INDIAN OIL CORPORATION LIMITED Annexure-III

(REFINERIES DIVISION)
PARADIP REFINERY

INDIAN OIL CORPORATION LIMITED

PARADIP REFINERY

TENDER DOCUMENT FOR DESIGN, ENGINEERING, MANUFACTURING, SUPPLY,

INSTALLATION, TESTING & COMMISSIONING FOR REMOTE AUTO CALIBRATION
/VALIDATION FACILITIES FOR SOX, NOX , CO ANALYZERS THROUGH OPCB/CPCB
SERVER FOR STACK ANALYSERS AT PARADIP REFINERY.

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 INDIAN OIL CORPORATION LIMITED Annexure-III
(REFINERIES DIVISION)
PARADIP REFINERY

1. PREAMBLE:

The Paradip Refinery is a 15 MMTPA Grass-root Refinery located at a site five Km south of
the Port of Paradip in the state of Odisha, on the northern part of the east coast of India.
At present Paradip Refinery has CEMS Analyzers (SOx, Nox, CO & SPM) installed at furnace
stacks of various units for emission monitoring. Theses Analyzers are interfaced with
CPCB/OSPCB for real time data viewing as per statutory requirement. At present Paradip
Refinery has Installation base of 21 nos. each of SOx, NOx, CO & PM Analyzers for emission
monitoring. As per recent guidelines of CPCB, remote calibration facilities are to be provided
for SOx, NOx and CO Analyzers for calibrating these Analyzers remotely from CPCB as and
when required.

To meet above requirement, it is planned to have facility for calibration of SOx, NOx & CO
Analyzers remotely from CPCB as per CPCB Guidelines.

2. EXISTING SYSTEM:
In IOCL Paradeep refinery there are 21 numbers Continuous Emission Monitoring Stations,
which are continuously monitored by Central Pollution Control Board and State Pollution
Control Board for monitoring emission parameters of SOX, NOX, CO and PM for each stacks.
Further for dual fired fuel applications dynamic data are also transmitted to OSPCB/CPCB
portals. The analyzer were supplied by M/s Chemtrols Industries Limited and Instrument
make and model numbers are as for the following in table A.

Table-A

Category Analyzer Make Model Port Dilution Scope of

Availability Controller/ remote
external validation
SOV
I SOX TELEDYNE 100E RS485/RS232 Dilution 18 nos
Analyzer Controller
II NOX TELEDYNE 200E RS485/RS232 18 nos
Analyzer
III CO SICK SIDOR RS232
IS Replay 18 nos
Analyzer board
IV SOX ENVIRONMENT AF 22M RS 232 / RS Dilution 2
Analyzer SA 422 Controller
V NOX ENVIRONMENT AF 32M RS 232 / RS 2
Analyzer SA 422
VI CO SICK GMS810 RS485/RS23 Not 2
Analyzer UNOR available
Total Analyzer 60

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 INDIAN OIL CORPORATION LIMITED Annexure-III
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PARADIP REFINERY

Presently all stack data parameters( SOX,NOX, CO,PM and dynamic limit data ) are being
monitored at OSPCB end through http:\\ ospcbrtdas.com portal and CPCB end through
http:\\ suncpcbrtdas.com by technology provider M/s SUNJRAY INFO SYSTEM PVT LTD,
Bhubaneswar through GPRS based communications.

GPRS BASED
Figure1: Existing Basic Schematics:- NETWORK

Individual Converter
GPRS Device
SOX, NOX,
CO, PM
analysers

DCS
Stacks (SOX/NOX/CO/PM)
CPCB/OSPCB RTDAS server at
+ dynamic limit
factor Bhubaneswar.

Total 21 Stacks & Analysers at Paradip Refinery

3. PROPOSED SYSTEMS REQUIREMENTS:

 Bidder's responsibility shall include Design, Engineering and supply of Remote

Calibration System suitable for all Analyzers (both 4-20mA based Analysers and Digital
output analysers).
 Bidder to design, supply necessary hardware’s and software’s and any associated items
for real time remote calibration/validation access to OSPCB and CPCB by accessing
the mentioned analyzers remotely either in this above mentioned portals or dedicated
portal of the solution provider based on clearance from the CPCB and OSPCB board.
 For real time remote calibration/validation Bidder needs to utilize RS485/RS232/ RS
422 port and associated relay circuits and triggering the MODBUS data for triggering
the relays for performing zero and Span check. It is Bidder responsibility to utilize
digital connectivity as per availability in the analysers as mentioned.
 Remote Calibration kit shall directly communicate with Analyzer and OSPCB & CPCB
server. It will perform following functions:
1) Data transfer from analyzer to OSPCB & CPCB,
2) Accept signal of Remote calibration from OSPCB & CPCB.
3) Line up ZERO/SPAN/SAMPLE gas to the analyzer as per remote calibration
command.
4) Local display facility for each station.
 The existing data transmission needs to be sent uninterrupted to the OSPCB and
CPCB. Existing GPRS technology and relevant hardware’s needs be taken in to
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 INDIAN OIL CORPORATION LIMITED Annexure-III
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PARADIP REFINERY

considerations. Bidder needs to consider GPRS based communications. At present

internet facilities (through Centralized IOCL IT network only) are not available at
respective analyser shelters. However, internet facility up to respective analyser is
under technical consideration. Bidder must consider both GPRS and internet facility
in their design considerations.
 Bidder to categorically review the data transmission speed and redundancy
requirements etc. Bidder to ensure at least 98% data availability at CPCB/OSPCB site.
If any problem arises that needs to rectify within 24 Hrs.
 General Information for SOX /NOX analyser of Teledyne make : Bidder to note, that
the Teledyne make SOx and NOx analyzers are having in built SOVs for calibration
purpose in the dilution probe controller. Digital communications can be established
through MODBUS communications. MODBUS protocols and standard registered bits
are readily available in the internets for respective make and models and same can be
provided during detailed engineering. Bidder to collect relevant information during pre-
bid meeting at site.
 General Information for SICK SIDOR make CO analyzers: Bidder to note that separate
24V Solenoid valves are available for calibration purposes.

4. REQUIREMENTS OF PRE-BID MEET

(i) It is advised that bidder should visit the site to collect the residual information not
specified in the tender document. Non familiarization with site condition will not be
accepted at any stage and it is deemed that the bidder has submitted the offer only
after making the study and has fully understood the requirement of IOCL. All
clarification shall be finalized during Pre-bid meeting at site.
(ii) Bidder’s quotation shall enumerate and include the detailed specifications of entire
system being offered supported by original catalogues of items being used.
(iii) Bidder shall furnish a detailed list of deviations / confirmations clause-wise described
in this specification. Bidder must provide enough supportive reasons for the deviations
listed. No revision in prices will be accepted against the tender, unless the revision in
price is asked by IOCL based on changes in specifications / scope of work / commercial
terms and conditions of the tender. Bidders are requested to quote considering the
complete specifications and scope of supply & work along with all terms and conditions
of the tender.

5. JOB SCOPE & INSTRUCTIONS TO BIDDERS:

(i) Design, Engineering, Supply of Hardware/Software, Installation, Commissioning,

Testing, Site Acceptance Test and Warranty of System for remote calibration of stack
Analyzers (SOx, NOx, CO) installed at various units of Paradip Refinery. The scope
shall also include configuration (including supply of hardware/software if required) at
CPCB as well as coordination with CPCB.
(ii) Detailed list of analyzers for remote calibration are mentioned in Table B.
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 INDIAN OIL CORPORATION LIMITED Annexure-III
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PARADIP REFINERY

(iii) Vendor shall maintain all type of special tools & tackles as required during installation
& commissioning.
(iv) It has to be noted that CEMS data of all these stacks are already commissioned and
should work independently without any kind of hindrance to the existing system. It is
indented that any point of time CEMS data transmission to CPCB /OSPCB which
includes stack data (SOX, NOX, CO, PM) and the dynamic limit data in 14 nos stacks
(SOX, NOX, CO) should not get hampered due this contract of remote calibration
requirements.
(v) The remote calibration technique should approved in OSPCB and CPCB norms and
bidders to be enlisted by the pollution control board.
(vi) It will be bidder’s responsibility to understand the existing CEMS data transmission to
CPCB and OSPCB board.
(vii) It will be the Bidders responsibility to comply all the data to CPCB /OSPCB to the
desired portal and required features as generally intended by them. Any future
software features Up-gradation requirement (if any) will be under bidder’s scope.
(viii) Repeat Order- Bidder must accept repeat order clause of this tender. In case of any
additional analyzer needs to added as per CPCB requirements same needs to be
executed as per repeat order.
(ix) Supply and installation of required hardware and software including cables, Power
distribution box, Junction box, Solenoid valves, IOT based GPRS devices, Data logger,
industrial grade display unit, MCB, LAN, Ethernet cable/switch including all required
accessories for completion of the job in all respect is in the bidder scope.
(x) Calibration gas cylinders required during commissioning of remote calibration systems
shall be arranged by Bidder.
(xi) The license for the application software or Mobile app etc. shall be provided for atleast
10-12 nos of people.
(xii) All necessary liasoning/ co-ordination with CPCB/statutory bodies for configuration
at CPCB end shall be done by vendor to complete the job.
(xiii) After finalization of the order bidder has to submit all relevant engineering documents
for necessary approval which includes network diagram, total Bill of Material, software
features requirements etc., site execution and mobilization plan, Site Acceptance Test
documents for approval.
(xiv) Bidder to provide facility of data backup facility at IOCL end.
(xv) Remote calibration implementation & demonstration needs to carried out in phased
manner:
a. In 1st Phase, remote calibration for each type of analysers needs to be demonstrated
for selected analyzers and same will be witnessed and reviewed by senior officers
of IOCL and after thorough testing it needs be connected with CPCB for testing
purpose.
b. In 2nd Phase, all analysers needs to demonstrate remotely within IOCL refinery
premises.
c. In 3rd phase, all the analyzer needs to tested through CPCB portal after necessary
clearance from concern officials of IOCL.
(xvi) The bid and supporting documents to be signed and stamped on each and every page
by authorized signatory of the bidder.

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 INDIAN OIL CORPORATION LIMITED Annexure-III
(REFINERIES DIVISION)
PARADIP REFINERY

6. LIST OF ANALYZER FOR REMOTE CALIBRATION REQUIREMENTS:

The analyzers installed in analyzer shelters in different units has been mentioned as below
in Table B.
Table-B

INST RANGE
Unit/Stat SERVICE ANALYSER ANALYSER
SL TAG NO. SHELTER NO
ion DESCRIPTIO MAKE MODEL
N

010-AT- CO /O2 0-250ppm

SICK MAIHAK SIDOR (0-15%)
1001A/B ANALYSER

CDU ( SOX 0-
1 010-AT-1004 10-AS-0001 TELEDYNE 100E 1000ppm
CEMS-4) ANALYSER

NOX 0-500ppm
010-AT-1006 TELEDYNE 200E
ANALYSER

010-AT- CO /O2 0-250ppm

SICK MAIHAK SIDOR (0-15%)
3005A/B ANALYSER

VDU ( SOX 0-
2 010-AT-3003 10-AS-0002 TELEDYNE 100E 1000ppm
CEMS-14) ANALYSER

NOX 0-375ppm
010-AT-3002 TELEDYNE 200E
ANALYSER
0-200ppm
14-AT-1502 CO ANALYSER SICK MAIHAK SIDOR

DHDT ( SOX 14/15-SK- 0-

3 14-AT-1503A TELEDYNE 100E 200ppmv
CEMS-1) ANALYSER 001

NOX 0-
14-AT-1503B TELEDYNE 200E 200ppmv
ANALYSER
0-
CO
020-AT-1602 SICK MAIHAK SIDOR 130mg/N
ANALYSER
m3
VGO-3 ( SOX 0-100
4 020-AT-1603A 020-SK-001 TELEDYNE 100E PPMV
CEMS-19) ANALYSER

NOX 0-
020-AT-1603B TELEDYNE 200E 200PPMV
ANALYSER

CO 0-130
021-AT-1502 SICK MAIHAK SIDOR mg/Nm3
ANALYSER
0-
VGO-1 ( SOX
5 021-AT-1503A 021-SK-001 TELEDYNE 100E 65mg/Nm
CEMS-2) ANALYSER
3
0-
NOX
021-AT-1503B TELEDYNE 200E 1000mg/
ANALYSER
Nm3

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 INDIAN OIL CORPORATION LIMITED Annexure-III
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PARADIP REFINERY

0-130
022-AT-1502 CO ANALYSER SICK MAIHAK SIDOR mg/Nm3

0-
6 VGO-2 ( SOx
022-AT-1503A 022-SK-002 TELEDYNE 100E 65mg/Nm
CEMS-13) ANALYSER
3
NOX 0-325
022-AT-1503B TELEDYNE 200E mg/Nm3
ANALYSER

SOX ENVIRONMEN 0-1000

023-AT-2004A AF 22M ppm
ANALYSER T SA

NOX ENVIRONMEN 0-500

FCC-1 ( 023-AT-2004B AF 32M ppm
7 ANALYSER 23-SK-001 T SA
CEMS15)
0-500
CO ANALYSER GMS810 ppm
023-AT-2100B SICK MAIHAK
FCC STACK UNOR

0-1500
SOX
ENVIRONMEN ppm
023-AT-2101A ANALYSER AF 22M
T SA
Regenerator

NOX ENVIRONMEN 0-1000

FCC-2 ( 023-AT-2101B AF 32M ppm
8 ANALYSER 23-SK-002 T SA
CEMS17)
0-1000
CO ANALYSER ppm
GMS810
023-AT-2103 HEATER SICK MAIHAK
UNOR
STACK

SOX 0-500ppm
030-AT-1701A TELEDYNE 100E
ANALYSER

DCU-1 ( 030-AT- NOX 0-500ppm

9 30-AS-0001 TELEDYNE 200E
CEMS-5) 1701B ANALYSER
0-200ppm
030-AT-1702 CO ANALYSER SICK MAIHAK SIDOR

SOX 0-500ppm
030-AT-1703A TELEDYNE 100E
ANALYSER

DCU-2 ( 030-AT- NOX 0-500ppm

10 30-AS-0002 TELEDYNE 200E
CEMs-3) 1703B ANALYSER
0-200ppm
030-AT-1704 CO ANALYSER SICK MAIHAK SIDOR

SOX 0-
040-AT-0002 TELEDYNE 100E 1000ppm
ANALYSER
40-AS-001
NHT ( NOX 0-500ppm
11 040-AT-0003 TELEDYNE 200E
CEMs-7) ANALYSER

CO/O2 0-250ppm
040-AT-0005A 40-AS-001 SICK MAIHAK SIDOR
ANALYSER

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 INDIAN OIL CORPORATION LIMITED Annexure-III
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NOX 0-500ppm
042-AT-0013 TELEDYNE 200E
ANALYSER

CCR( 0-130ppm
12 042-AT-0014A CO ANALYSER 42-AS-0001 SICK MAIHAK SIDOR
CEMs-18)

SOX 0-
042-AT-0015 TELEDYNE 200E 1000ppm
ANALYSER

SOX 0-500ppm
089-AT-0310A TELEDYNE 100E
ANALYSER
SRU/TGT 0-100ppm
CO/ O2
13 U( CEMS- 089-AT-0310B 89-AH-001 SICK MAIHAK SIDOR
ANALYSER
6)
NOX 0-
089-AT-0312 TELEDYNE 200E 1000ppm
ANALYSER

HRSG-1 SOX 0-100ppm

127-AT-001 TELEDYNE 100E
ANALYSER

HRSG-1 NOX 0-200ppm

HSRG-1 ( 127-AT-002 TELEDYNE 200E
14 ANALYSER 127-AS-1
CEMs-12)
0-
HRSG-1 CO
127-AT-003 SICK MAIHAK SIDOR 500mg/N
ANALYSER
m3
HRSG-2 NOX 0-200ppm
128- AT -002 TELEDYNE 200E
ANALYSER

HRSG-2 SOX 0-100ppm

HRSG-2 ( 128-AT-001 TELEDYNE 100E
15 ANALYSER
CEMS21)
0-
HRSG-2 CO
128-AT-003 SICK MAIHAK SIDOR 500mg/N
ANALYSER
128/129-AS- m3
HRSG-3 NOX 2 0-200ppm
129- AT -002 TELEDYNE 200E
ANALYSER

HRSG-3 SOX 0-100ppm

HRSG-3 ( 129-AT-001 TELEDYNE 100E
16 ANALYSER
CEMS-22)
0-
HRSG-3 CO
129-AT-003 SICK MAIHAK SIDOR 500mg/N
ANALYSER
m3
0-
UB-1 CO
131-AT-001 SICK MAIHAK SIDOR 500mg/N
ANALYSER
m3
UB-1 ( UB-1 SOX 0-
17 131-AT-005 TELEDYNE 100E 1000ppm
CEMS-8) ANALYSER
0-
UB-1 NOX 131/132-AS-
131-AT-006 TELEDYNE 200E 1000mg/
ANALYSER 1
Nm3
0-
UB-2 CO
132-AT-001 SICK MAIHAK SIDOR 500mg/N
UB-2 ( ANALYSER
18 m3
CEMs-9) 0-
UB-2 SOX
132-AT-005 TELEDYNE 100E 1000ppm
ANALYSER

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 INDIAN OIL CORPORATION LIMITED Annexure-III
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PARADIP REFINERY

0-
UB-2 NOX
132-AT-006 TELEDYNE 200E 1000mg/
ANALYSER
Nm3
0-
UB-3- CO
133-AT-001 SICK MAIHAK SIDOR 500mg/N
ANALYSER
m3
UB-3 ( UB-3 SOX 0-
19 133-AT-005 TELEDYNE 100E 1000ppm
CEMS-10) ANALYSER
0-
UB-3 NOX
133-AT-006 TELEDYNE 200E 1000mg/
ANALYSER
133/134-AS- Nm3
2 0-
UB-4 CO
134-AT-001 SICK MAIHAK SIDOR 500mg/N
ANALYSER
m3
0-
UB-4( UB-4 SOX
20 134-AT-005 TELEDYNE 100E 1000mg/
CEMS-11) ANALYSER
Nm3
0-
UB-4 NOX
134-AT-006 TELEDYNE 200E 1000mg/
ANALYSER
Nm3

7. IOCL scope
a. Power supply 110VA (UPS supply).
b. Related drawing and documents related to analyzers etc.
c. Review and approval for Bidders supplied documentations. Finalization to BOM.
d. Conducting SAT and its acceptance.
e. Co-ordinations with analyser vendors.
f. Job executions assistances, necessary permits for job executions.

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 INDIAN OIL CORPORATION LIMITED Annexure-III
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PARADIP REFINERY

8. WARRANTY

Warranty will start only after the completion of the site Acceptance Test at IOCL Paradip
Refinery. Warranty will be for 12 months after completion of Site Acceptance Test or 18
month from date of supply, whichever is earlier. The terms & condition of extended
warranty is also applicable during warranty period also. Any other item not listed /
indicated but required to meet specification indicated elsewhere shall also be Bidder scope
of supply.

9. PAYMENT TERMS:

 Payment as per GPC.

10. DELIVERY PERIOD :

Supply within 8-10 Weeks from date of Purchase Order.

Erection and Commission and SAT: 4 Months from the date of Purchase Order/LOA.
Vendor to plan the jobs meticulously to meet the deadline.

11. DOCUMENTATION & SOFTWARE TO BE PROVIDED BY BIDDER

For
For
Sl. No. Description Information As Built
Approval
/ Reference
1. Activity and time schedule √
2. Drawing/ document submission schedule √ √
3. All Data sheets including bought out items √ √
4. Complete supply items with Make & Model √ √
System architecture drawing for OPCB &
5. √ √
CPCB connectivity

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 INDIAN OIL CORPORATION LIMITED Annexure-III
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PARADIP REFINERY

12. SHIPPING
(i) All the materials used for packing, wrapping, seals, moisture resistant barriers and
corrosion prevention shall be of recognized brands and shall conform to the best
standards for the articles, which are packed.
(ii) Workmanship shall be in accordance with best commercial practices and requirements
of applicable specifications. There shall be no defects, imperfections or omissions,
which would tend to impair the protection offered by the package as a whole.
(iii) The packing shall be suitable for storing in tropical conditions, as specified in
requisition. Shipment shall be thoroughly checked for completeness before final
packing.

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 INDIAN OIL CORPORATION LIMITED Annexure-III
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PARADIP REFINERY

13.CERTIFICATE

(To be signed by Bidder’s corporate level signatory on company’s letter head)

I, on behalf of M/s _______________________________ confirm that System quoted by us for Paradip

Refinery against tender no.………………… shall continue to be supported by us. The quoted
system shall not be withdrawn from Indian market as a matter of our corporate policy as
supported by attached certificate form.

I further confirm that in case of placement of order by IOCL we will provide back-up Engineering,
maintenance and spare part support for a period of 10 years from the date of placement of order.

I further assure you on behalf of M/s that required up gradation

of hardware and software for successfully running of the system will be done by us without any
price implication during entire warranty period.

SIGNATURE WITH SEAL

AUTHORIZED,

SENIOR MANAGEMENT LEVEL SIGNATOR

DEVIATION (Please furnish separately, if any) NO DEVIATION

BIDDER'S SIGNATURE WITH SEAL ON ALL PAGES OF TECHNICAL SPECIFICATION IS

REQUIRED AS AN ACCEPTANCE OF TECHNICAL SPECIFICATION

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