety glass front.
The front glass keeps the switch in pressed condition. One spare front glass shall
be supplied spare with the MCP & ESD
Manual call point & ESD shall have CMRI certified flame proof enclosure.
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Resolution : +/- 1 mm
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application
Ullage (+/-2mm)
Interface Detector ( +/-2mm)
Approval : CCOE
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EARTHING SYSTEM
Vendor shall furnish recommendations for the grounding (Earthing) of the system
supplied by him. All the equipments installed in gantry & in the field need to be
earth by flexible 4 sqmm (min) copper wire of green colour of approved make.
The wire from instruments shall be taken inside the existing channel section of
gantry or thru cable tray and hooked up to earthing bus bar on each point. Two
GI Strip shall be taken out from each earthing bus bar which shall be connected
to the existing gantry structure earth pits.
Bus bar MOC shall be of copper with zinc coating and provided with two
insulators . Each bus bar back shall have minimum two insulators. The bus bar of
each point shall be fixed so that the cables are secured and are not prone to
snapping. Mixing of electrical and electronic earthing shall not be acceptable.
No bolting is allowed on the GI Strip. The joints shall be welded and protected
from rusting by treating with Barium chromate. Such welded surfaces shall be
treated with Bitumen paint. TFMS earthing shall be as per OEM recommendations
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3” / 1 ½” Sleeved Plug valves shall be non lubricated, PTFE sleeved with high pressure
sealing areas circumferentially around internal body bore tap & bottom and 360 degree
port defining lips and adjacent relief areas for sleeve expansion with 2 degree taper
plug & three point adjustment
Plug valve should be of short pattern , teflon sleeved type, wrench operated plug
valves. Valves should be of ANSI 150 lbs rating and should confirm to BS 5353.
Sleeved Plug Valves should provide “Bubble Tight Shut Off”. These valves should be
maintenance free and quick shut off (quarter turn) type. There should not have any
metal to metal contact in a Sleeved Plug Valve to avoid sticking problems. Sleeved plug
valves should have downward tapered plug to avoid any adjustment to maintain sealing
integrity.
DESIGN FEATURE
ENDS SHOULD HAVE RAISED FLANGES CONFORMING TO ASA 150 CLASS WITH HOLES
DRILLED AS PER ANSI-B-16.5
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All Valves (100 %) shall be tested by manufacturer's quality control officials, before
offering the valves for inspection.
All test certificates for material conformance and pressure test shall be verified and
endorsed by the third party inspection agency.
The following tests will be witnessed by the third party inspection agency
b) High pressure closure test -10 % Valves selected at random in one batch. (Minimum
of TWO Valves to be tested)
c) Low pressure closure test on 10% valves selected at random in one batch. (Minimum
of TWO Valves to be tested)
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DIMENSIONAL DETAILS :
-------------------------------------------------------------------------------------
ITEM SIZE (MM) THICKNESS
NO. (DIA) (MM)
----------------------------------------------------------------------------------------
A. SLIP ON FLANGE
-----------------------------------------------------------------------------------------
1. 600 48.0
2. 500 43.0
3. 450 39.7
4. 400 36.6
5. 350 35.1
6. 300 31.8
7. 250 30.2
8. 200 28.6
9. 150 25.4
10. 100 23.9
11. 80 23.9
12. 50 19.1
B. BLIND FLANGE
-----------------------------------------------------------------------
1. 600 48.0
2. 500 43.0
3. 450 39.7
4. 400 36.6
5. 350 35.1
6. 300 31.8
7. 250 30.2
8. 200 28.6
9. 150 25.4
10. 100 23.9
11. 80 23.9
12. 50 19.1
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The third party inspection shall be carried out by the approved agency:
a) Visual Inspection
b) Dimension check
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Third party inspection shall be carried out by one of the following agencies only :
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1. CHEMICAL REQUIREMENT :
The supplier shall conduct the above tests in an approved Chemical Laboratory, and
shall get the test results endorsed on the respective test reports by the third party
inspection agency.
The third party inspection agency shall ensure correlation between the
manufacturer's report of heat analysis with the material and the finished pipes.
2. PHYSICAL TESTS :
All Physical Tests, mentioned above, shall be done with samples from each lot. Lot sizes
for Chemical analyses as well as other Physical tests shall be as specified in relevant
IS code.
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TERMINAL AUTOMATION PROJECT
Supply, fabrication, erection, painting of all structural steel works required for the
automation job shall be in the scope of the Vendor. Separate payment shall be
made only for the structural steel used for extension of Gantry platform as per
the relevant line item of the ―Schedule of quantity‖.
All pipeline job required for mounting the Automation equipments & instruments
like Electronic Metering, Strainer cum Air Eliminator, DVC, Bulk Air Eliminator,
Orifice plates, Pressure Transmitters, RTD etc shall be in the scope of the Vendor.
In case it is not possible to modify the existing pipeline or the existing pipeline
length becomes inadequate to mount the Automation equipments &
instruments, new pipeline may be laid by the Vendor. Inside the Gantry, laying of
new pipeline is limited to downstream of existing 3‖ & 1 ½‖ tapping till loading
arm. The existing pipeline & isolation valves may be re-used to the extent
possible & any additional pipeline, valves, flanges, nut bolts, gaskets etc. required
shall be in the scope of vendor.
For payment of structural steel used for Gantry extension, the weight shall be
calculated based on section given in the standard steel tables and physical
verification whichever is less. The net fabricated dimensions edge to edge shall
be taken into account. The measurement shall exclude any allowance for wastage,
weld metal, etc. All other structural steel required shall be included in the
respective items & will not be paid separately.
No separate payment shall be made for pipeline work & it shall be included in
the cost of respective items.
Vendor shall arrange temporary power connection from the local Electric Supply
Authority by his own effort and cost. Alternatively, Vendor shall have to carry out
the work with his own DG sets at no extra cost. Vendor shall arrange 3 phase
rectifier & welding machine, approved brand of electrodes and skilled welders. All
welders need to be approved by HPCL/PMC before starting of the job.
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TERMINAL AUTOMATION PROJECT
indents, material lists, site bolt lists and dispatch documents for the steel
structures etc.
Erection (including tools, tackles and any staging, or false work, required for
erection) handling, transport and rectification of damaged structures, fixing,
aligning, leveling, bolting and welding etc. of all steel structures complete in all
respects. Vendor shall take necessary safety precautions for carrying out HOT
WORK in the premises after obtaining HOT WORK permit.
The steel structures shall include essentially (but not necessarily limited to) the
following:
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The contractor is required to prepare the drawings for the complete piping work
with its isometric view, etc., to calculate the actual requirement of various items /
fittings like bends, flanges, etc. The piping layout must show the expansion loops
as per the requirement. The complete set of drawings shall be submitted for
approval, before commencement of the work. No fabrication will start without
the approval of HPCL. The construction drawings shall include:
Material to be used.
Tolerances
The drawings shall be prepared on computer and the as built drawings shall be
submitted in a floppy after completion of work. All drawings are to be prepared
on Auto-CAD (on PC).
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Method of construction
The mode of construction shall be either welded and / or bolted to suit the
following but limiting the site work to minimum possible
Process requirements
Transportation
structures .
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All structural steel plates will conform to IS 2062 – 1992, Fe 410W, Grade A, for
thickness up to and including 20 mm. All structural steel rolled sections will
conform to IS 2062 Fe 410W Grade A
Electrodes for mild steel will conform to IS 814 – 1991. The electrodes will be
chosen according to the welding procedure to be adopted, and the quality of
metal to be welded. The strength of the weld metal will not be less than that of
the parent metal.
Hexagonal head bolts will generally conform to the property class 4.6 as specified
in IS 1367 (Part 3) – 1991 unless otherwise noted.
Bolts and nuts of property class 4.6 will conform to IS 1363 Part 3, 1984. Size of
permanent bolts will not be less than 16 mm
Fabrication
All welding shall be done by the Qualified Welder. The welder shall have
Welder Qualification Certificate or shall be qualified at Site as per IS 817.
Fabrication of all steel structures shall conform to the best practices and
relevant standards.
Welding shall be in accordance with the standard codes fulfilling the
requirements of electrodes and flux combination, current characteristics,
preheat and post weld heat treatments. Established practices shall be followed
to ensure that the weldment and the heat affected zone metal properties are
not inferior to the parent metal properties.
Elements shall be machined / finished as the case may be as per line and
levels in the shop and assembled suitable for transport / shipment.
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Bends, reducers, expanders, tees and end blinds provided shall be factory
made and forged irrespective of diameter of pipeline. Such fittings shall have
approximately the similar material composition as that of pipeline under
fabrication.
Inspection tests
Should any structure or part of a structure be found not to comply with any of
the drawings and specifications, it shall be rejected. No structure or part of
the structure once rejected shall be re-submitted for test except in case where
the corporation considers the defects as rectifiable.
Defects, which may appear during fabrication, shall be made good by the
contractor.
The suitability and capacity of all plants and equipments used for erection
shall be to the satisfaction of the engineer.
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Painting
General
All surfaces need to be manually cleaned with sandpaper /emery paper etc
before painting. Surfaces in direct bonded contact with concrete, stainless
steel or other corrosion resistant alloys, metals are not required to be painted,
unless specified, except for identification marks wherever relevant.
Color scheme of painting of structures shall take into account national and
international safety standards on accident prevention and shall also be subject
to HPCL/PMC‘s approval.
The primer painting shall consist of 2 coats of Zinc Phosphate red oxide
primer & the finish coat shall consist of 2 coats of black synthetic enamel
paint for structural steel/ 2 coats of Aluminum paint for product pipes & HPCL
approved colour banding
All paints shall be of approved quality.
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The approved makes for paints are Berger, Asian Paints, Jenson Nicholson,
Shalimar, ICI
Erection
The erection of structural steelwork shall be done in accordance with the
relevant standards and in the proper sequence.
The Vendor shall manufacture, erect and dismantle any false work, staging,
temporary supports, bracings etc. required for safe and accurate erection of
steel structures.
Bolts used for site erection shall be long enough so that the end of the bolt
protrudes or is at least flush with the edge of the outer face of the nut, when
the nut is fully tightened. Nuts shall be tightened to maximum limit to prevent
loosening. All Bolts shall be supplied with the correct length of shank and
thread considering the grip length of the elements in the joint to be fastened
together.
The number of washers on permanent bolts shall not be less than two, one for
the bolt and one for the nut.
All site welds shall be uniform and shall be free from any slags, cracks and
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blow holes.
During site assembly by welding, suitable jigs and fixtures must be used to
avoid distortion of members after welding.
Before erection of all pre-fabricated spool pieces, pipe fittings etc., shall be
cleaned inside and outside by suitable means. The cleaning process shall
include removal of foreign matter such as scale, sand, weld spatter, cutting
chips etc., by wire brushes, cleaning tools, etc., and blowing out with
compressed air and / or flushing out with water.
Pipe supports are designed to effectively sustain the weight and thermal
effects of the piping system and to prevent its vibrations. Location and design
of pipe supports will be as per the following table or as given by site engineer:
The above spacings are indicative and will be kept as per site requirements
169 | 2 3 8
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LIMITED
TERMINAL AUTOMATION PROJECT
All equipment, materials, consumables and services required for carrying out
the pressure testing of piping system shall be provided by the contractor at
his own cost.
Complete record of the Hydrostatic testing carried out on each section of the
pipeline.
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General
The testing and acceptance of the system shall be carried out based on the
mutually agreed procedures and criterion based on this specification and
Vendor‘s standard procedures.
Final acceptance of the System is divided broadly into the following stages :
Inspection & Testing at OEMs works by Vendor‘s appointed & HPCL approved
Third Party Inspection (TPI)agency
Trial Run
Stabilization Period
The System shall be accepted after successful completion of all the above stages.
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submitted, submit the report to HPCL both in Hard & Soft Copy and issue
dispatch clearance. HPCL reserves the right to be involved and satisfy itself at
each and every stage of inspection. HPCL shall be free to request specific test on
any equipment considered necessary by them although not listed in this
specification, the cost of performing all tests shall be borne by the Vendor.
The inspection and testing shall include but not be limited to raw materials,
components, Sub assemblies, prototypes, produced units, guaranteed
performance specifications etc. For factory inspection and testing, Vendor shall
arrange all that is required e.g. quality assurance personnel, space, test gear etc
for successfully carrying out the job by the HPCL and/or his representative at
Vendor‘s cost at the manufacturer's works.
Scope of inspection
Scope of Third Party inspection shall be as per the approved QAP unless
otherwise specified in this document. All inspection and testing shall be carried
out based on the following documents:
a) Approved QAP
b) Relevant standards
c) Purchase Order Specifications
d) Approved Data sheets
e) Approved drawings
SAT is excluded from the scope of TPI & shall be witnessed by HPCL
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TERMINAL AUTOMATION PROJECT
Third Party Inspection at OEM‘s factory is mandatory include, but not limited, to
the following items:
The inspection for the Metering Instruments & Accessories shall include PD
meters and accessories, set stop valves, and other associated field instruments
and accessories.
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The Vendor shall demonstrate the functionality of the system hardware and
software. No materials shall be transported to site until all required tests have
been successfully completed and the material / equipment have been certified
―ready for shipment― by TPI.
The Metering BAT shall be carried out for 10% of the Metering Units covering all
covering all combination of batch accuracy related equipments randomly picked
up by HPCL for the purpose of BAT.
Delay, if any, for verification and approval by third party inspection agency shall
be on account of vendor and HPCL shall not be responsible for the same.
Vendor may deploy more than one inspection agency for carrying out the above
inspections as per the requirement.
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Vendor shall include all incidental charges towards facilitating third party for
inspection like lodging, boarding, travelling etc and applicable taxes and duties
under respective items. No Separate payment shall be made towards TPI
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TERMINAL AUTOMATION PROJECT
Vendor shall deploy its 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 of interference with other concurrent construction and
commissioning activities.
Loop checking.
Field tests.
Test run.
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Test report
LOOP CHECKING:
i. Loop check shall be carried out by the vendor for checking the
interconnection, configuration and overall system functioning.
FIELD TESTING:
All the equipment shall be checked thoroughly after its receipt at site. The
tests as a minimum shall include:
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CALIBRATION OF EQUIPMENT:
Vendor shall make available all consumables, instruments, and equipment
necessary for testing, calibration, maintenance, etc. as required by the defined
scope of works .All instruments and equipment used for the above purpose shall
be of standard make with accuracy better than the accuracy expected from the
calibrated/tested instruments and certified by standard testing agencies. These
instruments and equipment shall be provided as & when required during testing
calibration, maintenance of instrument & equipments in commissioning, testing,
warranty & comprehensive AMC.
All equipments which need calibration either once or on regular periodic or non
periodic time interval shall be calibrated by OEM approved standard guidelines
and procedures. The document specific to project for calibration of the
equipments proposed shall be submitted along with the datasheets. Also the
methodology to verify the calibrated instruments shall form part of datasheets
which shall be submitted for approval. Datasheets of such equipments without
the calibration and verification document shall be not be considered in submitted
category.
Vendor shall conduct trial run of his system for a minimum period of 15 days
after the mechanical completion of job. These trial runs are conducted to verify
the satisfactory performance of the system. In case of major failure in the system
or non-achievement of consistent accuracy, the trial run shall be repeated for a
period of another 15 continuous days.
After trial run site acceptance test (SAT) will be conducted. The project is deemed
to be complete after the compliance of pending points of SAT.
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In case of non availability of Ethanol during trial run, the vendor shall
demonstrate the performance of additive system using MS/ HSD in lieu of
additive. In case of non availability of ethanol during commissioning, the vendor
shall demonstrate performance of ethanol dosing system using MS as an
alternate product. In both the above cases, the Corporation shall make available
the products required for trial run/ commissioning.
Quality control tests shall be carried out to ensure quality of all components and
modules in accordance with Vendor's quality controls and assurance procedure.
Vendor shall submit the QAP along with Data sheets of individual equipment.
QAP for site work shall be submitted min 30 days before the start of Site work.
All assemblies shall be aligned and adjusted and all test observations shall be
recorded as per manufacturer published set ups and testing methods.
Vendor shall notify in writing HPCL minimum 15 days in advance for SAT
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STABILIZATION PERIOD
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SCOPE :
Forged 90 deg.(1.5D) and 45 deg. bends and concentric reducers of SCH 40 thickness
with bevelled ends conforming to ANSI B 16.9. Material for the fittings shall conform to
ASTM A-234 Grade WPB.
Fittings shall be inspected for dimensional accuracy , uniform surface, edge preparation,
bevel angle etc. They shall be within permissible limits specified in the relevant
standards.
Hydrostatic test certificate of pipe used for making the bends to be submitted and
verified at the time of third party inspection.
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Failure of equipments
Following action shall be taken in case of failure of listed equipments. For other
instruments failure vendor shall advise the action taken in FDS document for
approval or modification
DCV failure: Though DVC is fail safe, still the failure may occur due to
diaphragm failure. In such case, the pumps of that particular product &
header line MOV shall be tripped by system with alarm logged in the
alarm section with alarm of DCV and pump tripping specifying the reason.
The method to restart the tripped pump sets shall be submitted by
vendor. Same shall be possible from soft and hard buttons.
Excess filing above preset quantity : incase of excess filling over the preset
due to failure of DCV, pulsar failure or batch controller or loss of
communication, the said problem clearly identified shall be logged in the
alarms. In case of filled quantity exceeding preset quantity by 10 litres ,
the pumps of that particular product shall be tripped by system indicating
alarm ―(Product ,specify) pumps tripped ,excess filling loading point(no,
specify)‖. In all cases of pump tripping the alarm shall specify the root
cause of pump tripping .
Card reader: System shall have inbuilt diagnostic tools which shall be put
in system health screen to diagnose health of card reader through
software. The system shall detect the hardware and software( drivers etc)
healthiness.
Failure of any command: Incase of failure of execution of any command
sent to field devices or control room devices , the same shall be generated
by system on real time basis under system alarm category.
Low pressure in header line: The system shall stop the loading of product
at all loading points of particular product in case the header pressure falls
below the set pressure. Such set pressure shall be configurable in the
system. Such events shall be captured under events screen. The alarm
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Vendor shall submit to HPCL for review and approval of the draft of the operating
manual for the facilities as per requirements listed in contract documents. Final
operating manual shall only be issued after approval on draft is obtained. Five
sets of final approved operating and maintenance manual shall be made available
before commencing the commission of the plant.
The operation manual shall have two parts. One shall give the details of the
individual instrument/ equipment. The other part shall contain the system details.
The objective of the manual is to assemble under one bound cover all the
instructions, data and drawings necessary for the operations personnel to start,
operate, control, shut down and maintain the systems under normal and
emergency conditions in a safe manner. It is desired that the instructions to be
written for clarity and simplicity.
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Vendor shall be responsible for proper design, quality, workmanship, operation &
maintenance of all equipment, accessories, etc. supplied by the Vendor for a
period of 24 months from the date of commencement of Stabilization. In case
commencement of stabilization is delayed due to non availability of products or
any other reason not attributable to Vendor, then warranty shall be 30 months
from the date of mechanical completion only for that equipment in question.
Further Vendor shall provide written guarantee that the back-up engineering,
maintenance and spare parts shall be available for a minimum period of 8 years
after warranty period for all equipment supplied by the Vendor. In the event of
non-availability of spares due to fast obsolescence of hardware and software, the
vendor shall arrange to upgrade/ replace the equipments with equivalent or
higher hardware and software at no additional cost till end of this 8 year period.
It shall be obligatory on the part of the Vendor that during the defect
liability/warranty period, Vendor will take complete responsibility for any defect
observed in the system supplied by the Vendor, any modification and/or
replacement of any hardware from the supplied equipment and attend to the
maintenance of the system, free of cost, during start-up and on-line operation of
TAS. Any emergency requirement shall be attended by Vendor‘s Senior Team
within one day notice. The replacement of any sub-system, modules and or entire
system shall be attended within one day.
Cost of all spares, equipment, instruments & services, (be preventive &
breakdown) to take care of the above points has to be borne by the Vendor
during the warranty period In case of failure to attend to these promptly, these
will be attended through alternate agency at vendor‘s risk and cost.
All road permits for supply of any spares/ materials during CAMC shall be in the
Vendor‘s scope.
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The vendor‘s resident engineer will check and service of each equipment &
instrument and its accessories and maintain them in good working condition. Any
consumables required for servicing the equipments shall be arranged by the
Vendor at no extra cost to HPCL during Warranty
Vendor shall maintain minimum consumables for smooth working of equipment/
instrument supplied by them.
W&M stamping of the electronic metering system during the warranty period
shall be in the scope of Vendor. All incidental charges for W&M stamping shall
be in the scope of the Vendor. Statutory fees shall be reimbursed by HPCL
against submission of Original receipt. The receipt shall be in the name of HPCL
location. Any additional W&M stamping required, apart from the yearly
stamping, due to reasons attributable to automation equipments like change in
calibration, K factors, replacement of pulsars etc. shall be in the scope of Vendor.
Vendor shall provide Resident Engineer (Min. degree holder) with minimum one
year experience / familiarity in erection/ commissioning/ maintenance of TAS
should be positioned at the location during working hours for taking care of
normal system operation, all Preventive & Breakdown maintenance during the
total warranty period. The Resident Engineer shall submit fortnightly report on
the System operation, preventive & breakdown maintenance carried out. This
includes backup coverage for such engineers for vacations, illness, training etc at
no additional costs.
The Resident Engineer shall assist the Location in verification of metering system,
etc as & when required by the location.
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The post warranty comprehensive AMC shall be a separate contract for the 5
years period and shall be signed at beginning of the respective year. The post
warranty Comprehensive AMC rates quoted in price bid for 5 years shall be
included in the evaluation.
6 Nos. normal visits (once in two months) and 4 No. emergency visits per annum
(as & when required) are included in scope of C.A.M.C. (Comprehensive Annual
Maintenance Contract). HPCL will have the right to reschedule the visits and
adjust the total no. of regular and emergency visits.
The vendor‘s service engineer will check and service of each equipment &
instrument and its accessories and maintain them in good working condition. Any
consumables required for servicing the equipments shall be arranged by the
Vendor at no extra cost to HPCL during CAMC.
During the CAMC, Vendor will hold the inventory of minimum spares inventory at
the site required for maintaining the system in operating condition. The vendor
shall ensure availability of spares (at minimum) at all times at the site. The vendor
shall always promptly replenish the spares as & where the same are used. The
vendor should do proper spares management by carrying out periodical testing
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W&M stamping of the electronic metering system during the warranty period
shall be in the scope of Vendor. All incidental charges for W&M stamping shall
be in the scope of the Vendor. Statutory fees shall be reimbursed by HPCL
against submission of Original receipt. The receipt shall be in the name respective
HPCL location. Any additional W&M stamping required, apart from the yearly
stamping, due to reasons attributable to automation equipments like change in
calibration, K factors, replacement of pulsars etc. shall be in the scope of Vendor.
Vendor shall furnish Bank Guarantee equivalent to the rates quoted for 5 year
comprehensive Annual Maintenance Contract. This Bank Guarantee shall be
submitted 2 months before the expiry of warranty period failing which retention
money shall stand forfeited. BG for CAMC shall be valid for minimum 62 months
or till the end of 5th year AMC whichever is later.
The vendor shall ensure availability of spares for the Automation System for a
minimum period of 8 years after warranty period. In the event of non-availability
of spares due to fast obsolescence of hardware and software, the vendor shall
arrange to upgrade/ replace the equipments with equivalent or higher hardware
and software at no additional cost till end of CAMC period.
The Vendor must note that all commissioning spares and the spares /
consumables during warranty and comprehensive CAMC shall be supplied by the
vendor free of cost.
All road permits for supply of any spares/ materials during CAMC shall be in the
Vendor‘s scope.
Agreement for the Post warranty CAMC shall be entered before the start of each
year. HPCL reserves the right to sign the post warranty AMC for all 5 years or part
of it or none or to extend the contract after 5 years.
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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
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SAFETY PRACTICE
Contractor shall have to take all safety precaution for carrying out hot work in the
premises after obtaining hot work permit from location in charge at his own cost
as directed by the Engineer-In-Charge. Necessary safety equipment such as
safety belts, helmets, etc., and other safety instruments are to be positioned by
the contractor and the same shall be used by the work force as per work
requirement. The contractor has to enforce the same.
Safety distance as per CCE Rules and Oil Industry Safety Directorate shall be
maintained strictly.
The contractor shall strictly follow safety practices during construction as per the
OISD 192.
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After completion of work, the site should be cleared of all scrap, contractor‘s
equipment and machinery used in fabrication.
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Flexibility should be kept in the software to re-designate each tank, pump for a
new product which will in turn maintain the stock accounts as per the change.
System initialization and setup parameter for entry of the database for tank farm
specifications including system security shall have user friendly interface. System
should have appropriate user interface for data entry of tank calibration charts as
per standard format and bidder shall use the same for tank farm system
configuration.
The Tenderer has to make his own estimate of quantity of the cables and
erection hardware requirement, based on the layout drawing enclosed and his
own site assessment.
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The system shall be internally protected against system errors and hardware
damage resulting from electrical transients on power wiring and signal wiring
which may be generated by switching large electrical loads or by power line
faults, and connecting & disconnecting devices or removing or inserting printed
circuit boards in the system.
The system design shall permit for future expansion, on line addition of new
systems/ subsystems without any disruption to either the operation or system
communication.
Vendor shall obtain all the required approvals from statutory bodies like CMRI,
CCOE, W & M etc at no extra cost to HPCL. Annual calibration including
coordination with local W & M inspector is included in the scope of the Vendor.
However the stamping charges will be paid by HPCL (Location) on proof and
production of original receipt during Warranty & AMC period.
A corrosion resistant nameplate will be securely fastened to the equipment in a
visible and accessible place. Nameplate shall bear the following data:-
Manufacturer‘s Name
Model Number
Serial Number
Size, rating (s) and Range (s)
Electrical data (where applicable)
Approval for Electrical Area Classification (with approving authority's
monogram where applicable)
HPCL‘s Tag Number.
Detailed Design and Engineering for various items involved for the total project
for Instrumentation and automation including detailed material specifications /
requisition, project specific drawings, obtaining necessary approvals and
preparation of detailed report is in the scope of the Vendor .
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shall be submitted with the following details apart from technical specifications
Equipments list :
Batch controller
LRC servers
Client PC
Windows software
Terminal server
Ethernet switch
VFD
Densitometer
PLC
Card reader
RIT
Pressure Transmitters
Equipment name:
Model number :
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soft format. Datasheets of such equipments without the product life cycle
document shall be not be considered in submitted category.
Trending
The trending feature shall be of various types like Single Bar, Multiple Bar, X-Y,
Numeric, etc. The module shall be able to show at least
Gantry area
Header pressure for all products
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Product pumps, Fire water pumps (tank truck filling pumps , Additive
dosing pumps, ethanol pumps, fire water pumps)
All trends can be plotted as individual or combination of the above points. TAS
system shall provide a seperate tab for Trends in the index. Once user clicks
Trend tab then screen for various options shall be displayed. The options shall
include above menus Gantry area, TFMS area, Product pumps and fire water
pumps with sub headings or submenus as defined above or the same can be
achieved through drop down menus. The user shall have the facility of plotting
any one feature in menu or all features in one menu or combination of some or
all features for one or more menus. In any given case if user wants to plot
multiple menus as gantry and TFMS in one single sheet the same shall be
possible however all lines representing individual dedicated parameters shall
have different colours .In the event when cursor is pointed on the line in the
trend graph , system shall show the item name its value and the time . The facility
of export of trend to MS office or Star office or office viewer shall be provided.
The size of trend screen shall be minimum 75% of the total screen size and
customized zooming facility shall be provided without blurring of original line,
dimensions, colour and the text . For zooming , the software shall provide the
options in drop down box or user entry upto 400 % of original size. A legend
needs to be provided indicating the acronyms used if any and the colour of the
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line. Acronyms shall not be used as far as possible and the colour of the line shall
be chosen as close as possible to product colour wherever trend is of feature
which involve product.
The trend screen when plotted shall display the trend for the chosen parameters
and in the balance 25% of the screen area corresponding table shall be shown
which shall depict the value of that particular feature
The software shall plot the trend for current date data as well as for historical
data.
A Trend Set display shows Historical information, of the point/tag such as PV, SP,
OUTPUT, for up to eight related points. The information is displayed in an
appropriate manner, such as:
• Bar graphs
Line graphs
• X-Y plot of the value of one point against another (that is, one point on the X-
axis and the other on the Y-axis)
HISTORISATION PHILOSOPHY
Software shall store the values of points over time to create a history of plant
process. There are three types of history which shall be configured.
• Fast History
Allowing to store 5 seconds snapshots of a point parameter i.e. PV, SP, OUTPUT
etc
• Standard History
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• Extended History
The type of parameters and the type of history required shall be advised to
successful bidder .
USER PROFILES
In all the client and server machines ( including gateway server) two profiles shall
be available. One profile is for administrator login and other profile shall be
group profile. When the machine ( client or server ) is booted then the machine
shall display group profile of TAS users only. Log in screen shall contain three
fields viz user name , profile and password. In the profile field shall be non
editable and TAS group to be displayed , User name shall be selectable from
drop downmenu which shall display the name of all the users who have been
configured for that location. User needs to enter the password and upon
successful validation of the password the system shall direct the user
automatically to software login. Users in TAS group shall have the facility of
logging in , logging off and shutdown of the machine only. No TAS user shall be
allowed by TAS profile to access or work upon OS , TAS software files.
For administrator login : Whenever ctrl+ alt+delete is pressed the system shall by
default go in TAS group profile. When different set of keys are pressed then only
administrator profile is enabled which also requires password authentication. In
administrator profile the administrator needs to enter two passwords for
successful login ie his user id password and transaction password. Upon
successful validation of both the passwords the administrator shall log in the
system. It is mandatory that login password and transaction password for the
administrator shall be different. The TAS software shall record the log in time of
administrator , log off time of administrator and shall record the files name
accessed ,modified with date and time stamping. Such events of administrator
activities shall be separately recorded in reports also and in events under
subhead administrator events.
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All exe. files in TAS software and database shall be stored on every month basis in
all clients in separate folder named as backup folder. The password protection is
required for the folder. The folder shall contain the sub-files or sub-folders
indicating name and year of the backup. Nomenclature of such subfolders shall
be first three letters of month name followed by last two digits of year for
example backup subfolder of January 2010 shall be named as jan10. The backup
folder shall reside in D drive of all the client machines . After every one year of
the subfolder creation date the old subfolder shall be deleted so that the space
constraint does not happen in client machines. The client machines shall be
suitably selected such that the graphics updatation time, data updation time are
not affected due to backup data stored in client machines.
After every month end , the system on the first day of the next month shall
prompt the user to take backup in DVD or data storage media by a pop up on
the screen if end of month has not been performed by user on the last day of
month after operation are over. The pop up shall indicate clearly that system shall
not proceed further unless and until the backup is taken on media. Software
check to be ensured that card allocation should not be possible till the time data
backup is taken .The backup functionality to be provided inline with description
of end of month requirement also.
In case of crash of any of the servers wherein data is lost or TAS software needs
to be reloaded or the machine needs to be formatted the retrieval facility shall be
provided.
In case of formatting of machine the user shall be able to load the operating
system with the help of Operating system provided. After loading of OS , the user
shall be able to load the In case of TAS software reloading, the same shall be
possible to load with the help of restore CD .Such restore CD shall be given apart
from the TAS software with necessary CD key and license by TAS vendor. The
restore CD will have all required drivers, communication IPs etc so that once the
restore CD installation is complete the system should start functioning with all
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In case of data required which is not in server database the user shall have the
facility to restore database for days or months with the help of database in client
or from the backup media. Software shall be provided with separate screen for
retrieval of data with date option From XX-XX-XX To CC-CC-CC . Wherever the
user is asked dates option whether in reports, trends or retrieval the dates shall
be selected from standard calendar which will come as popup from calendar icon.
Typing of dates with format DD-MM-YYYY shall also be acceptable. Once data is
retrieved from such sources , all reports & trend etc shall be made available for
such duration also.
After successful completion of SAT , vendor needs to handover DVD/data storage
media containing all files of TAS folder and database as on SAT date. The media
shall be made such that ghost image of the entire TAS folder is taken . Software
etc if any required for providing the same shall be in the scope of vendor.
The TAS software shall generate the TFMS file either automatically on EOD
command or it can be generated manually by the user. The system shall
generate the file automatically incase the EOD is done automatically by system.
The TFMS file can be generated once a day based on date and time of data . In
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case the user gives command to generate the file ,after the file has been
generated manually or automatically the system shall not allow second
generation. The facility to generate TFMS file in case of manual generation shall
ask user id and password again even if the user is logged in the system. The time
along with date stamping , user id shall be recorded in events.
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Synchronization of database
The database in the primary and backup server shall be same at any given point
of time when both the servers are in working condition. The database shall be
synchronized in both the servers on real time basis in auto mode. The toggle
switch shall be provided in the system status screen to switch over from auto
mode to manual mode. The system status screen shall also show the state of
database as either synchronized, not synchronized or synchronizing. Further a
separate screen shall show the following details
Last synchronized on
Synchronisation lost at : ( specify time)
Synchronised status :
All the Tank Trucks (T/T) will come to the Terminal and report at S & D
counter.
The load is planned by JDE operator and sent to JDE sever.
The load is sent from JDE server to TAS LRC through gateway server.
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Once the preload packet is received the LRC displays the truck details ,
customer name and number, and quantity of product to be loaded and
load segregation based on compartment capacity. Compartment
allocation logic and preferred bay configuration logic needs to be part of
TAS software.
TT is allocated proximity card number. The facility to allocate card shall be
dual i.e. by card reader and through keyboard pads.
TTES allocates Bay no., based on total no of T/T inside and 1 + 2 criteria
(User Configurable) for TLF bay. TTES operator can override the bay
allocation, if required. Card reader at TTES reads Card number for printing
on FAN (filling advice note). LRC sends a visual communication by means
of display on electronic display unit in T/T parking area, asking T/T to
report for filling bay. FAN is printed by TTES operator and handed over to
the driver along with card and seals. Validity of card vis-a-vis time elapsed
since time of issue & expiry of FAN should also be programmed. The
display to EDU and announcement shall be programmed so that it is in
line with the printing of FAN ie truck whose FAN is printed first shall be
displayed and announced first .
T/T enters through main Gate of the terminal / depot at TLF entry gate
Barrier.
Driver shows the card at barrier gate card reader. Card validation is done
by LRC. Gate opens on command from PLC based on clearance from main
computer of control room, and the T/T enters the licensed premises.
T/T reports for filling at the allocated bay. The Red lamp in the RIT is ON at
particular TLF bay. T/T driver shows the card at the card reader provided at
the bay. LRC checks its validity, downloads the loading information to
batch controller. If card is not current or valid, Batch controller displays
invalid card or un -authorised card or Go to bay no XXX and RIT will
display steady red lamp. Upon successful completion of identification
sequences, truck registration no is displayed on batch controller.
Driver connects earthing to the T/T.
T/T driver inserts loading arm in the first compartment of T/T i.e. Starting
from T/T cabin side.
Batch controller checks for safety permissive interlocks. RIT lamp
changes from Red to yellow. Batch controller shall simultaneously display
truck no, compartment number and preset quantity. Driver need to
acknowledge once per compartment.
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Failure of equipments
Following action shall be taken in case of failure of listed equipments. For other
instruments failure vendor shall advise the action taken in FDS document for
approval or modification
DCV failure : Incase of DCV failure , the pumps of that particular product
shall be tripped by system with alarm logged in the alarm section with
alarm of DCV and pump tripping specifying the reason. The method to
restart the tripped pump sets shall be submitted by vendor. Same shall be
possible from soft and hard buttons.
Excess filing above preset quantity : incase of excess filling over the preset
due to failure of DCV, pulsar failure or batch controller or loss of
communication, the said problem clearly identified shall be logged in the
alarms. In case of filled quantity exceeding preset quantity by 10 litres ,
the pumps of that particular product shall be tripped by system indicating
alarm ―(Product ,specify) pumps tripped ,excess filling loading point(no,
specify)‖. In all cases of pump tripping the alarm shall specify the root
cause of pump tripping .
Card reader: System shall have inbuilt diagnostic tools which shall be put
in system health screen to diagnose health of card reader through
software. The system shall detect the hardware and software( drivers etc)
healthiness.
Failure of any command : Incase of failure of execution of any command
sent to field devices or control room devices , the same shall be generated
by system on real time basis under system alarm category.
Low pressure in header line : The system shall stop the loading of product
at all loading points of particular product incase the header pressure falls
below the set pressure. Such set pressure shall be configurable in the
system. Such events shall be captured under events screen. The alarm
generated shall display loading stopped at (product points, specify
product) due to low pressure in header.
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Batch Controller : whenever any batch controller goes in manual mode the
same shall be advised to user through popup indicating which loading
point has gone in manual.
System health screen shall also capture the input power supply to UPS (both),
PLC on screen. In the event of main power failure the UPS shall draw the power
from batteries. The DG set provided by vendor shall run after preconfigured time
of mains power failure. In the event there is no power backup due to UPS except
from batteries, the UPS shall give command to TAS servers for shutdown at
preconfigured time before the batteries are completely discharged. The time shall
be user configurable in system health screen. All field equipments and control
room equipments which are connected through various sub links shall be shown
live on the system health screen. Any failure of link or sub link shall be shown in
red colour on real time basis. System shall also indicate mode of UPS batteries.
All RIT stops shall be recorded in the event section of TAS software. In case
emergency stop is pressed at loading point once, the loading shall resume only
after the supervisory card is shown at the gantry.
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Vendor shall submit to HPCL/PMC for review and approval of the draft of the
operating manual for the facilities as per requirements listed in contract
documents. Final operating manual shall only be issued after approval on draft is
obtained. Five sets of final approved operating and maintenance manual shall be
made available before commencing the commission of the plant.
The operation manual shall have two parts. One shall give the details of the
individual instrument/ equipment. The other part shall contain the system details.
The objective of the manual is to assemble under one bound cover all the
instructions, data and drawings necessary for the operations personnel to start,
operate, control, shut down and maintain the systems under normal and
emergency conditions in a safe manner. It is desired that the instructions to be
written for clarity and simplicity.
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Vendor shall be responsible for proper design, quality, workmanship, operation &
maintenance of all equipment, accessories, etc. supplied by the Vendor for a
period of 24 months from the date of commencement of Stabilization. In case
commencement of stabilization is delayed due to non availability of products or
any other reason not attributable to Vendor, then warranty shall be 30 months
from the date of mechanical completion only for that equipment in question.
Further Vendor shall provide written guarantee that the back-up engineering,
maintenance and spare parts shall be available for a minimum period of 8 years
after warranty period for all equipment supplied by the Vendor except
Computers and Servers for which the minimum period shall be 5 years after the
warranty period. In the event of non-availability of spares due to fast
obsolescence of hardware and software, the vendor shall arrange to upgrade/
replace the equipments with equivalent or higher hardware and software at no
additional cost till end of this 8 year period.
It shall be obligatory on the part of the Vendor that during the defect
liability/warranty period, Vendor will take complete responsibility for any defect
observed in the system (i.e. in instrumentation software, hardware,
communication & networking media‘s/protocol interfacing with ERP etc.), any
modification and/or replacement of any hardware from the supplied equipment,
modification the operating system software, Automation software, and any other
software, and attend to the maintenance of the system, free of cost, during start-
up and on-line operation of TAS. The Tank Farm system along with Valve sub
system shall also be integrated with the software as & when hardware are
erected, installed & handed over. Any emergency requirement shall be attended
by Vendor‘s Senior Team within one day notice. The replacement of any sub-
system, modules and or entire system shall be attended within one day. All the
proximity Cards shall be reprinted every year by the Vendor during 2 year
warranty period.
Cost of all spares, equipment, instruments & services, (be preventive &
breakdown) to take care of the above points has to be borne by the Vendor
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during the warranty period In case of failure to attend to these promptly, these
will be attended through alternate agency at vendor‘s risk and cost.
The vendor‘s Resident engineer( Min. Engineering Graduate) will check and
service of each equipment & instrument and its accessories and maintain them in
good working condition. Any consumables required for servicing the equipments
shall be arranged by the Vendor at no extra cost to HPCL during Warranty
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The Resident Engineer shall assist the Location in verification of metering system,
Tank gauging system etc as & when required by the location.
Warranty of the Add-ons provided by the Vendor in the free issue items for
making it compatible with TAS shall be included in the scope of the Vendor.
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The system is to be maintained for a period of five years after expiry of warranty
period. Cost of all spares, equipment, instruments & services, (Preventive &
Breakdown) to take care of maintenance, has to be borne by the Vendor during
the AMC period. In case of failure to attend within 2 days, these will be attended
through alternate agency at vendor‘s risk and cost.
The Tank Farm system along with Valve sub system shall also be integrated with
the software as & when hardware are erected, installed & handed over.
The post warranty comprehensive AMC shall be a separate contract for the 5
years period and shall be signed at beginning of the respective year. The post
warranty Comprehensive AMC rates quoted in price bid for 5 years shall be
included in the evaluation.
Min. 6 Nos. normal visits (once in two months) and 4 No. emergency visits per
annum (as & when required) are included in scope of A.M.C. (Annual
Maintenance Contract). HPCL will have the right to reschedule the visits and
adjust the total no. of regular and emergency visits.
The vendor‘s service engineer will check and service of each equipment &
instrument and its accessories and maintain them in good working condition. Any
consumables required for servicing the equipments shall be arranged by the
Vendor at no extra cost to HPCL during CAMC.
During the AMC, Vendor will hold the inventory of minimum spares inventory at
the site required for maintaining the system in operating condition. Vendors are
required to confirm compliance towards stocking of minimum spares at site as
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per quantity indicated in spare parts list format enclosed in the tender & submit
the same duly filled along with bid documents. These spares shall need to be
positioned at site before commencement of Stabilization & kept at site till the
end of AMC period. These Spares at the end of AMC shall be handed over to
HPCL & shall be property of HPCL. The vendor shall ensure availability of spares
(at minimum) at all times at the site and in the custody of HPCL location-in-
charge. The vendor shall always promptly replenish the spares as & where the
same are used. The vendor should do proper spares management by carrying out
periodical testing of the spares, safeguards against obsolescence, any up
gradation, timely replenishment, etc. All the proximity Card shall be reprinted
every year by the Vendor during 2 year warranty & 5 year CAMC period.
W&M stamping of the electronic metering system, 2 KL mobile Prover Tank
during the warranty period shall be in the scope of Vendor. In case of Black Oil,
the Mobile Master flow meter shall have W&M model approval and shall be
calibrated at FCRI yearly or as & when demanded by W&M whichever is earlier.
This Mass Flow meter shall then be stamped by local W&M. Only Master Meter is
required to be calibrated at FCRI yearly. Other MFM shall be calibrated at FCRI
before installation only. Stamping of these equipments by state W&M
Department & the entire coordination shall be in the scope of the Vendor during
5 year Comprehensive AMC period. All liaison & incidental charges related to
W&M approval, FCRI approval, to & fro transportation cost shall be borne by the
Vendor. Statutory fees shall be reimbursed by HPCL against submission of
Original receipt. The receipt shall be in the name respective HPCL location. Any
additional W&M stamping required, apart from the yearly stamping, due to
reasons attributable to automation equipments like change in calibration, K
factors, replacement of pulsars etc. shall be in the scope of Vendor.
In the event of HPCL requiring the services of vendor‘s resident engineer during
the CAMC, the vendor is required to position one resident engineer at site at 10%
higher rate than quoted by the Vendor for the 2nd Year of the Warranty period.
Vendor shall furnish location wise Bank Guarantee equivalent to the rates quoted
for 5 year comprehensive Annual Maintenance Contract. This Bank Guarantee
shall be submitted 2 months before the expiry of warranty period failing which
retention money shall stand forfeited. BG for CAMC shall be valid for minimum 62
months or till the end of 5th year AMC whichever is later.
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The vendor shall ensure availability of spares for the Automation System for a
minimum period of 8 years after warranty period. In the event of non-availability
of spares due to fast obsolescence of hardware and software, the vendor shall
arrange to upgrade/ replace the equipments with equivalent or higher hardware
and software at no additional cost till end of CAMC period.
The Vendor must note that all commissioning spares and the spares /
consumables during warranty and comprehensive CAMC shall be supplied by the
vendor free of cost.
Agreement for the Post warranty CAMC shall be entered before the start of each
year. HPCL reserves the right to sign the post warranty AMC for all 5 years or part
of it or none or to extend the contract after 5 years .
Vendor shall quote 5 year composite rate for CAMC . The composite rate quoted
by vendor for 5 years CAMC period shall be split year wise in the following
percentage for evaluation & payment purpose
Incase HPCL intended to extend the CAMC beyond 5th year, the amount for 6th year
onwards shall not be greater than 15% of cost of previous year cost of AMC.
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SAFETY PRACTICE
HPCL shall not be responsible for the security of Contractor’s materials / equipment.
Contractor shall have to take all safety precaution for carrying out hot work in the
premises after obtaining hot work permit from location in charge at his own cost as
directed by the Engineer-In-Charge. Necessary safety equipment such as safety belts,
helmets, etc., and other safety instruments are to be positioned by the contractor and
the same shall be used by the work force as per work requirement. The contractor has
to enforce the same.
Safety distance as per CCE Rules and Oil Industry Safety Directorate shall be maintained
strictly.
Any casualty or damage caused to property or person by any untoward incidents while
executing this contract will be at the contractor’s risk and cost.
The contractor shall strictly follow safety practices during construction as per the copy
of OISD 192 enclosed along with the tender document.
No hot work is permitted without issuance of hot work permit by location in-charge. The
hot work permit will be issued in the HPCL approved format on a day-to-day basis.
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After completion of work, the site should be cleared of all scrap, contractor’s equipment
and machinery used in fabrication.
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HEALTH, SAFETY
AND ENVIRONMENT
REQUIREMENTS
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CONTENTS
________________________________________________________________
1.0 SCOPE
2.0 REFERENCES
1.0 SCOPE
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2.0 REFERENCES
3.1.2 The HSE management system of the Contractor shall cover the HSE
requirements including but not limited to what is specified under Para
1.0 and para 2.0 above.
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above.
(for every 500 or less)
Contractor shall indemnify & hold harmless Owner / HPCL & either representative
free
from any and all liabilities arising out of non – fulfilment of HSE
requirements.
3.1.4 The Contractor shall ensure that the Health, Safety and Environment
(HSE) requirements are clearly understood & faithfully implemented at
all levels at site.
3.1.5 The Contractor shall promote and develop consciousness for Health,
Safety and Environment among all personnel working for the
Contractor. Regular awareness, programme and fabrication shop / work
site meetings shall be arranged on HSE activities to cover hazards
involved in various operations during construction.
3.1.6 Arrange suitable first aid measures such as First Aid Box, trained
personnel to give First Aid, Stand by Ambulance or Vehicle and
install fire protection measures such as : adequate number of steel
buckets with sand and water and adequate fire extinguishers to the
satisfaction of HPCL/Owner.
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3.1.11 All fatal accidents and other personnel accidents shall be investigated
by a team of Contractor’s senior personnel for root cause &
recommend corrective and preventive actions. Findings shall be
documented and suitable actions taken to avoid recurrences shall be
communicated to HPCL/Owner. Owner / HPCL shall have the liberty to
independently investigate such occurrences and Contractor shall extend
all necessary help and co-operation in this regard.
a. All surplus earth and debris are removed/disposed off from the
working areas to identified location(s).
d. Roads shall be kept clear and materials like: pipes, steel, sand
boulders, concrete, chips and bricks etc. shall not be allowed on
the roads to obstruct free movement of men & machineries.
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3.3.1 The Contractor shall provide safe means of access to any working
place including provisions of suitable and sufficient scaffolding at
various stages during all operations of the work for the safety of his
workmen, and, HPCL/Owner. Contractor shall ensure deployment of
appropriate equipment and appliances for adequate safety and health of
the workmen and protection of surrounding areas.
3.3.2 The Contractor shall ensure that all their staff and workers including
their sub-contractor(s) shall wear Safety Helmet and Safety shoes.
Contractor shall also ensure use of safety belt, protective goggles,
gloves etc. by the personnel as per job requirements. All these gadgets
shall conform to relevant IS specifications or equivalent.
3.3.3 Contractor shall ensure that a proper Safety Net System shall be used
at appropriate locations. The safety net shall be located not more than
30 feet (9.0 metres) below the working surface at site to arrest or to
reduce the consequences of a possible fall of persons working at
different heights.
3.3.4 Contractor shall ensure that flash back arrester shall be used while
using Gas Cylinders at site. Cylinders shall be mounted on trolleys.
3.3.5 The Contractor shall assign to his workmen, tasks commensurate with
their qualification, experience and state of health for driving of
vehicles, handling and erection of materials and equipments. All lifting
equipments shall be tested certified for its capacity before use.
Adequate and suitable lighting at every work place and approach there
to, shall be provided by the Contractor before starting the actual
operations at night.
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3.3.7 All hazardous materials shall be labeled with the name of the
materials, the hazards associated with its use and necessary precautions
to be taken.
3.3.8 Contractor shall ensure that during the performance of the work, all
hazards to be health of personnel, have been identified, assessed and
eliminated.
3.3.13 Suitable facilities for toilet, drinking water, proper lighting shall be
provided at site and labour camps, commensurate with applicable Laws
/ Legislation.
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- arrange all HSE permits before start of activities (as applicable) like
hot work, confined space, work at heights, storage of chemical /
explosive materials and its use and implement all precautions
mentioned therein.
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ENCLOSURES
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ATTACHMENT-1
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ATTACHMENT –II
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6 Earthing Relay
a. Earthing relay board 4
b. Earthing Clamp with cords of 3 m length. 6
c. Lamp cover with lamps (red, green) 2
7 RIT
a. Indicating lamp – RED, GREEN & AMBER – (Set) 2
b. Push Button Set- Red , yellow, green 2
8 Access Control System
a. Proximity Card 10
b. Card Reader 1
c. Electronic card for card reader 2
d. Power supply module 2
e. Access control unit (incase of Nexwatch system) 2
6 Density meter
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Spares indicated above are minimum requirement. Any additional items required
during the warranty and CAMC period, the same shall be maintained at site by TAS
vendors. The spares shall be sited/ delivered at each site before the start of
stabilization. The spares shall be replaced as and when it is consumed.
Additional quantity may be kept at the terminal by the Vendor based on OEM
recommendation. Tenderer to specifically indicate the spares / items which are not
applicable to the equipments offered by then in technical bid document.
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ATTACHEMENT - III
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ATTACHEMENT- IV
LIST OF FACILITIES
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NB : 3(2+1) indicates that total 3 nos product pumps are there of which 2 shall be
running and 1 standby.
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