Professional Documents
Culture Documents
IDT00548700000000000 Isro 05401
IDT00548700000000000 Isro 05401
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VOLUME-I
VOLUME I
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VOLUME-I
1. INTRODUCTION
The execution period reckoned from signing of the Contract to final acceptance
of Automated Continuous Cleaning Facility is 10 months.
Some of the key terminologies used in this document are defined as follows:
“Department” shall mean and include the President of India acting through
the Director, IPRC and any representative(s) of the Department duly
authorized on his/ her behalf.
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“Contractor” shall mean the individual or firm or company, whether
incorporated or not, chosen by the Department among the Bidders to this
RFP, undertaking the work and shall include the legal personal
representatives of such individuals or the persons composing such firm or
company or the successors of such firm or company and the permitted
assignee of such individual or firm(s) or company.
“Date of Contract” shall mean the date on which the Contract becomes
effective with signing by all the Parties.
“Site” shall mean the land and or other places at Mahendragiri on which
work is to be executed under the Contract which is to be allotted by the
Department for the purpose of carrying out the work.
“Test object” shall mean the test article which is to be automated continuous
cleaned and is under the scope of Department.
“Material” shall mean all the goods/ items required for realizing and
forming the automated continuous cleaning Facility including raw materials,
semi-finished & finished products & sub-assemblies & assemblies which are
manufactured by the Contractor or their Sub-contractor(s) or bought-out from
their Sub-vendor(s).
“Service” shall mean all the activities performed by the Contractor for
realizing the Automated Continuous cleaning Facility including design,
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detail engineering and onsite construction, fabrication, erection &
commissioning.
The overall layout of equipments is given in the isometric layout for the
Automated continuous cleaning Facility (ACCF), given in Annexure I. The
ACCF is intended for cleaning of test object. It comprises following circuits
IPA circuit.
GN2 circuit.
IPA system is used to clean the test object. Initially, IPA bought in 25L cans
is used for filling of 500L container from which IPA will be pumped into the run
tank. .Thus, the IPA required for cleaning of test object shall be stored in 3000L
capacity run tank. Subsequently, the IPA will be sprayed inside the hardware
(test object). The IPA will then be collected and fed back to the run tank for
continuous operation of cleaning cycles. This process continues till the particle
contamination of the test article achieves certain level i.e. Class 4 of SAE AS 4059
E & for oil contamination is ≤ 3mg/m2.
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pressurization/compression and depressurization/decompression to remove
moisture from IPA cleaned test object. Venting rate is 40 g/s.
a) Instrumentation system
PLC based measurement, Command and control system is designed to meet the
aforementioned process and requirement of the facility and is dealt in this
report. The Instrumentation system caters to the requirement of monitoring,
controlling and recording the various process parameters during cleaning
phases.
PLC based measurement, Command and control system: It does the function of
commanding & controlling of Electro Pneumatic (EP) Valves and Pumps. It is
also required for measuring & monitoring of process parameters such as
Pressure, temperature, flow and level. The analog input parameters are
digitized and digital data are transferred to PC for storage, real time monitoring
and off-line processing.
Configuration
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The system is designed to control and acquire all digital and analog
inputs/Outputs with 500 msecond cycle time. However, the system has
provision to acquire at different sampling rates with 500 ms/ 1 s/ 5s resolution
to enable longer duration acquisition. The acquired parameters can be further
processed and viewed in required print format with suitable printing and
averaging intervals. All data are acquired by the PLC and raw data are sent to
the storage node for on-line display and data storage. For data processing
database containing details of all digital/analog channels such as tags,
description, channel address, unit, range, gain, offset, sensor constants will be
created. This database is used for processing and printing of parameters from
the raw data. All the processed data and raw data are stored on DVD as back up
for future reference. The specification of control system is given in Volume-II.
The operator station/SCADA node and data storage node (all in one pc with 24
inch monitor) have Ethernet ports interfaced to programming node through
High speed Ethernet switch in Client-Server configuration. The Programming
node communicates with PLC through switch for data transfer. The SCADA
node have necessary SCADA package for online monitoring of operations and
process parameter in different mimic diagrams. The SCADA package has
necessary standard library and tools for building functional blocks and symbols,
so that mimic page can be developed depending upon the various requirements.
Typical features of PLC based measurement, command and control system
Cycle time 500 msecond
Hardware clock =100 msecond
SCADA based operation
PLC based PID loops
Data Acquisition, Retrieval & Processing
MIMIC updation better than 1 sec
Analog Acquisition : 500 ms /1s/5s
Auto sequence command generation with 500 ms interval
Abort sequence with conditional based logics and Safety Interlocks
The figure-1 gives the configuration diagram for PLC based Control
System.
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N/W Switch
PLC
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3. LOCATION AND LAY-OUT OF ACCF
Rainfall
Maximum daily rainfall : 50 mm
Maximum monthly rainfall : 120 mm
Average annual rainfall : 550 mm
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Temperature
Maximum temperature in shade : 311 K
Minimum temperature : 293 K
Humidity
Maximum relative humidity : 80%
Minimum relative humidity : 25%
Type of climate : Tropical
The scope of the work and the demarcation of responsibilities between the
department and the contractor in the realization of fluid servicing system for
Automated Continuous Cleaning Facility are given in this section.
In order to realize the Fluid servicing system for ACCF, the department
will provide the following services.
The preliminary design of the system has been done by the department.
Process and Instrumentation Diagram (Ref ANNEXURE-III) with the
specifications of the fluid circuit components (Ref section 1, Vol.II) are given in
this document along with the specification of the system requirements
(ANNEXURE-IV).
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4.1.3 Review of detail engineering
Upon award of the contract and after design review, the contractor shall
carry out detail engineering. The scope of work to be done by the contractor
under detail engineering is given in section 4.2.2.The department will review
the detail engineering done by the contractor.
Process fluids such as IPA and GN2 for commissioning at free of cost.
The scope of work to be done by the contractor for the realization of FSS
is given in this section. The bidder shall submit a complete bid for the entire
works mentioned herein as per the formats specified.
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The design calculations are based on the codes/ standards mentioned in
various sections of this document. In case the contractor prefers to employ
alternative codes/ standards, the Department may agree, provided that the sizes
of the fluid circuits chosen as per the alternative codes/ standards are equal to
or the next higher standard ones than those specified in the contract. In such
case where the contractor employs alternative codes/ standards, it shall be their
responsibility to submit a copy of such codes/ standards in English language to
the Department during design review. The design review shall primarily
address the following issues:
● Design of P&IDs to comply with specified functional requirements
f. The detailed Quality Assurance Plan (QAP) for the materials such as
pipes, pipe fittings, flow components, instruments, etc., fabrication
erection and commissioning shall be provided.
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4.2.4. Purchase of materials
The following spare shall be supplied along with FSS. The break-up
prices of the spares shall be given in the bid separately.
b. Spare parts and consumables for erection and commissioning: For the
materials used in the realization of FSS, contractor shall also supply the
spare parts (like seat insert, body gasket, gland packing, plug stem
assembly etc., for valves) and consumables like gaskets, PTFE tapes, etc,
used during erection and commissioning.
4.2.6 Fabrication
4.2.7. Inspection
All the bought-out materials and the works during fabrication at the
contractor’s factory shall be inspected by reputed third party inspection agency
(TPI) like Lloyds, BV, TUV and inspection during fabrication & erection at the
department’s site shall be done by department’s representative(s).
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f. Witnessing of pressure test, leak test and cleanliness test of the system
during fabrication and erection.
4.2.8. Transportation
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Imported items
The Contractor shall provide the list of items with cost break up to be
imported. Custom Duty Exemption Certificate (CDEC) for availing
concessional custom duty as per notification no. 5/2018 dated 25/01/2018 shall
be provided by the Department only for items consigned to IPRC Mahendragiri
against invoice submitted by the Contractor and concessional IGST as against
notification no. 47/2017. Necessary exemption certificates shall be issued by
IPRC as and when required. The Contractor shall be responsible for
transportation of items from their factory’s site to Chennai seaport/Trivandrum
airport. The Contractor shall be responsible for customs clearance and
transportation of consignment from seaport/airport to IPRC, Mahendragiri.
4.2.8.1 PACKING
The Contactor shall pack the control system and its accessories and make
the identification names at the top of each pack with order/contract no.
4.2.9. Erection
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4.2.10 Commissioning
4.2.11. Documentation
4.2.11.1 The Contractor shall submit the relevant documents during different
phases of the Contract as per the details given Sl. 4.2.2, Volume –I of this
RFP document for the respective systems. The documents are subject to
review by the Department. However, the Department’s approval shall not
absolve the Contractor of their responsibility to comply with the
specifications and obligations of the Contract.
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4.2.11.5 The Master documentation shall be exhaustive covering, but not
limited to, Contract & amendment (if any), FEED review report, Risk
analysis report, detail engineering documents & review reports, purchase
orders, general arrangement drawings of equipments, flow components &
instruments, pre-delivery inspection & test documents, invoices,
manufacturer’s instruction manuals for installation, operation, maintenance
& trouble-shooting, guarantee/ warranty certificates, construction/ erection
test & inspection documents, commissioning reports, PVTR execution report,
standard operating procedures, final acceptance certificate, minutes of
meetings, schedule charts, payment reconciliation statement, inventory of
spares with proper identification number correlating to their location in the
appropriate place, etc.
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5) Installation and commissioning of the system at Department site. Site
Acceptance Test (SAT) for control system. Training at Department site
6) Operation and Maintenance support for a period of two years after SAT.
7) Annual Maintenance contract (non-comprehensive) for a period of three
years.
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c) Supplier shall provide one copy of detailed engineering document in Hard
& Soft form to the purchaser for review and approval.
d) The soft copy shall be in editable version so as to enable modification in
future.
e) Only the purchaser approved document shall be followed for all further
commissioning activities.
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Software document in line with ISRO standard (ISPD-2). Necessary
template for preparing the document shall be provided by the
department.
4A.5.1 Positioning
Vendor’s responsibility at site shall include the following activities
necessary to be performed to complete the job satisfactorily.
Transport of system from site stores to actual location.
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The Vendor shall be responsible for lifting, transportation and safe
custody of the equipment until completion of its installation and
acceptance by Purchaser’s representative.
Copies of instructions/manuals shall be handed over to the
purchaser’s Engineer.
I/O nodes, Control system, command system, measurement system
and Programming, SCADA & Storage nodes shall be positioned in
instrumentation room.
Control system equipment shall be located such that it is easy to
approach for operation and maintenance.
Instrumentation rack, Junction box, cables, cable trays, cable lying
from cleaning facility to instrumentation rack shall be scope of
Vendor.
4A.5.2 Identification & verification
Unpacking the system and inspection of the same for damages.
All equipments shall be inspected thoroughly by vendor for
completeness and proper functioning. Vendor must initiate the
remedial action to replace the faulty equipment or item with
intimation to Purchaser.
Each individual component (e.g. input/output modules, switch, etc.)
shall be identified by part/model number and serial number. The
documentation shall reflect these identification marks.
Racks / enclosures shall be labeled in front and rear for easy
identification.
All internal & inter-cabinet wiring shall be ferruled with permanent
markers bearing identifications that can be cross referenced with
appropriate documentation. Colored ferrules shall be used with
proper coding philosophy. Tag plate shall be provided for the cable
no. identification on the top of the related terminal strip in the
cabinet. Cross ferruling shall be done.
4A.5.3 Installation, erection and commissioning of PLC based
measurement, command and control system.
Best engineering practices shall be followed to maintain high
standard of workmanship & quality in a neat and safe manner.
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Installation to be carried out as per approved detailed engineering
document.
All equipments, instruments, tools & materials required to carry out
the work shall be brought by the Vendor.
4A.5.3.1 Installation of control system
The control system shall be positioned.
Laying and termination of all inter panel earthing cables.
Ensure the correctness of control system hardware integration.
Ensure the loading of necessary software like system software,
application software etc.
The control system shall be powered ON.
4A.5.3.2 Functional checking of the control system
Vendor shall be responsible for loop checking which shall include
checking of the configuration, network interconnection from node to
PLC, I/O module to control system rack termination end and
ensuring over all system functioning.
Loop checking shall be carried out to check the functional
performance of all elements in the loop and thereby ensuring proper
functioning.
Inter system (control system functional check with field devices)
panel loop checking shall be carried out along with purchaser.
After completion of all functional tests as per specification, the
whole work shall be subjected to final inspection to ensure that start-
up trial can be commenced in the presence of Department Engineer.
If any defect is noticed, the Vendor shall arrange to rectify the
defects noticed.
4A.5.3.3 Erection and commissioning.
GENERAL INSTRUCTIONS
The contractor shall bring necessary tools required for erection &
commissioning of the instruments & components and an instrument
work shop shall be made ready at the erection site.
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Erection & commissioning works shall be carried out strictly according
to the specifications stipulated in the contract, documents/drawings
approved by department during detailed engineering. Also it shall be
carried out as per the supervision of the department’s representative.
The Contractor shall provide and maintain a formal system for
documenting technical clarification from the Department.
Only correctly signed documents which are marked “Approved for
Construction” (AFC) shall be used for installation work.
Only the best trade practices and correct tools shall be used and all
works are expected to be completed in a neat and safe manner.
Welding shall be done only by qualified personnel.
Electrical installation shall only be performed by appropriate qualified
trade persons.
Holes shall be drilled or punched and not burnt out by gas torches or
electric arcs.
Piping and tubing shall be formed with the appropriate pipe or tube
bending equipment.
Instrument/equipment shall be mounted using suitable
stands/brackets/clamps. As far as possible all instruments shall be
mounted on instrument support stands. These shall be installed on
floors, RCC columns and walls using approved make anchor
fasteners/Hilti bolts and on steel structure by drilling suitable holes and
using chromium plated/galvanized bolts and nuts or in exceptional
cases by welding. After welding, the slag on weld surface shall be
removed and one coat of Red-oxide primer and two coats of paint shall
be applied over the surface.
Equipment shall be installed in a neat, workman like manner so that it is
level, plumb, square and properly aligned and oriented.
Instruments should not be supported from impulse lines, hand rails and
vibrating structures.
Instruments shall be located such that it is easy to approach for
operation and maintenance. Cover can be removed without obstruction
and there should not be any problem in re-glanding the cable later on.
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All indicating instruments shall be located such that its scale is
conveniently visible to plant operator.
Canopy shall be provided for all the instruments, JBs and SOV located
outdoor.
All threaded opening of the instruments shall be protected by suitable
Aluminium/Chromium plated plugs.
During installation of the signal and control cables and prior to
connection up to the instruments, the cables shall be checked for the
insulation resistance, continuity and tagging.
If the insulation resistance is not found within the limits, these cables
shall not be used. The contractor should lay new cables, meeting the
continuity and insulation resistance requirements, without any cost
implication.
The signal and control cable wires shall be connected to respective
terminals, as per the wiring drawings.
Equipment shall be properly grouped at a convenient location based on
the equipment layout diagrams.
Allocation of grouping of channels based on signal levels in junction
boxes and racks shall be finalized during detailed engineering.
Separate trays shall be used for routing pneumatic tubes and cables.
Field transmitters (pressure, temperature, Flow &level) shall be
mounted on 2” pipe stands. The instrument stands shall have a suitable
height so that instrument shall be mounted at 1.4m from ground or
platform / catwalk. If the instrument to be mounted on a catwalk /
platform the preferred location shall be on the outside of the hand
railing.
To protect temperature probes from mechanical damage /entry of
water, suitable individual enclosures shall be designed.
Handling and Storage instruments
The Contractor shall be responsible for the collection of “free-issue”
instrument items, transportation, storage and safe custody of the
equipment until completion of its installation and acceptance by
Department’s representative. Contractor shall maintain a stock system to
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enable material tracking throughout the installation & commissioning of
the facility.
All instruments shall be visually examined by the Contractor on receipt
to ensure that they have not been damaged in transit. Instruments shall
then be replaced in their original packing and housed in a separate
secure, dry, cool storage area provided by the department.
If any item is lost or damaged by the contractor, new item may be
procured and replaced by the contractor with their own cost or the cost
of the item will be deducted from the contractor’s bill.
When unpacking is necessary, care shall be taken to ensure that
accessories are not mislaid or mixed.
Instruments shall not be left lying around the construction area.
All covers and plugs on the instrument connections shall be left in place
until connections are used.
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Radar based level sensors are to be used for level of fluid (IPA)
measurement inside the collection tank.
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RACK
Ra da r ba s ed level
s e ns o r
MU LTI 2-10V
4- 20mA CO RE
ISOLATOR CONTROL
JB
C
BARRIER SYSTEM
C
2 cor e pvc
Ar m our ed
cabl e PVC
CABLE
P ro ce ss
Li n e
24V DC,10A SMPS
C – C o n n ecto r
DP r. TX - Di ffere nti al Pre ssu re Tran smi tte r
JB – Ju n cti o n B o x
This measurement chain is used for monitoring the surface& fluid line
temperature.
4 wire RTDs are used as sensors. The sensors are interfaced to temperature
transmitters.
The 4 to 20mA output of temperature transmitter is wired to isolator.
Isolator is powered from 24V DC SMPS. The isolator and 24V DC SMPS
with low ripple are housed inside instrumentation rack located at
instrumentation room.
The output of isolator is given to PLC based Control system for acquisition
and monitoring.
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RACK
TEMP.
4 CORE
PVC CABLE TX 2-10V
CONNECTOR
MULTI CONTROL
4-20mA CORE SYSTEM
C
JB ISOLATOR
2 CORE PVC BARRIER
ARMOURED PVC
RTD CABLE CABLE
SENSOR
C – Connector
TEMP.TX - Temperature Transmitter
JB – Junction Box
RACK
M ass Flow meter
with TX.
M ULTI 2-10V
4-20mA
JB
COR E
ISOLATOR CONT ROL
C
A RM OURED
CA BLE
PV C
CABLE
Process
Line
24V DC,10A SM PS
C – Connector
JB – Junction Box
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4A.5.3b.5 E/P valve Command
SCOPE:
The scope involves procurement, installation & wiring of field elements like
SOV, pneumatic tubing, erection of cable trays, cable laying on cable trays,
wiring of instrumentation rack and interfacing between racks. List of E/P valves
is tabulated below.
In the Process Mode, relay PR1 is actuated. One contact of PR1 is given to
relay C1 Contactor for linking the field power supply to valve driver relay. The
other contact of PR1 relay is fed to DI card for PRO/SIM feedback indication.
When valve actuation command is generated from PLC Digital Output R1 valve
driver relays is actuated. The contacts of R1 relay are closed and Solenoid Valve
is actuated. In Simulation mode, the relay PR1 are not energized hence 24V DC
is not available for energizing Solenoid Valve.
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E/P valve status reception: For E/P valve switch status reception, 2 channel
Isolator is used in between field status switch of E/P valve and Digital Input
(DI) card of control system. Each isolator provides 2 sets of potential free
contacts, which is activated based on status inputs from the EP valve. Common
point of potential free contacts (Open and Close) are connected to +24V DC
Power Supply. ‘NO’ contacts are connected to DI card of Control System for
status reception. switches are used in field EP valves for status. Command
execution status is displayed by SCADA software of the PLC.The specifications
of relay, power supply and isolators are given in Volume-II.
Multi Command
EP Valve core
C RELAY C Multi core
Solenoid PTFE cable
PVC CONTROL
cable COM.ACK C SYSTEM
Status
Switches
OFF ON
Status Status
4 core RACK
PVC
STATUS
armoured
C BARRIER C
cable
JB
C – Connector
JB – Junction Box 24V DC SMPS
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ACK PS
+ -
PROCESS/ PR1
SIMULATION
SWITCH FIELD PS
+ -
+ POWER -
SUPPLY
CONSOLE
C
C1
CONTACTOR
PROC/SIM FEEDBACK
DI
DO
COMMAND R1
DI
COMMAND ACK
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Pump control is used for controlling flow of IPA through different tanks.
On/ Off command is given to each Pump valve through PLC for operation of
the pump. Flow rate is to be controlled by varying the speed of the pump.
Analog output is to be given to drive the pump from the PLC. Chain diagram
and Pump control details to be finalized after detailed engineering. Pump
monitoring and control are required for Feed Pump and recirculation pump
only. Pump P1 shall be manually operated. List of pump is tabulated below.
2 Drive Run FB DI 1
2
3 Drive OFF FB DI 1
4 Drive Trip FB DI 1
5 Speed Reference AO 1 1
6 Speed Feedback AI 1 1
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1 Drive Ready FB DI 1
2 Drive Run FB DI 1
2
3 Drive OFF FB DI 1
4 Drive Trip FB DI 1
5 Speed Reference AO 1 1
6 Speed Feedback AI 1 1
The scope of work involves procurement, conduit laying and laying of cable
through conduits with one end termination in MCB and the other end
termination in instrumentation rack, console or other equipment.
For equipment powering, 230V, 50Hz power outlet is available in
instrumentation room at MCB distribution board.
This power from these MCB boards has to be distributed to equipment,
racks and consoles.
Main panel to Rack/console/equipment power distribution: The power
from MCB board is to be distributed to racks/consoles/equipment. The
power cable shall be laid in conduits and terminated in Terminal blocks/
sockets/ Master MCB on one side. The other end termination shall be
made in MCBs of MCB board.
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Rack power distribution: One master MCB shall be planned for
instrumentation rack for power distribution within rack equipment. From
Master MCB, power shall be distributed to other equipment of rack using
terminal blocks.
Console Power distribution: One master MCB shall be planned for 3
segments of console. From Master MCB, power shall be distributed to
other equipment of consoles using terminal blocks.
The work involves cable shield preparation & and its wiring, laying of
grounding cable with one end termination in racks/ rack equipments and the
other end termination in grounding strip.
Separate instrumentation and power earth grounding strips are
available in the instrumentation room (Department scope).
The instrumentation earth and power earth are separately maintained.
The cable shields of all cables shall be prepared and terminated at all
termination points (Junction box/connector) in cleaning facility bay
except at sensor. The isolation from ground shall be ensured at all
termination points in cleaning facility bay.
In instrumentation rack, isolated instrumentation earth strip are
available. The instrumentation cable shields shall be connected to
earthing strip in rack and in turn to instrumentation earth strip
running through the building.
All the equipment body are to be connected to power earth.
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In these console, All in one PC (Personal Computers) will be placed for
data display/configuration/data processing/mimic display. These
consoles will be positioned in instrumentation room.
The switches, keys, indicators, power supply, keyboard for CCTV system
controller and intercommunication equipment shall be mounted in
consoles. Items like CCTV system controller and intercommunication
equipment will be in scope of Department. The consoles will be located
in instrumentation room.
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c) The details of training shall include
i. Hardware Installation
ii. System program development
iii. System Engineering & Configuration
iv. Networking / Communication technique
v. Installation of all software packages
vi. PID programming
vii. Data base creation & Management
viii. Mimic page creation and tag assignment
ix. Application program development in control system
x. Error diagnostics & trouble shooting
xi. Any other area on mutually agreed basis
xii. Hardware maintenance
The contractor shall bring all the required test and measure instruments
required for testing and evaluation. The standard Source/Measure equipments
with calibration validity traceable to national standards shall be used by the
contractor. The equipments of ±0.02% accuracy class of shall be used for
sourcing and measuring.
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3. Check and log insulation resistance of all cables, continuity of wiring of all
instrument loops as per the relevant drawings.
4. Integrity test up to sensor shall be done.
5. Power supply load test: All the power supplies shall be load tested up
110% of rated load. The stability and ripple test shall also be carried out.
Measurement system
Command System
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16. The inspection by the department’s representative and issue of inspection
certificate thereon shall in no way limit the liabilities and responsibilities
of the contractor in meeting the specification and quality requirements
specified.
17. The contractor shall supply the material test certificates / calibration
certificates (wherever mentioned) for the items under the supply of
contractor’s scope.
18. The contractor shall supply and maintain an independent comprehensive
database system containing inspection & testing and performance records
for each instrument.
5. EXECUTION SCHEDULE
The total contract period, reckoned from the date of award of the contract
to the date of commissioning and final acceptance of the system, shall be 10
months. The bidder shall indicate, in the bid, the schedules for various work
phases, which shall not exceed the overall contract period. Upon award of
contract and before commencement of work, the Contractor shall prepare a
detailed and comprehensive schedule for review and approval by the
Department. This approved schedule shall form the basis for all the works to be
performed by the Contractor.
The schedules shall be shown in the form of master PERT network and
show the date on which each part of the work is expected to begin and to be
finished. The Contractor shall prepare the detailed network charts for the total
contract period and it shall be up-dated once in a month. For each sub-system
or work package, an independent network chart is to be prepared. It is to be
noted that the schedule is the essence of the contract and Department will
closely monitor and take appropriate actions wherever necessary.
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5.2. Project reviews and meetings
The preparation of all documentation for reviews and meetings is
the Contractor’s responsibility. The reviews shall be based on PERT/
CPM network schedules in each phase and shall be adhered to by the
Contractor. The deviations, if any, are to be clearly documented and
possible end effects brought out at each phase. The frequency of review
at the closing phase of the project shall be suitably increased to resolve
any outstanding issues.
6. PHASES OF WORK
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Department at Mahendragiri immediately on receipt of the Contractor’s
comments/ recommendations. The design mutually agreed after the
review shall be the basic document for execution.
6.3. Fabrication
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6.4. Erection
6.5. Commissioning
A final acceptance review will take place after all the necessary
commissioning trials are over and are documented as per the Department’s
requirements. A training program on the systems and on each applicable
sub-system shall be given at the end of the acceptance test to the
Department’s representative(s).
7. WARRANTY
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reserves the option to reject the ill-performing equipments/ systems and
when this option is exercised by the Department, the Contractor shall
replace the rejected equipments/ systems by new ones at his own cost to
the Department’s satisfaction within a reasonable period of time as
indicated by the Department.
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8 GENERAL CONDITIONS
8.1.1. The contract to be entered into shall convey the final agreement
between the Department and the Contractor on the terms and
conditions and be a complete and exclusive statement of the terms of
the agreement.
8.1.2. In the event of conflicts between general conditions of contract and the
specification documents furnished by the Department, the latter will
take precedence.
8.3.1. The Department will have the right, at any time, to cancel the contract
either wholly or in part by giving one month written notice. The
Contractor shall undertake to observe the instructions of the
Department as to the winding up of the contract both on his own part
and on the part of his sub-contractors.
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the Contractor under the contract and its amendments, if any, exceeds
the total payment for the work set forth in the contract and its
amendments, if any.
8.3.5. The ownership of all materials, part and unfinished work paid for by
the Department under the provisions of this Section shall be vested in
or transferred to the Department as soon as they have been paid for.
8.4.1. The department shall reserve the right to terminate the contract in the
circumstances detailed hereunder:
8.4.2. When the Contractor makes themselves liable for action under the
circumstances mentioned above, the Department will have power to
forfeit the security deposit of the Contractor and the Contractor shall
have no claim for damages whatsoever on such forfeiture.
The Department will pay to the Contractor as per the quoted prices in
the contract for completed system/ sub-system/ equipment delivered
to and accepted by the Department and for manufacturing materials
delivered and accepted. For the partially completed system/ sub-
systems/ equipment accepted by the Department, payment will be
made at mutually agreed prices. After termination of the contract, the
balance items of work shall be got executed by the Department
through other agencies at the risk and cost of the Contractor.
8.5.1. The Department shall reserve the right at any time to modify the
qualitative requirements, specifications, patents or drawings relating
to the work covered by the contract. The Contractor shall inform the
Department, within 30 days, of any objection they have to the
modifications required.
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8.6. Sub-contracting
The Contractor shall not assign or sub-contract the work or any part of
the work without the written approval of the Department. In the event of
approval of sub-contractors, the detailed specifications and drawings of sub-
contracted items shall be approved by the Department.
All the works carried-out by such sub-contractors shall also be
scrutinized, inspected and approved by the Department. However, the
responsibility of the performance of such sub-contracted systems shall lie with
the Contractor. Any delay in carrying out the work by the sub-contractor which
affects the overall schedule of the work does not absolve the Contractor from
payment of compensation for the delays. All terms and conditions applicable to
the Contractor shall also be applicable to the sub-contractor who has been
assigned the sub-systems.
All the materials supplied or used shall be new and of first quality and
manufactured and tested in accordance with the latest editions of the relevant
Indian/ International standards. Wherever imported components are used,
they shall be manufactured in accordance with the relevant standards published
in the country of manufacture after allowing for specific aspects under Indian
conditions such as tropical climate, etc. Any material or work, where no
specific standard is applicable, shall be fabricated as per the instructions and
directions of the Department.
All the electrical equipments used shall conform to the latest Indian
Electricity Rules as regards safety, earthing and other essential provisions
specified therein for installation and operation of electrical parts.
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8.8. Secrecy
The technical information, drawings, specifications and other related
documents forming part of enquiry or contract are the property of the
Department and shall not be used for any other purpose, except for execution of
the contract. All rights, including rights in the event of grant of a patent and
registration of designs are reserved. The technical information, drawings,
specifications, records and other documents shall not be copied, transcribed,
traced or reproduced in any other form or otherwise in whole and/ or
duplicated, modified, divulged and/ or disclosed to a third party and/ or not
misused in any other form whatsoever without the Department’s consent in
writing except to the extent required for the execution of this contract. These
technical information, drawings, specifications and other related documents
shall be returned to the Department with all approved copies and duplicates, if
any, immediately after they have been used for the agreed purpose.
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8.14. Arbitration
The Parties shall carry out their respective obligations under the Contract
in the spirit of mutual cooperation, good faith & harmony. Except in matters in
respect of which the decision of the Department is final as specified in the
Contract, any difference, dispute or controversy shall be resolved and settled
amicably among the Parties through mutual consultations. If, however, that is
not possible, the Parties shall agree that all disputes arising out of or in
connection with the Contract shall be finally and conclusively decided by
arbitration and the award in pursuance thereof shall be binding on the Parties.
The court of arbitration shall base its decision on this Contract with resort
to Indian law. The arbitration shall take place in India. The language shall be
English. Work under the Contract shall, if reasonably possible, continue during
arbitration proceedings.
a. In the event of any question, dispute or difference arising under these
conditions or any condition contained in the Contract (except as to any
matter the decision of which is specially provided for by these
conditions), the same shall be referred to the sole arbitration of the
Director, IPRC or some other person appointed by him. There shall not
be any objection that the arbitrator is a Government servant; that he had
to deal with matter to which the Contract relates; or that in the course of
his duties as Government servant he has expressed views on all or any
other matters in dispute or difference. The award of the arbitrator shall
be final and binding on the Parties to the Contract.
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If the arbitrator be the Director, IPRC,
ii. In the event of his being unwilling or unable to act for any
reason, it shall be lawful for the Director, IPRC to appoint
another person as arbitrator.
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8.15. Assignment
The contract shall be binding upon the successors and assignees of the
parties hereto. It shall not be assigned in whole or in part by either party
without prior written consent of the other. If the Contractor becomes insolvent
or being a firm or company whether incorporated or not is dissolved or goes
into bankruptcy or is caused to be wound up except for re-construction
purposes or carried on its business under a receiver, the representatives in law
of the estate of the Contractor or any such receiver, liquidator or any person in
whom the agreement may be vested shall forthwith give notice thereof in
writing to the Department and shall remain liable for the successful
performance of the Contractor or the successors of their obligations under this
contract under any circumstances.
The specifications of the contract are intended to describe and provide for
a finished system. It is to be understood and agreed by the Contractor that the
work described shall be complete in every detail, even though every item
necessarily involved is not particularly mentioned. The Contractor shall be
required to provide all labour, materials and equipment necessary for the entire
completion of the work described and shall not avail themselves of any
manifesting unintentional error, omission or inconsistency that may exist. The
Contractor shall carry out and complete the work in every respect in accordance
with the contract and the directions and to the satisfaction of the Department.
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a. The Department will have the right to direct the manner in which all work
under this contract shall be done, in so far as it may be necessary to secure
the safe and proper progress and the specified quality of the work and all
work shall be done and all material shall be furnished to the satisfaction
and approval of the Department.
d. The work by the Contractor at site beyond normal working hours (08:45 to
17:15 hr) on working days and any time on holidays (including Saturdays
and Sundays) shall be permitted only with prior approval of the
Department. The Department may also direct the Contractor to operate
extra shifts over and above normal day shift to ensure completion of the
contract on schedule if, in the opinion of the Department, such work is
required.
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8.19.1. The Contractor shall provide everything necessary for the proper
execution of the work according to the intent and meaning of the
specifications whether the same may or may not be particularly shown
or described therein, provided that the same can reasonably be
inferred there-from and if the Contractor finds any discrepancy there-
in, they shall immediately and in writing refer the same to the
Department whose decision shall be final and binding on the
Contractor.
8.19.2. If any part of the Contractor’s work depends for proper execution
upon the work of any other contractor, the Contractor shall inspect
and promptly report in writing the Department any defect in such
work of the other contractors that tender it un-suitable for proper
execution of the work under this contract. Their failure to so inspect
and report shall constitute acceptance of the other contractor’s work as
fit and proper for the reception of their work, except as to defects
which may develop in the work of the other contractors after proper
execution of the work. To ensure proper execution of their subsequent
work, the Contractor shall measure the work already in place and
shall at once report to the Department any discrepancy between the
executed work and the drawings.
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8.19.3. The Contractor shall not sell, assign, mortgage, hypothecate or remove
equipments or materials which have been erected or which may be
necessary for the completion of the contract without the written
consent of the Department.
8.19.4. In the execution of the work, no person other than the Contractor, or
their duly appointed representatives, their sub-contractors and their
workmen, shall be allowed to do work at the site except by the special
permission, in writing by the Department.
8.19.5. The Contractor shall proceed with the work to be performed under
this contract and each and every part and detail thereof, in the best
and most workmen-like manner by engaging qualified, careful and
efficient workers and do the several parts thereof at such time and in
such order as the Department directs and finish such work in strict
conformance with the plans, drawings and/ or specifications, and any
changes, modifications or amplifications thereof made by the
Department.
8.20.1. For full completion of the work, the Contractor shall, at their own
expense, furnish all necessary false work, erection tools, machine tools,
power tools, tackles, hoists, cranes, derricks, cables, slings, skids,
scaffolding, work benches, tools for rigging, cribbing and blocking,
welding machines, pre-heating and stress relieving equipment, X-ray
and all associated protective equipments, appliances, materials and
supplies required to accomplish the work under the contract unless
otherwise provided for. Adequacy of such tools shall be subject to
final determination of the Department.
8.20.2. The Contractor shall also furnish all necessary expendable devices like
anchors, grinding and abrasive wheels, plugs, hacksaw blades, taps,
dies, drills, reamers, chisels, files, carborundum stones, oil stones, wire
brushes, necessary scaffolding, ladders, wooden planks, timbers,
sleepers, and consumable materials like oxygen, acetylene, argon,
lubricating oils, greases, cleaning fluids, cylinder oil, graphite powder
and flakes, fasteners, gaskets, temporary supports, stainless steel
shims or various thicknesses as required, cotton waste, PTFE tapes
and all other miscellaneous supplies of every kind required for
carrying out the work under the contract.
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8.20.3. The Contractor shall provide all reasonable facilities including tools,
personnel, etc and ensure co-ordination with the Department and their
inspection agencies so as to enable them to carry out all supervision,
measurements, checks, etc in a satisfactory manner.
8.20.4. The Contractor shall not dispose, transport or withdraw any tools,
tackles, equipments and materials provided by them for the contract
without taking prior written approval from the Department and the
Department at all times shall have right to refuse permission for
disposal, transport or withdrawal of tools, tackles, equipment and
material if in their opinion, the same will adversely affect the efficient
and expeditious completion of the work.
8.21.1. The Department will not be responsible or held liable for any damage
to person or property consequent upon the use, misuse or failure of
any construction/ fabrication tools and equipment used by the
Contractor or any of their sub-contractor’s, even though such
construction tools and equipment may be furnished, rented or loaned
to the Contractor or any of their sub-contractor. The acceptance and/
or use of any such construction tools and equipment by the Contractor
or their sub-contractors shall be construed to mean that Contractor
accepts all responsibilities for and agree to indemnify and save
harmless the Department from any and all claims for said damages
resulting from said use, misuse or failure of such construction tools
and equipment.
8.21.4. The Contractor shall effectively protect all the works from action of
weather and from damages or defacement and shall cover finished
parts where required for their thorough protection.
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8.21.5. The Contractor shall cover the work by a Contractor’s all-risk policy
during the currency of the contract.
The contractor may have access to the Departments qualified first aid
personnel and ambulance in case of accidents, subject to the availability of the
same. However, the Contractor shall make his own medical and transport
arrangements to take care of his employees in case of accident. The Contractor
shall provide a first aid kit at the work site to meet the requirements of minor
injuries.
8.24 Reporting
a. Progress achieved
b. Expected dates for completion of individual works
c. Any actual or likely delay in the execution of work
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8.25 Working and Safety Regulations
The Contractor shall observe all statutory and legal requirements
enforced by Central and State Government applicable to the work as well as any
local regulations applying to the site issued by Department or any other
authority. Particular attention is drawn to the following;
a. In case of accident, the Department shall be informed in writing
forthwith. The Contractor shall strictly follow the regulations laid down
by the Factory Inspector, Central and State Government authorities in this
regard.
b. Compliance with all electricity regulations.
8.27 . Power
Electricity will be supplied as mentioned in Sl. 4.1.5/Volume-I.
Contractor must provide power supply distributor with isolator for taking
power for his equipments. Contractor should obtain Electrical safety clearance
from both CMG group and safety clearance from safety division of IPRC before
starting the work.
8.28. Water
The Department will provide at a fixed point near the work spot of the
Contractor electrical power free of cost. It shall however be the responsibility of
the Contractor to extend the facility to suit their requirement at their own cost.
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The Contractor shall not however have any claim against the Department
in the event of failure, interruption/ insufficiency of these services. If required,
the Contractor may employ a portable Diesel Generator (DG) set to get regular
power supply. The Department will provide at site, free of cost, space for
construction of an office and of a room for proper storage of instruments and
precision tools. However, the office, the room for storing instruments, precision
tools, etc and other constructions such as tool room adjacent to place of
installation, welding sheds, fabrication sheds, labour rest rooms, etc, shall be
installed by the Contractor at their own cost, only at locations designated and
only if approved by the Department.
Since the systems are highly complex in nature, the philosophy and
criteria to be adopted shall be highly safety-and-reliability-oriented for their
systematic and proper functioning. The designs of the sub-system, components,
equipments to be carried out by the Contractor shall specifically address
essential safety provisions both in-built and external. Reliability is a prime
factor, which has to be embedded in the process of realization of the system. To
ensure that the sub-system design, development, selection of equipment,
components, material, etc are in compliance with the standard engineering
practices, it is necessary to follow established design codes and standards.
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8.34 Purchase of Materials
The Contractor shall deploy Indian National only for execution of the
work.
Only skilled employees with experience of this particular work shall be
employed.
No person below the age of 18 years shall be employed.
The Supplier shall pay to each person, wages not less than those specified
by Minimum Wages Act.
The employees/labour, for carrying out all the site works shall be
identified well in advance by the Contractor and necessary approval shall
be obtained from the Department for entry permit to the work site.
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During the currency of the contract, the Department may have its
authorized representative(s) stationed at the factory of the Contractor. The
Contractor shall provide office accommodation for the Department’s
representative(s) and also to permit the usage of telephone, fax, E-mail, etc, as
and when found necessary.
9 INSTRUCTION TO BIDDER
The proposals are invited on behalf of the President of India by the Head,
Purchase & Stores, IPRC, Mahendragiri, from the Bidders for the work
described in this RFP document for IPRC, Mahendragiri. The bids shall be
submitted online through IPRC centre e-link.
9.1 Scope of work: The scope of the work is establishment of Fluid
Servicing system through Engineering, Procurement & Construction
(EPC) mode as per the specification given in this document. The
Contractor is required to submit a complete bid for the entire work
mentioned herein. Any incomplete bid will be summarily rejected.
9.2 Execution period: The entire work is to be completed within
10 months. The Contractor shall submit a master schedule detailing their
realization plan so as to comply with the overall execution period stated
herein, in the form of a Gantt chart, indicating the sequence and duration
of the various phases of work.
9.2.1 Validity: The bid submitted shall be valid for a period of 8 months
from the due date for opening of the techno-commercial bid.
9.2.2 The Department reserves the right to reject any or all bids in whole
or part without assigning reason thereof.
9.3 Form of bid: The bid shall be submitted in 2 separate parts viz Part 1 for
Techno-commercial bid and Part 2 for Price bid.
9.3.1 Techno-commercial Bid: The techno-commercial bid shall give the
complete details on technical & commercial aspects only. The techno-
commercial bid shall not contain any price detail. Mention of any price
detail in the techno-commercial bid will render the entire bid invalid.
The techno-commercial bid may include a format of the price bid by the
Contractor, without any detail of the price quoted. Deviation, if any, in
the Contractor’s proposal with respect to this document shall be explicitly
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mentioned in the schedule of deviations to be provided in the bid. If the
Contractor does not mention any deviation, it shall be construed by the
Department that the Contractor agrees to comply with each and every
aspect of this document.
9.3.2 Price bid: The price details shall be mentioned only in the price-bid
template in e-Procurement portal.
9.3.2.1 Any additional price detail may be attached as a pdf.
document (signed & scanned) to price bid only. Mentioning
any form of price in the techno commercial part will result in
summary rejection of the bid submitted by the particular
bidder.
9.4 Online Bid Submission
9.4.1 The Bidders shall arrange all resources, including Digital Signature
Certificates (DSC) and Internet connections, at their own cost for
participating in online bidding. The bid shall be submitted online in the
IPRC Centre link before the due date and time as specified in the tender
schedule in the portal.
9.4.2 All enquiries regarding the tenders and submission of offers shall be
online and only through our e-Procurement portal.
9.4.3 The Bidder may approach helpdesk on the home page for any technical
help (e-mail: support.isro@nextenders.com and Phone: 0091 20 2531555)
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9.4.5 The time taken to ascertain, evaluate and suggest a solution for the
problem reported by the Bidder may vary from case to case. Hence, the
Bidders are advised to submit the bid well in advance before closing date
and time to avoid last-minute issues.
9.4.6 The Department will not be responsible for failure of the Bidders in
submitting bids online caused due to technical reasons at the Bidder’s end
such as network or power failures, computer failure, internet browser,
mistakes/ errors in filling the bids online, etc.
9.4.7 Queries by the Bidders on technical problems on the last day of bid
submission will not be binding on the Department for resolving/
addressing. The Department will not be responsible for non-submission
of bids in those cases.
9.4.9 Request, if any, for extension of tender due date shall reach the
Department at least 4 working days in advance of due date and time for
consideration. The Department is not bound by such requests to extend
the due date unless it feels necessary.
9.4.10 The e-procurement system does not permit submission of any bid after
closing date and time of the e-tender. Hence, there is no scope for any
late or delayed bid in the online process.
9.4.11 Requests for extension of due date and time citing technical issues in
online submission of bids will not be entertained.
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9.4.13 The Bidders have to note that once rework is initiated, the status of the
earlier submitted bid becomes pending till the bidding process is
completed once again. During the process of rework, bid data submitted
earlier becomes invalid and will not be available for opening. If rework is
initiated, then Contractor has to complete the entire process of bid
submission once again within the due date and time for a valid bid
submission.
9.4.16 The Bidders shall note that since this is a two-part bid, the price details
shall be mentioned only in the price-bid template. If the price
details either in part or full are indicated in the technical bid, the
bid will be disqualified.
9.4.17 The Bidders may note that, in e-procurement system, submission of bid is
a 2-step process. After submission of their bids, the Bidders have to wait
for bid sealing by the Department. Following that, the Bidders have to
submit open authorization in the e-procurement system to enable the
Department to open the bid. If open authorization is not completed by the
Contractor, then the Department will not be able to open the bid and the
bid becomes invalid.
9.4.18 The Bidders may note that digital keys of Class III USB tokens, which
support both digital signing and encryption are to be used for bidding in
IPRC e-procurement system
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9.4.19 The Bidders may note that they have to use the same digital key
with which they submitted the bid to give open authorization. If
the Bidders use different key for open authorization, the system will not
accept the open authorization and the bid becomes invalid.
9.4.20 In case the digital key which is used during bid submission expires before
giving open authorization, then the Bidder has to first login with the new
key and use the expired key for completing open authorization process
for the bid.
9.4.21 The Bidders may note that the maximum file size that can be uploaded
per attachment in e-procurement system is 4 MB (in pdf format). If the
document is more than 4 MB, then the document is to be split into
multiple documents of size less than 4 MB and uploaded into
attachments. Literature/ Technical data should accompany the bid.
9.4.22 Similarly, if the number of files to be uploaded is more than the number
of attachments allowed in the bid, then the files are to be grouped into
folders such that the number of folders is less than the number of
attachments. Further, the folders may be compressed using zip/ archive
format and uploaded as attachments. However, the attachment size
should still be less than 4 MB.
9.4.23 The Bidders may note that documents including literature/ technical data
are to be uploaded through e-procurement system only.
9.4.24 Bids sent through post, telegram, fax, telex, e-mail, courier, etc will not be
considered. Partially completed/ incomplete bids will not be considered.
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9.8 Documents
On the other hand, if the Department accepts the system, though it fails to
meet the specification fully, the Department will, at their own discretion, make
necessary recoveries for such shortfall in performance.
9.9 Prices
The bidder shall quote firm and fixed prices valid during the currency of
the contract till commissioning and final acceptance of the test stand to the
satisfaction of the Department. The prices shall include all taxes, levies like
octroi, duties, taxes, royalties, permits charges, etc, levied by any central, state,
local or other Governmental authority, which the Contractor is required to pay
in their country as well as in India with reference to the fabrication, purchase,
transportation up to the delivery point stated in this document.
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The bidder shall provide the minimum level of break-up prices as given
in the Table. A in PRICE DETAILS . However, the bidder is advised to quote
the item-wise break-up prices of the various items forming the sub-systems, to
such fine extent as necessary and possible.
The price of the materials purchased from the sub-contractors and the
services rendered by the sub-contractors in India shall be separately mentioned
in the bid, for which the payment shall be made in Indian currency only.
There shall not be any change in the contract price due to addition/
deletion and reduction/ increase in the sizes of fluid circuits arising out of the
design review and detail engineering review.
9.10.1 IPRC is eligible for concessional GST @ 5% for supply portion and
@ 18% for service portion against notification no. 47/2017 and
45/2017. Necessary exemption certificate shall be provided as and
when required against invoice.
9.10.2 The Bidder shall indicate, separately in the price bid, the applicable
rate of Goods and Service Tax (GST) and Custom Duty levied by
the Central or State Governments within India for materials or
services prevailing at the time of submission of bid. In case of any
change in rate or structure of taxes, duties or levies by the Central
or State Governments within India, the taxes shall be reimbursed at
actual.
9.10.3 The Department is eligible for concessional rates of GST for supply
of materials as per Notification # 45/2017- Central Tax and
47/2017-Integrated Tax dated 14/11/2017.
9.10.4 The Department is eligible for concessional rates of Custom Duty
as per Notification # 5/2018 dated 25/01/2018 for imported
materials and also the materials manufactured in Special Economic
Zones in India exclusively to be utilized for this CTPT project of
IPRC against proforma invoice submitted by the Foreign
Contractor/ Sub-vendor.
9.10.5 The Department will make statutory deduction on account of
Income tax as per the extant provisions of the Indian Income Tax
Act, 1961 and issue “Tax Deducted at Source (TDS)” certificate to
the Indian Contractor.
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Unit prices specified in contract for all the items shall remain valid as
long as actual quantity installed is within ± 25% of the total quantity specified in
RFP.
For variation above ± 25%, due to any change in scope of work, a Joint
Review Board including /Contractor’s representatives shall be constituted to
arrive at the price on mutual agreement without holding the work.
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9.12.2Milestone Payment
b. 100 % of the applicable taxes, duties, levies, etc will also be paid along
with the milestone payment claimed against actual delivery of the
material/service.
c. The invoice for each milestone payment for delivery of material shall be
accompanied by
i. Certification by the Department of having accepted the Pre-
Delivery Inspection (PDI) document
ii. Certificate of country of origin (for imported materials)
iii. Packing list/ Delivery Challan (DC) showing dimensions, gross
mass, net mass, quantity & content of packages
iv. Non-negotiable copy of Lorry Receipt (LR)/ Bill of Lading
(BL)/ Master Air Way Bill (MAWB)
v. Freight insurance policy
d. The invoice for each milestone payment for service shall be
accompanied by certification by the Department to the effect that the
Contractor has completed the service satisfactorily. The milestone
payment for design review & detail engineering will be made against
submission of BG valid till final acceptance of Fluid servicing system
for Automated Continuous Cleaning with additional claim period of 2
months.
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9.12.3Final payment
The balance of 10% of the total Contract price will be paid upon final
acceptance of Fluid servicing system for Automated Continuous Cleaning. The
invoice shall be accompanied by
a. Final acceptance certificate by the Department upon successful
completion of all contractual obligations by the Contractor, including
commissioning.
b. Warranty certificate
c. Performance Bank Guarantee
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9.15 Prior Turnover and prior experience:
9.15.1 The average annual financial turnover during last 3 years ending
31/03/2019 must be at least Rs 75 lakh. Escalation at the rate of 7% per
full year may be added on the annual turnover to arrive at the present
value as on 31/03/2019.
9.15.2 The Bidder shall attach audited balance sheet/ Annual report for prior
turnover.
9.15.3 The price of similar works successfully completed during last 7 years
ending 31/03/2019 must be as follows:
1 similar completed work costing not less than Rs 2 Crore
OR
2 similar completed works costing not less than Rs 1.25 Crore each
OR
3 similar completed works costing not less than Rs 1 Crore each.
Note:
(a) Engineering shall comprise design, detail engineering and analysis.
(b) Procurement shall comprise purchase of materials, quality control and
project management service.
(c) Construction shall comprise fabrication (offsite/ onsite), erection, testing &
commissioning.
9.15.4 The Work completion/ Final acceptance certificate issued by the Client in
favour of the Bidder or Inspection release note by Third Party Inspection
agency/ Consultant must be dated between 31/01/2011 and 31/03/2019.
Escalation at the rate of 7% per full year may be added on the price of
previously completed works to arrive at the present value as on
31/03/2019.
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9.16 Technical capability of Bidder:
9.16.1 The Bidder or Bidder along with proposed 1 or 2 subcontractor(s) shall
have capability covering piping, IPA and GN2 system. In any case, the
Contractor (successful Bidder) will have overall responsibility.
9.16.2 The Bidder shall mention, in the techno-commercial bid, whether they
propose to execute the Contract on their own OR they propose to engage
sub-contractor(s) for (i) Engineering AND/ OR (ii) Construction.
9.16.3 Group/ Parent/ subsidiary company of the Bidder may also be engaged
as subcontractor. The Contractor (successful Bidder) shall not be
permitted to change the Subcontractor upon award of Contract, till the
completion of work, without permission of the Department.
9.16.4 The Bidder shall give full information about their credentials/
subcontractor’s credentials substantiated by valid documents (Work
completion/ Final acceptance certificate issued by the Client in favour of
the Bidder/ subcontractor or Inspection release note by Third Party
Inspection agency/ Consultant) to comply with criteria mentioned
above. Experience shall pertain to works completed within 7 years
ending on 31-03-2019.
9.16.5 The Bidder and their subcontractor(s) must possess adequate & suitably
qualified and experienced in-house personnel at all levels such as
managerial, supervisory & tradesmen level and in the area of design,
procurement, fabrication & erection to execute the works given in this
document. The details shall be provided along with the techno-
commercial bid.
9.16.6 The Bidder and their subcontractor(s) must possess adequate facilities
(hardware & software) for design & detail engineering. The details shall
be provided along with the techno-commercial bid.
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9.17 Execution plan
The bidder shall provide the execution plan for design review & detailed
engineering, purchase of materials, fabrication, erection and commissioning.
The bidder shall highlight the works proposed to be done in their own factory
and the works proposed to be done by their sub-contractors. The list of sub-
contractors from whom the bidder proposes to purchase the materials and the
sub-contractors with whom the bidder proposes to sub-delegate part of the
work shall be provided. The company profile of such sub-contractors/ sub-
contractors shall be given as per the requirements given in Section 5 volume-II.
The Department will have the right to scrutinise and to agree/ disagree with the
sub-contractors/ sub-contractors proposed by the bidder.
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MEMORANDUM OF UNDERTAKING
I/ We hereby submit the bid for the execution for the President of India of
the work specified in the underwritten memorandum within the time specified
in such memorandum, at a total price as specified and in all respects in
accordance with the specifications, design, drawings and instructions in writing
referred to in this document and with such materials as provided for by and in
all other respects in accordance with such conditions as are applicable.
Witness Bidder
(Signature) (Signature)
Name: Name:
Designation: Designation:
Address: Address
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17. Power supply :
24V±10%- 10A SMPS (Low ripple) 3 Sets
(one set is 2 individual power
supplies with diode oring mode)
18. Connectors and its accessories 5 Set
19. Instrumentation rack 1 No.
20. 3 segment Console 1 No.
21. Power cable 100 m
22. Earth cable 50 m
23. Terminal block
Terminal block- powering 200 Nos
24. Switches, Keys &indicators
Indicators 5 Nos
Authorization keys 2 Nos
Switches (in two position) with 2 Nos
Indicators
25. MCBs 20 Nos
PLC based control system including 1 Set
26. 3 user PCs, operating software,
SCADA, Printer, etc.
Spare 1 Set
1. Processoe-1 no.
2. ALL I/O module each
27. type-1no.
3. PC-1 NO.
4. Printer-Black & white -
1 no.; Colour-1 no.
Sub Total -1
B. ERECTION WORKS
1. Mounting of pressure transmitter 16 Nos
and its impulse tubing
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5. Mounting of 5 SOVs with E/P valve 5 Nos
11. Training
12. Commissioning
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Volume II
VOLUME II
VOLUME-II
1.A.1 Pipes
TESTS
Chemical analysis: One specimen from each lot shall be subject to detailed
chemical analysis as per ASTM A 751
Mechanical tests: One specimen from each lot shall be subject to tests for
mechanical properties per ASTM A 370 (including Impact test.)
Eddy current test: All the SS pipes of size 20 NB shall be subject to eddy
current test as per ASTM E 426.
Flattening test: Pieces of pipes of length 63.5mm (2.5”) cut form the ends of
5% of pipes lengths per lot shall be subject to flattening test as per ASTM A
530 in 2 steps to prove ductility and soundness.
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Inter-granular corrosion test: One specimen per lot shall be subjected to inter-
granular corrosion test as per ASTM A 262 (practice A/E).
Dimensional check: One specimen from each lot shall be checked for
dimensions as per the standard.
Chemical analysis: One specimen from each lot shall be subject to detailed
chemical analysis.
Mechanical tests: One specimen from each lot shall be subject to mechanical
test to verify mechanical properties.
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Application : Isolation
End connection
Style of construction:
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Bonnet : Bolted or screwed to body with spring-
energised seals
Material of construction:
Body and Bonnet : ASTM A182F 304 L / 316L / 321 For
≤DN40
ASTM A351 CF3 /CF3M For ≥DN50
Stem, plug, seat : ASTM A479 304L/ 316L/ 321
Note:
1. The valves shall be either inherently anti-static or provided with
anti-static features.
2. Dual marking material (SS304L/304 or SS316L/316) is also
acceptable wherever applicable.
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Design code : BS 5352/ BS 6364/ API 6-D/ ANSI B16.34
Test code : BS 6755/ API 598
Tests:
Welding joint test: Any butt welding joint in the valve shall be subject to DP
Test, radio-graphic test with X-rays or gamma rays to 2-2T sensitivity.
Soundness test for castings: All the castings shall be subject to soundness
test with radio-graphic test with X-rays or ultra-sonic technique for flaw
detection.
Hydraulic shell pressure test: The valve shall be upon assembly subject to
pressure test with Water (with suitable corrosion inhibitor) at 1.5 times the
maximum rated working pressure of the particular pressure rating class of
the valve. The test procedure and acceptance criteria shall be as per BS 6755
part 1 or API 598 or ANSI B 16.34.
Hydraulic seat pressure test: The valve, in closed position, shall be subject
to pressure test with water (with suitable corrosion inhibitor) at 1.1 times the
maximum rated working pressure of the particular pressure rating class of
the valve. The test procedure and acceptance criteria shall be as per Rate A of
BS 6755 part 1 or API 598 or ANSI B 16.34.
Pneumatic seat leak test (for ball valves only): The Leak rate across the seat of
ball valves shall be tested with dry air or GN 2 at 4 to 7 bar by water
displacement (bubble) method. The acceptance criteria shall be as per Rate A
of BS 6755 Part 1 or API 598
MSLD shell leak test: (For globe valve only) The global leak rates across
body shall be measured with GHe MSLD to establish the leak tightness
values specified above by hood technique as per Article 10, Section V, ASME.
The leak test shall be performed by shrouding the entire outside surface of
the valve with a plastic bag to hold GHe at a positive pressure and by
evacuating and connecting the inlet/ outlet port to MSLD. Leak test by
detector probe or tracer probe technique is not acceptable.
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MSLD seat leak test (for globe valves only): The global leak rates across seat
shall be measured with GHe MSLD to establish the Leak tightness values
specified above by hood technique as per Article 10, Section V, ASME. The leak
test shall be performed by pressurising the inlet with GHe and by evacuating
and connecting the outlet to MSLD. Leak test by detector probe or tracer
probe technique is not acceptable.
Functional test: The valve with all accessories mounted shall be subject to
functional test to validate the performance.
Cleanliness: All the interior flow surfaces of the valve shall be degreased and
cleaned to O2 service standards as per CGA G-4.1 or MIL-C-52211 or ASTM
G-93.
Marking: All the valves are assigned tag numbers for the sake of
identification. The tag number for each valve, as indicated above, besides
size, pressure rating class, material of construction, etc, shall be legibly and
indelibly engraved on the body of the valves.
ACTUATOR
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Normal position : As given in Table 3/ ANNEXURE-V
STATUS SWITCHES
The valve shall be provided with a pair of non-contact type proximity
status switches to indicate the “opened/ closed” status of the valve. The
status switches shall be mounted on the valve with such proper
arrangement that does not require any adjustment/ alignment for the
specified cycles of operation of the valve.
Nominal voltage : 8V
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Short circuit protection : Shall be Protected for short circuit
Protection Degree : IP 67
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1.A.5 TECHNICAL SPECIFICATION OF SAFETY RELIEF VALVES
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Material of construction:
Disc : Viton (for set pr.≤1 MPa & op. temp. 300 K)
PTFE (for set pr.1 to 15 MPa & op. temp. 75 to
300 K)
PCTFE (for set pr.< 15 MPa & op. temp. <75 K)
ASTM A182F304/304L/ 316/316L stellited (for
set pr.> 15 MPa)
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Tests:
All the interior flow surfaces of the valve shall be degreased and cleaned
to Oxygen service standards as per CGA G-4.1 or ASTM G 93.
Marking
All the valves are assigned tag numbers for the sake of identification. The
tag number for each valve, as indicated above, besides manufacturer, set
pressure, size & pressure rating class of inlet & outlet connections,
material of construction, etc, shall be legibly and indelibly engraved on
the body of the valves.
1.A.6 Filters
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for butt welding. The butt welding ends
shall be suitable to mate with the
interfacing pipe of schedule number as
given in Table 5/ ANNEXURE-V
Material of construction:
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c.The welding joints (including
longitudinal seam joint of welded
pipes) shall be subject to 100 %
radiographic test.
Tests:
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d. Hydraulic shell pressure test: The filter, upon final assembly shall
be subject to pressure test with Water (with suitable corrosion
inhibitor) at 1.3 times the maximum allowable working pressure.
e. MSLD shell leakage test (for filters with fluid medium gaseous
Hydrogen, gaseous Helium and Vacuum): The global leakage rate
across body shall be measured with gaseous Helium Mass
Spectrometer Leakage Detector (MSLD) to establish the permissible
leakage rate values specified above by hood technique as per Article
10, Section V, ASME. The leakage test shall be performed by
shrouding the entire outside surface of the filter with a plastic bag
to hold gaseous Helium + gaseous Air mixture at a positive
pressure and by evacuating and connecting the inlet/ outlet port to
MSLD. Leakage test by detector probe or tracer probe technique is
not acceptable.
Cleanliness
All the interior flow surfaces of the filter shall be degreased and
cleaned to Oxygen service standards as per CGA G-4.1 or ASTM G 93.
Marking
All the filters are assigned tag numbers for the sake of identification.
The tag number for each filter, as indicated above, besides
manufacturer, size, maximum allowable working pressure, degree of
filtration, material of construction, etc, shall be legibly and indelibly
engraved on the body of the valves
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1.A.7 TECHNICAL SPECIFICATION OF NON-RETURN VALVES
End connection :
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Permissible leakage : Bubble-tight as per API 598
rate across seat at a or Rate A as per BS 6755 Part
pressure differential of 1 for soft seated valves
As per FCI70.2 for metal
0.2 MPa(d) along non-
seated valves
flow (reverse) direction
Style of construction:
Lift mechanism : Lift plug type, globe pattern
for valves of nominal size ≤
DN 100
Swing/ butterfly/ dual plate
type for valves of nominal
size > DN 100
Cover : Screwed or bolted to body with
suitable seals
Material of construction
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Tests:
a. Material certificates: The material certificates, detailing the
physical and chemical properties, of the principal pressure–
bearing parts shall be provided.
b. Welding joint test (wherever applicable): All butt welding
joints in the valve (including the joints between the body and
the pipe stubs) shall be subject to radiographic test with X-
rays or gamma rays to 2% equivalent sensitivity.
c. Soundness test for castings (wherever applicable): All the
castings shall be subject to soundness test with radiographic
or ultrasonic technique for flaw detection.
d. Hydraulic shell pressure test: The valve, upon final assembly,
shall be subject to pressure test with Water (with suitable
corrosion inhibitor) at 1.5 times the maximum rated working
pressure of the particular pressure rating class of the valve.
e. MSLD shell leakage test (for valves for fluid medium of, IPA,
gaseous Nitrogen and Gaseous helium): The global leakage
rate across body shall be measured with gaseous Helium
Mass Spectrometer Leakage Detector (MSLD) to establish the
permissible leakage rate values specified above by hood
technique as per Article 10, Section V, ASME. The leakage test
shall be performed by shrouding the entire outside surface of
the valve with a plastic bag to hold gaseous Helium +
gaseous Air mixture at a positive pressure and by evacuating
and connecting the inlet/ outlet port to MSLD. Leakage test
by detector probe or tracer probe technique is not acceptable.
f. Seat leakage test: The leakage rates across seat in flow and
non-flow directions shall be measured with gaseous nitrogen
/ dry Air to establish the permissible leakage rate values
specified above by bubble emission method.
Cleanliness
All the interior flow surfaces of the valve shall be degreased and
cleaned to Oxygen service standards as per CGA G-4.1 or ASTM
G 93.
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Marking
All the valves are assigned tag numbers for the sake of
identification. The tag number for each valve, as indicated
above, besides size, pressure rating class, material of
construction, etc, shall be legibly and indelibly engraved on the
body of the valves.
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Materials of construction:
Tests:
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1.A.9 TECHNICAL SPECIFICATION OF PRESSURE GAUGES
Scale : Concentric
Window : Shatter-proof
OR
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Case and bezel : Weather-proof housing with screwed
outer bezel
Tests
Cleanliness
All the interior flow surfaces of the pressure gauge shall be degreased
and cleaned to Oxygen service standards as per CGA G-4.1 or ASTM
G 93.
Marking
All the pressure gauges are assigned tag numbers for the sake of
identification. The tag number for each pressure gauge, as indicated
above, besides size, pressure rating class, material of construction, etc,
shall be legibly and indelibly engraved on the body of the pressure
gauges.
Design Data
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Service Medium : GN2
Mounting : Horizontal
Material Of Construction
Bolts : SA 193 Gr B – 8
Nuts : SA 194 Gr B – 8
Outlet - 15 NB
Material Testing
The material to be used for fabrication shall be tested for their physical
and chemical properties and it shall be carried out in a government
approved laboratory.
Fabrication
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5. All the nozzles flanges shall be provided with mating
blind flanges ( including gasket , bolts and nuts).
Testings
NDT & Hydro – static shall be carried out as per code requirement.
Cleaning
1.A.11 Pump
Type : Centrifugal
Head : 30 meter
Power : 3.7 KW
RPM : 2900
Frequency : 50 HZ
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The pump should be compatible with variable feed drive and provide
varying flow rates.
Water capacity : 3000 litres for Run Tank, 1000 litres for
Collection Tank
Material : SS 304 L
Mounting : Vertical
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Design:
Material:
Fabrication:
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Cleaning:
Mechanic Cleaning:
All surfaces inside and outside having scales and foreign
materials have to be cleaned. This can be done by;
a. Scrubbing with metallic brush
b. Sand blasting (iron free sand) and the loose scales and
powders obtained from the above process shall be cleaned by
blowing or washing.
1. Degreasing:
This is to remove oil and grease. This can be achieved by
vapour phase degreasing using trichloroethylene.
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a. The cleaned surface is to be checked by using a white filter paper.
Rubbing of the paper on the surface should not change the colour of
the paper.
b. By analyzing the final used water the quality of cleaning can be
checked. The rinse water should not have suspended particles
more than 20mg/m2 (based on surface area). The pH value of the
de-mineralised water must be between 6.5-7.5.
4. Drying:
The drying is done to remove water and is to be done by
purging with Nitrogen having dew point less than -25°C and free from
oil and grease (less than 10ppm) at 60°C till the moisture level at the
exit comes to the inlet concentration.
5. Sealing:
Material:
Inner corrugation : SS316/316L
Braided wire : SS304/304L
End fittings : SS304/304L
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Scope of Inspection:
Visual Examination:
The hose shall be free from oil, grease, dirt or any other foreign material
both internally and externally. Broken or missing reinforcement wires
shall be cause for rejection.
Dimensional Inspection:
The hose and end fittings shall meet the requirements as per approved
drawings.
Radiography:
100% radiographic examination at crimping points should be done after
proof pressure test. No crack or damage is acceptable.
Material Test:
Material test certificates (Mechanical & Chemical) for PTFE, end fittings
& SS PIPING.
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Identification:
Part No., Operating & Proof pressure test details to be engraved
in the tag of hose assembly as per table-12/Annexure-V.
Packing:
The hoses shall be provided with suitable Aluminium alloy end
closures to avoid damage during transportation and each hose is to be
packed separately along with dehydrant bag.
Material of construction:
Disc : Inconel
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Safety head : ASTM A 182 F 304L/ 316L/ 321
Tests:
Cleanliness
All the interior flow surfaces of the device shall be degreased and cleaned to
Oxygen service standards as per CGA G-4.1 or ASTM G 93. (Strike out if not
applicable.)
Marking
All the devices are assigned tag numbers for the sake of identification. The
tag number for each device, as indicated above, besides nominal size, burst
disc, etc, shall be legibly and indelibly engraved on the body of the devices.
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1.A.15 Spray Nozzle
6. Quantity :4
7. Materials
Housing : SS316L
Bush/seals : PTFE
Nozzle head : SS316L
Gears : PEEK and SS316
8. Max. working temp : 160°C
13. The nozzle shall have variable cycle time according to variation in inlet
pressure.
14. Nozzle shall have provision for self cleaning and self lubrication.
15. Nozzle shall have high impact jets, orbital wash pattern with high
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1.A.16 Vacuum Breaker :
Type : Tec –Vent Air Admittance valve
Fabrication:
Cleaning:
Mechanic Cleaning:
All surfaces inside and outside having scales and foreign
materials have to be cleaned. This can be done by;
a. Scrubbing with metallic brush
b. Sand blasting (iron free sand) and the loose scales and
powders obtained from the above process shall be cleaned by
blowing or washing.
1. Degreasing:
This is to remove oil and grease. This can be achieved by
vapour phase degreasing using trichloroethylene.
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a. The cleaned surface is to be checked by using a white filter paper.
Rubbing of the paper on the surface should not change the colour of
the paper.
b. By analyzing the final used water the quality of cleaning can be
checked. The rinse water should not have suspended particles
more than 20mg/m2 (based on surface area). The pH value of the
de-mineralised water must be between 6.5-7.5.
4. Drying:
The drying is done to remove water and is to be done by
purging with Nitrogen having dew point less than -25°C and free from
oil and grease (less than 10ppm) at 60°C till the moisture level at the
exit comes to the inlet concentration.
5. Sealing:
Flame proof items shall have Ex ‘d’ classification with the gas group as per
IS/IEC 60079-0, IS/IEC 60079-1 with latest amendments with gas group
classification of IIA/IIB, Zone 1 and temperature classification shall be T4.
All the flame proof items shall be certificated by CIMFR.
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1.B.1 Electric Motors
Method of starting /
Variable Voltage Variable Frequency (V3F) drives
Speed control
IP 65
Duty S1
Application Pump
Motor Makes CGL, BBL, SIEMENS, ABB
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1.B.3 Power and Control Cables
All control cables shall be FRLS 2.5 sq.mm, 1.1 kV grade, ISI marked,
PVC insulated single core, stranded copper conductor wire / cable
conforming to IS:694 (with latest amendments).
Compression type cable glands suitable for cable sizes used shall be
provided on the motor terminal box. Flameproof double compression
type cable glands shall be provided for flameproof motors.
The VFD panel shall made of 2mm thick CRCA, powder coated, paint
shade RAL7032/35, and Gland plate – 3.0 mm Thickness CRCA.
The VFD shall have local HMI & Class “A” Input/EMI filter and
breaking chopper shall be the integral part of VFD panel.
Panel cooling fans with louvers.
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The provision shall be made for VFD’s ON/OFF in from VFD panel as
well as from motor location by selection of Local/ Remote.
1.B.5 Earthing:
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5 Power Supply 12 to 30 V DC.
8 Zero & Span Adjustments Zero and Span are to be adjusted from the
Handheld HART Communicator and
provision for local adjustment to be set
anywhere within the range limits.
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19 Transient Protection 3kAcrest (8/20microsecond) as per IEEE
C62.41.2 , IEC61000-4-4& IEC61000-4-5.
21 Electrical Connection ½ " – 14 NPT (F) with SS plug for dust proof.
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10 Zero & Span Zero and Span are to be adjusted from the
Adjustments Handheld HART Communicator and provision for
local adjustment to be set anywhere within the range
limits.
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14 Stability ≤±0.2%URL for 5 years , for URL above 100 mbar
≤±0.2% URL for 1 year, for URL below 100 mar
17 Static Pressure effect Span error: ≤ ± 0.2 % of span /70 bar for URL above
100 mbar.
Span error: ≤0.45 %span/70 bar for URL below 100
mbar
27 Transmitter Process ½ " – 14 NPT (F) or suitable for the quoted manifold
Connection
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29 External Grounding Required.
screw assembly on
transmitter body
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15. LPIA04 IPA AP 0-5 280-350
16. LPIA05 IPA AP 0-5 280-350
17. LPIA06 IPA AP 0-5 280-350
18. DP1 IPA DP 0-500mbar, LP=5bar 280-350
19. DP1(S) IPA DP 0-500mbar, LP=5bar 280-350
20. DP2 IPA DP 0-2 bar, LP=5 bar 280-350
21. DP2(S) IPA DP 0-2 bar, LP=5 bar 280-350
22. DP3 IPA DP 0-500mbar, LP=2 bar 280-350
23. DP3(S) IPA DP 0-500mbar, LP=3 bar 280-350
(S) indicates spare measurement
2 Material : 316 SS
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1.C.3b. SPECIFICATION OF 5 WAY MANIFOLD
2 Material : 316SS
Along with offer, the vendor shall supply the detailed catalogue and the selected
model matrix for pressure transmitter and manifold. The dimensional drawing for
manifold shall also be provided.
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T/C
Ambient Temp effect : RTD (IEC: Pt500, Pt100): 0.04ohm
for 10 °C variation in
temperature
Stability 0.05%URL for 5 years
Indication : Minimum 4½ or 5 digit LCD indicator
Zero and Span : By Hand-Held Terminal or Local adjustment.
Adjustment
Temperature Limits : Operation: 280-350K
: Storage : 280-350K
Sensor Failure : In case of sensor or circuit failure, theself diagnostics to drive
the output to 3.9 or to 21.0mA,user selectable.
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Max. Flow rate: 20 m/s (perpendicular to the sensor)
Suitable mounting interface for mounting is to be provided
Calibration certificate for the measurement range is to be provided
Table-2 List of Temperature Transmitter
Sl.
Tag No. Range (K)
No.
1 LTI701
2 LTI702
3 LTCA01 280-350
4 LTCA02
5 LTCA03
6 LTCA03 (S)
Sl.
Tag No. Range (K)
No.
1 LTI701 280-350K
3 LTI701(S)
RTD Probes to be supplied by vendor but surface RTD (Test article measurement)
will be under department scope. But, all temperature transmitters to be supplied by
vendor.
Flow tube :
Type : Coriolis Mass flow
Tag No : As per Table-3
Fluid Medium : IPA
Maximum Operating pressure : 10bar
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Operating Flow range : 0-5 kg/s
Line size (NB) : 2”
End Connection : RF Flanged ANSI B16.5, #150 class
flange rating
Process temperature : 280 to 350 K
Mass flow accuracy (Including linearity ,
Repeatability & zero stability)
@ Max. flow & Min. flow : ≤± 0.15% of Reading
Pressure Drop
@ Max. flow & Min. flow : < 0.05Mpa
Temperature accuracy : ± 1°C ± 0.5% of rate in °C
Materials of construction
Flow Tube & Flange : SS 304L/SS316L
Transmitter
Housing SS 304/SS316
Transmitter Output : 1. One active 4-20 mA output to
represent Mass Flow with HART
communication
2. One passive 4-20 mA output to
represent Mass / temperature /
density
3. One active pulse output for mass
flow rate
Power supply : 24 V DC ±10%
Field mount housing : Epoxy painted cast Al housing
Housing protection : NEMA 4X (IP67)
Flow Transmitter Mounting : Remote/Integral mount (For remote
mount: mounting kit to be provided,
interconnecting cable to be supplied)
The party shall provide the following along with the quote
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Catalogue, Drawing & Specifications:
The party shall provide detailed catalogue showing part numbers and
options selected in their quotation.
The party shall provide with dimensional drawing of quoted flow meter.
The quote shall indicate the inaccuracy of flow meter including Non-
linearity, Repeatability, Long term stability & Zero stability for the minimum
and maximum flow rates.
The party shall provide detailed sizing sheet with Pressure drop, Velocity &
Accuracy for operating flow range.
During procurement and supply phase, the vendor shall provide with
Calibration Certificate
The accuracy change due to calibration medium other than water shall be
provided.
The vendor shall dispatch the items, only after the approval of calibration
certificates.
Sl.
Tag No. Fluid medium Mass flow rate Temperature (K)
No.
LFQA01
1 IPA 5 kg/s 280-350
LFQA02
2 IPA 5 kg/s 280-350
LFQA01(S)
3 IPA 5 kg/s 280-350
(S) indicates Spare measurement.
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1.C.7 HART COMPATIBLE HAND HELD COMMUNICATOR FOR
PROGRAMMING THE TRANSMITTERS.
HART communicator suitable for communicating with all quoted pressure,
temperature, Guided Wave level & flow transmitters. The communicator should be
able to communicate all device specific and generic commands. The required
updated versions of DDs shall be loaded.
Note: The party shall provide detailed catalogue along with offer. Along with the
supply of items, the party shall provide test certificates.
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Process condition
Fluid: Given in table-4
Operating Pressure: Min. 2 bar, Max. 10 bar, Nominal: 7 bar
Service Life : 50,000 cycles
Operating Temperature: 280-350K
Relative humidity: up to 95%
The party shall provide the following along with the quote.
The party shall provide detailed catalogue showing part numbers and
options selected in their quotation.
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Conduit and cable entry- Side & Bottom Entry
Door of JB- Hinged with proper locking arrangement to avoid entry of
dust and moisture
Ambient temperature-50 deg C
Ambient humidity-0-100 % RH
Earthing : Two numbers of Earthing bolts for JB Earthing.
Junction box size shall be of 300 x 300 x 165mmdimensions. The exact
dimension shall be finalized during Detailed Engineering.
2. Terminal blocks
3. Name plate
4. Mounting
Junction Box shall have 4 lugs for fixing on wall or fabricated steel support.
The lugs shall be offset so that the rear of the unit stays away from the
surface by at least 5mm. Two of the holes shall be round and the other two
oblong to facilitate correct positioning. All screws, nuts and studs etc. shall
be of electro galvanized or zinc passivated type.
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5. Painting
The enclosure shall be treated & prepared for painting with two coats of
Dark admiralty grey shade 632 of IS-5 epoxy paint (Both inside and
outside)
The party shall provide the following along with the quote
The party shall provide detailed catalogue & dimensional drawing of quoted
junction box.
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2 Core PVC Cable (Armoured) – FRLS Type
One pair of 7/0.31mm (20 AWG) annealed tinned copper conductor,
polyethylene insulated, cores colour coded, melinex taped, mylar backed
aluminium taped with a drain of size 7/0.31mm Annealed tinned copper, melinex
tapped, PVC sheathed steel round GI wire armoured and overall sheathed with
FRLS PVC and Blue in colour.
DETAILED SPECIFICATIONS:
3. Conductor :
18AWG (19/0.25mm)
4. Insulation
b) Screening
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6. Inner sheath
c) Colour : Black
7. Outer sheath
c) Colour : Blue
64 Core : 46.0 mm
16 Core : 23.0 mm
4 Core : 16.0 mm
2 Core : 10.0 mm
b) Tolerance : ± 2mm
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c) Max. Mutual capacitance : 75.00 pF/m at 0.8/1.0KHz
18AWG:< 40H/ohm
HV test
i) Conductor to conductor :
1 KV for 1 minute
ii) Conductor to screen :
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12. General : Cable should be Anti-Rodent and Anti-
termite type
16. Armouring
General Specifications:
2. All cables should have ‘anti-rodent’ type outer sheath and should be
immune to termite attack. It is required to have these protections by
addition of chemicals to outer sheath.
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c. PVC insulation : IS 5831.
Cable Testing
f) FRLS tests:
iv. Max Acid gas generation test as per IEC 754 (I)
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Note:
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TEST DETAILS ON EACH OF THE ABOVE MENTIONED CABLES AS PER
JSS: 51034 STANDARDS
Note:
1. The party shall provide detailed catalogue along with offer.
2. The vendor shall provide sample piece during detailed engineering from the
manufacturer.
3. The vendor shall provide test certificate before dispatch of items. The vendor
shall dispatch the item only after clearance of test certificates by Department.
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1.C.13 CABLE TRAYS
Perforated Cable Tray:
Type : Perforated type cable tray
Material : Mild Steel As per IS: 2062 / 1079
Finish : Hot dip galvanized, Self-color.
Galvanizing : As per IS: 2629 / 4759
Length : Standard length of tray is 2500 / 3000mm
Loading : As per NEMA standard
Size : As per table
Table
50 25 1.6
100 25 2.0
300 50 2.0
Note: Accessories like cross, Vertical bend, Reducer, Horizontal Tee, Coupler
plates, necessary Bolts & Nuts to be quoted as 1 lot.
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Note:
The Accessories like cross, Vertical bend, Reducer, Horizontal Tee,
Coupler plates, necessary Bolts & Nuts shall be quoted.
The vendor shall provide detailed catalogue along with offer
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7. General
Operating temperature : 15°C to 60°C
Power supply feed provision : Through power rails/Back plane
Mounting : DIN rail (35mm)
ACCESSORIES
The party shall quote for all required accessories such as power rails, power feed
modules, Din rail, mounting kit, Backplane etc.
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Note:
The party shall provide detailed catalogue along with offer. Along with the supply
of items, the party shall provide test certificates. The isolators shall undergo
functional test, linearity check etc at Department site after supply. After passing the
test as per specification only, the isolators shall be accepted by Department.
Coil side:
Nominal i/p voltage : 24 VDC
Nominal i/p current : 18 mA
Typical response time : 8 ms
Typical release time : 10 ms
Protective circuit : Reverse polarity diode and
Free wheeling diode provision.
Contact side:
Contact type : DPDT
Contact material : AgNi
Maximum switching voltage : 250VAC/DC
Minimum switching voltage : 5VAC/DC (at 10 mA)
Minimum switching current :10 mA
Limiting continuous current :6A
Interrupting rating max : 140 W (at 24 VDC)
General data:
Test voltage relay winding/relay contact : 4 KVAC (50 Hz, 1min)
Test voltage PDT/PDT : 2.5 KVAC (50 Hz, 1min)
Operating temperature : 15 to 60 º C
Mechanical life service : 3*107 cycles
Standards/Regulations : IEC 60664, EN 50178, IEC 62103
Indication : LED for indicating Command ON
Connection data:
Connection method : Screw connection
Conductor cross section solid max : 2.5 mm2
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Note:
1. The party shall provide detailed catalogue along with offer.
2. Along with the supply of items, the party shall provide test certificates. The
relays shall undergo functional test at Department site after supply. After
passing the test as per specification only, the relays shall be accepted by
Department.
Input:
Voltage : 230V AC
Frequency : 50 Hz
Power factor Correction : ≥ 0.9 at 230V AC input
Output:
Voltage : 24V ±10%
Voltage setting accuracy : ±1%
Current rating : 10 A
Ripple : 5 mVrms
Efficiency : 85%
Output voltage setting : Through front panel
Status output:
Power supply O.K. signal : Potential free contact
LED Indications:
For output voltage : To be provided
For output low voltage : To be provided
Protections:
Short circuit protection : To be provided
Over voltage protection : To be provided
General:
Operating temperature range : 15˚ to 55˚C
Cooling : Natural air cooling
Parallel Operation : Set in single or parallel mode
Mounting : DIN rail mountable
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Connection type : Screw connection
Isolation Voltage : Input to output 3KVAC for 1 min.
Compatibility to EMI : As per applicable standards
Note:
The party shall provide detailed catalogue along with offer.
The power supply shall undergo load regulation test, ripple test, stability test and
line regulation test. After passing the test as per specification only, the power
supply and shall be accepted by Department.
Type : Crimp
Working Current : 10 A
Crimp connection
2. Inserts:
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Rated current : 10 A
Flammability to UL 94 : V0
3. Hoods
Flammability to UL 94 : V0
Protection : IP65
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Flammability to UL 94 : V0
Protection : IP65
4. Class of protection : IP 65
5. The thread shall suit to the cable entry points at the Hood and Housing.
7. Sealing Plug
Note:
The party shall provide detailed catalogue along with offer indicating the part
number of items and specifications.
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Cabinet Temperature
Current
Voltage
16. Make : Rittal / President System
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1.C.19.2 WIRING
1. Wiring shall comply with the applicable IEC codes. Wiring for different
voltage signals or different functions shall be terminated separately on
dedicated terminal strips/ raceways with color coding.
2. Separate color coding to be followed for utility power (fan, temperature
monitor) and process power (I/O modules, processor).
3. Wiring shall be accomplished with flexible stranded tinned copper wires
sized 18/20 AWG, PTFE cable in compliance with the applicable codes.
4. Wires shall be housed in plastic raceways of suitable dimensions to
accommodate system cables, I/O signal cables etc.
5. The routing shall be neat and have elegant look.
6. Electrical power distribution shall be done as per requirement for system
cabinet and cables shall be routed through separate raceways.
7. Control system cabinet shall have local MCBs for isolating different loads.
8. Power supply positioning in the cabinet shall be suitably placed to avoid
electromagnetic interference to electronic components.
9. The cabinet shall be supplied with all necessary hardware & accessories
and with complete wiring.
10. Wiring and workmanship shall be of good quality.
11. Cable glands suitable for I/O cables are included in the vendor’s scope.
The cable glands shall be of polyimide material.
12. All I/O cables to be terminated at lock type plug-in multipin connector
and to be mounted at the system cabinet.
13. The panel shall have at least 20% extra terminals for future use.
14. Terminations, cables, wiring, components shall be properly tagged with
ferruling at both sides of the termination.
15. Terminal strips shall be of adequate size min 1.5 mm2.
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1.C.20 SPECIFICATION OF 3 SEGMENT CONSOLE
The console shall have work surface with a closed equipment cabinet
at back to accommodate equipments like power supply, terminal
blocks and a box on the work surface to accommodate
intercommunication equipments and switches. (Intercommunication
equipments will be supplied by Department and details will be
provided during detailed engineering)
The consoles shall be provided with aesthetically pleasing curved end
panels. The layout of console shall have curved design.
Console should be designed in accordance with the ergonomics
standards and accepted human factors guidelines of ISO 11064.
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A box shall be provided with a removable panel for mounting
illumination switches, Authorization keys and
intercommunication equipments. Easy human access to remove
and re-fix the box shall be possible.
The rear view of the console shall be aesthetically pleasing and
shall be provided with slat wall.
Cabinet:
The console shall be provided with a rigid structured cabinet
back of the work surface, heavy-duty to accommodate power
supply, terminal blocks and other necessary equipments.
The rear compartment of console shall have holed profiles
suitable for mounting 19” width 2U height equipment (power
supply and terminal blocks) shall be provided.
Complete frame structure shall be of made of steel structures.
The cabinet shall be made from Cold Rolled Steel (CRS) Metal
(14 Gauge) with powder coated finish.
The structure shall allow easy assembly of Gland Plate, Monitor
arms etc in extremely rigid manner.
Rear access doors shall provide accessibility for easy installation,
operation& servicing of the equipments inside the console.
The console shall be designed to have adequate space for
accommodating the equipments.
The Console shall have earthing provision in structure.
Console cabinet shall be provided with fan for Cooling.
The console shall be provisioned with concealed electrical
outlets, information outlets (LAN) and RJ-11 Telephone jacks.
The provision for mounting of electrical outlets and telephone
jacks shall be designed for flexible placement of monitors,
telephones, intercommunication units and laptops on the
console with zero cable clutter on the work surface.
Industrial grade metal powder coated finish Universal socket
type Power Distribution unit (5A, 5Nos and a master MCB) must
be provided for power supply.
Cable entry holes shall be provided in Support legs of the
cabinet for data and power cables entry in console cabinets.
PVC cable ducts with covers shall be provided for concealed and
neat cable routing.
Grommets/Gasket shall be provided for cable entry holes to
avoid damage of cables.
Sharp edges at the consoles base shall be avoided.
End Panels:
The end panels shall be with glossy finish and should seamlessly
integrate with the structure.
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The leg cover element shall cover the structure and should
increase the aesthetic look of the console.
The end panels at the extreme end of consoles shall matching
curved shapes designs.
Detailed Engineering phase
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Fully detailed assembly instructions in the English language
shall be supplied with both written and pictorial descriptions for
each item/model numbered component with dimensions.
Insulation : PVC
Colour : Green
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Mounting : Din rail: 35mm width
Accessories : End plate, Mounting rail,
Marking ferrule.
Types I
No: of terminals :2
No of levels :1
Types II
No: of terminals :4
No of levels :2 with internal short link.
Types III :
No: of terminals :4
No of levels :2 with cross link 3 pole.
Types IV
No: of terminals :2
No of levels :1
All Accessories like Separators, marking labels and end stoppers shall be included
as one lot
Note:
The party shall provide detailed catalogue along with offer indicating the part
number of items and specifications.
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1.C.24 INDICATORS, SWITCHES AND KEYS
i. INDICATORS
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iii) KEYS
General:
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1.C.25 MCB
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Type Main (Qty)
Digital input (DI) for E/P valve, pump control and 32
console switches including spare
Digital Output (DO) ) for E/P valve, pump control 24
and console switches including spare
Analog Input (AI) (0-10V) for pressure, Level, flow 32
and pump control including spare
Analog Output (AO) (4-20mA) for pump control 8
including spare
Programming, SCADA and Data storage node 3 + 1 (Spare)
2 nos. (B&W-1 no. and
Printer
Colour-1 no.)
Pump control valve I/O channel requirements to be finalized after detailed
engineering.
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all data base and control strategies for the current I/O quantities
plus the 20% of growth and also extra memory of 20% for future
expansion requirement. Requirement of spare memory capacity can
be decided / finalized on approval of Purchaser.
iii. Greater than 64 MB DRAM and greater than 512 KB user SRAM
iv. Flash Memory shall be greater than 64 MB
v. Power back up shall be provided for memory storage programs.
vi. Shutdown resetting shall be possible manually and confirmation of
the same after that all variables and concerned has returned within
normal conditions.
vii. Even though the hardware details of the control module is specified
here, Vendor can recommend/offer a better & latest CPU and other
hardware to meet this system requirement. The suitability will be
reviewed by Purchaser.
viii. Vendor to certify system response time, type of memories, backup,
percentage of loading etc.
ix. System scan time ≤ 500 ms (including 64 K application program, 8
PID loops )
x. Detailed calculation demonstrating scan time to be provided along
with offer.
1.C.26.3.3 INPUT/OUTPUT MODULES
1. The following types of I/O modules are required
Analog Input (AI) [0-10V DC]
Digital Input (DI)
Analog Output (AO) [4 -20mA]
Digital Output (DO)
2. These modules are to be interfaced with Department supplied devices
like isolated barriers/relays.
3. All I/O modules shall be rack mounted in an enclosure which is
proximal or integral with the associated control module.
4. All I/O modules shall be slot independent.
5. All I/O modules shall be hot swappable. The back plane shall permit the
removal of I/O cards without the need to isolate power supply to the
card.
6. Time synchronization between all I/O bases is required.
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7. All the I/O terminations from the I/O module shall be wired to
connectors in the system cabinet.
8. Each I/O module shall contain status display LEDs on the front panel of
the module itself.
9. Digital I/O module shall contain status display LEDs for individual
channels at the front panel of the module.
10. Forcing/ simulating of analog and digital outputs shall also be a
standard feature. Indication and logging of the simulated signals shall be
made available. Disabling/ normalizing the forcing on individual
channel basis as well as card basis shall be possible.
11. Environmental conditions:
Operating Temperature: 0-50 Deg C,
Humidity: 0-95 %, non condensing
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C. Digital Input Module
a) No. of inputs : 16 per module
b) Input voltage(Nominal) : 24 V DC
c) Input voltage(Maximum) : 28 V DC
d) Switching Threshold
i. Low : < 5V
ii. High : > 10V
e) Input Resistance : > 2KΩ
f) Switching Delay : ≤5ms
g) Input Current : < 10 mA
@ maximum input voltage
h) Electrical Isolation : : > 250 V rms (Input to PLC)
D. Digital Output Module
a) No. of Outputs : 16 per module
b) Type : Transistor
c) Output Voltage : 24 V DC (nominal)
d) Minimum voltage : 20V DC
e) Maximum voltage : 28V DC
f) Continuous Current : ≥ 0.1 A per Output
g) Electrical Isolation : > 250 V rms Output to PLC
h) Short circuit protection to be provided
i) Overload Protection to be provided
j) In case of failure of processor, the digital outputs shall remain in fail
safe (OFF/de energized) state.
E. COMMUNICATION REQUIREMENT
1. The controller shall transmit the data to Programming, SCADA and
Data storage node through Ethernet for online display, storage and
offline data analysis. It shares the same to mimic, processing station,
Printers etc. for control, real time display and acquisition through
Ethernet LAN.
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i. The industrial grade Ethernet bus shall operate at 100/1000
Mbps.
ii. Work stations are to be connected via Ethernet links and
Ethernet switch and shall communicate on TCP level.
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8 Management Telnet,
CLI/ConsoleHTTP,SNMPv1,v2/v3,SSH
9 Quality of Ingress policing, Rate -Limit, Egress
Service Queuing/shaping, Auto Qos
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1.C.26.6 PROGRAMMING STATION, OPERATOR STATION & DATA
PROCESSING STATION
1. Programming station shall be capable of project development and be
capable to upload and down load the user program to controller.
2. Data processing station shall be loaded with all required software for
data acquisition, logging and reporting.
3. Operator station shall be capable of continuous display for 100 hours.
4. Specification
CPU : All in One PC
Processor : Intel Core i7 or latest at 3.6 GHz
Memory : 2 x 4 GB DDR3 /DDR4 upgradable to 16 GB
( 4 DIMM slots)
Hard Disk : 1TB SATA III with 10,000 RPM
Mouse : 2-Button optical scroll mouse with USB 2.0 Interface with
Mouse Pad
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1.C.26.7 PLC SOFTWARE AND PROGRAMMING
1. The supply shall include all software required for developing the
application programs, graphics, event sequencing, alarm history, PID
loop, their modification and debugging.
2. Software shall be menu driven and easy to use. It shall incorporate on-
line tutorials and help functions to assist the user.
5. System software for writing application shall run on latest version OS.
6. PLC shall have the provision for on line and off line programming with
Hardware/Software lock.
9. The software shall be easily loaded from CD/DVD media and shall be
easily configurable in case of software crash/system failure.
10. All hardware & software shall be the most recent, field proven
models/versions and revision levels marketed by their manufacturers at
the time of proposal submission.
11. The following programming languages and tools but not limited shall be
provided.
i. Programming (IEC 61131-3 Compliant): Ladder Diagram (LD),
Functional Block Diagram (FBD), Structured Text (ST), Instruction
List (IL), and Sequential Functional Chart (SFC) and C language
(optional).
ii. Graphics editing software with all necessary tools
iii. Drag & Drop facility for graphics and programming
iv. Zooming, resizing, rotating, grouping & layering facility in graphics
v. Faults status (accessible via the applications software)
vi. On-line data modification.
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vii. Exporting/importing standard objects/images
viii. Input / output forcing or simulating
ix. Fault status display in different group shall be provided
x. Tools for alarm management
xi. Online documentation for operation & programming
12. The programs and logic diagrams implemented in the system shall be
available in printed form by means of the printer.
17. Run level licensed Software shall be provided to all the workstations.
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9. Online debugging of SCADA packages under development should be
possible. This should cause minimal disturbance to the runtime system.
10. The development package should consist of a full-fledged online help
system in English with provision for context sensitive help.
11. The graphic building utility with full-animated graphics should provide
necessary support to import custom photographs as background images.
The package should support user configuration for animation of the
graphics objects in runtime Environment.
12. Graphical utility to develop mimic pages and PID control panels.
13. System should provide real time Trend display and Bar chart with alarm
conditions of critical parameters to be displayed by visual indication (eg.
color change) and audio signal.
17. Provision should exist for developing user triggered pop-up messages
and alerts with customizable command on the popup messages. These
popup messages and closing the messages by either operator action event
or program triggered variables should exist.
18. User defined alarms and events should be configurable for their
properties and messages. All alarms and event should be immediately
logged in a database time tagged with the IST. The alarm/event Database
access for online/offline viewing and extracting data should be provided.
Necessary tools for customization of the event/alarm reports should be
provided.
1.C.26.9 Sample SCADA screen format id given in SCADA BASED PID LOOP
1. PLC /SCADA based PID loops are used to operate the pump control for
controlling flow.
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3. Proportional (P), Integral (I) and Derivatives (D) constants are
programmed through SCADA.
6. The PID loops shall have auto tuning feature and provision to enter
manually the PID constants.
8. The PID loop software shall have the provision to control the speed of
pump by external step input, ramp input or trigger inputs.
9. PID loop standard libraries shall be available for control purpose such as
ratio control etc.
1.C.26.10 DATA ACQUISITION, LOGGING & REPORTING SOFTWARE
1. Data acquisition, logging and reporting software shall have capability to
Acquire, store and report all required Digital and Analog Parameters wired
to control system in graphical and numerical format at required time
intervals. The minimum time interval in 500ms.
The time stamping of data with IST code reader shall be possible.
Store all events, process parameters and alarms with their description,
occurrence time and priorities and print out of the same on demand.
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5. The software shall allow the operator to edit, replace values or insert new
values in database records. Altered values in the database shall be tagged for
reference purpose.
8. System shall have provision to acquire & retrieve the analog/ digital
parameters at different sampling rates (500ms, 1s, 5s).
9. Data reporting software for processing of all analog and digital I/O’s shall be
developed and loaded with reference to IST code reader for printing and
plotting in offline.
10. The software shall be capable to retrieve, print and plot the data in
engineering unit and raw data formats.
11. Provision to process and print out / plot the analog and digital data through
network from all operator stations.
14. System shall store all data including process variable, set points and
manipulated outputs at different sampling rates.
17. For every restart or when the file size exceeds 700 MB, new data file shall be
created automatically with unique configuration file name without any data
loss.
18. The data reporting software for plotting analog & digital parameters
separately and with the option to mix up both parameters shall be developed
and loaded.
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20. The raw data shall be split into multiple files of 700MB size for CD backup.
21. The data reporting software for analog parameter should take 4th order
curve fitting sensor constants for engineering unit calculation in on line
display, offline print out and trend.
22. Source code for software with details for modification during future
requirement shall be provided.
23. Processed data suitable for online test server should be confirmed and
modified accordingly.
3. Auto Sequence
i. The auto sequence is used for operating field control elements in
auto mode. The time and parameters based sequence shall be
developed in Control system using PLC programming language.
The programming shall have the flexibility to change the variables
(time, Analog & Digital) through separate Input data files. The time
base event should be synchronized with software timer.
ii. Separate Data Base files to be incorporated for Analog & Digital
constants/details for Processing & Display.
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based abort sequence to be executed. The program shall have the
flexibility to change the variables (time, Analog & Digital) through
separate data table to execute abort sequence. The logging of
Interlocks enable/ Disable, setting and generation of Alarm limit,
execution of interlock shall be provided for offline analysis.
ii. The program shall have the flexibility to enable/disable a particular
interlock/abort group.
iii. Generating alarm contacts, for audio visual alarm, event logging etc.
iv. Interlock for controlling field equipments such as E/P valves, Pump
control etc.
v. The system shall also execute Safety interlocks to provide safe test
operation under abnormal conditions. For Automatic operation of
various elements during preparation phase and during test, the
required sequence of operations is to be programmed based on
predetermined timings and/or limits of process parameters for
parameter based operations.
vi. The Operator Station shall have facility for monitoring and
operating each interlock group through soft keys / key board /
mouse. There shall be facility for accessing interlock logic groups in
one key stroke which shall be freely configurable.
vii. During operation, the system has to monitor critical facility
parameters and abort the sequence if the majority of parameters in
any abort group exceed the limit.
viii. The alarm indication is to be available as alarm summary/ pop up
window/ logging in file/ display.
ix. Program shall have the flexibility to change the logics, parameters,
limits, validity time through separate data table/ input files.
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The Department supplied SCADA support will be provided for the required
tests during SAT. All the performance specification of the control system
with the field terminations will be verified and supplier should demonstrate
the following major performance as a minimum:
1) Hardware verification as per final bill of material
2) Visual and mechanical check-up for proper workmanship, identification,
ferruling, nameplates, etc.
3) System configuration as per approved configuration diagram
4) Demonstration of all system diagnostics
5) Cycle time verification 500ms along with 64K application program with
full load (with all mimic diagrams in all nodes). The checking conditions
stated in FAT shall be followed here also.
6) Demonstration of failure cases and verification of error indication in
diagnostic mimic
7) Recording of time based events
8) Demonstration of security login levels
9) 500 ms for all analog data acquisition
10) 500 ms for all digital data acquisition
11) Isolation & accuracy check of all I/O cards.
12) Functional verification of all I/Os
13) Real time display & data reporting software for continuous acquisition of
24 hour.
14) Demonstrating the network speed with full load
15) Error diagnostics of the network failure, system failure, I/O failure.
16) Fail safe mode condition to be demonstrated in case of any failure of
CPU, power supply, interface cards, communication, I/O cards etc.
17) Ensuring system behavior over a duration of 10 days with multiple
restarts.
18) Auto and abort sequence, interlock application program
19) Event & Analog data retrieval in the required format within five minutes
for acquired continuously for 1 hour.
20) Retrieval of Digital & Analog data as per the requirement
21) Plotting of Analog Data
22) Archiving of Data
23) Demonstration of PID loops
24) Checking of proper functioning of all disc drives, alarm summary,
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printers etc.
25) Burn in test for 72 hours & any other mutually agreed test.
26) Time accuracy check
Any malfunctioning in the system shall be rectified /replaced as required.
Failure of any component shall be replaced with new one. No repaired
parts/modules shall be accepted.
After confirming that the control system is meeting all requirements, the
total system will be switched on continuously for 3 days and performance of
the system will be monitored. On successful completion of the above period,
if the performance of the system is satisfactory, Department and supplier
will provide the acceptance test certificate jointly.
Client shall take over the system from the vendor after the final acceptance
test, which is defined as successful operation of the integrated system. The
vendor’s personnel shall be present up to this period.
The Purchaser shall provisionally takeover the systems from Vendor after
Site Acceptance Test.
After SAT, one service engineer to be provided for local support to maintain
the system. The person shall have a sound technical knowledge in both H/W
& S/W of the supplied system and capable to ensure a trouble free
operation.
Note: This specification provides the minimum requirement of the system but it
does not relieve the supplier from his responsibilities for completeness of
the system concerning the design, the reliability and the safe operation of
the supplied equipment. Site preparation, Erection and Commissioning of
the complete system work shall be quoted in lump sum amount and not in
man hour basis
Moreover, it is stressed that Control System (Hardware & software) shall
be of latest proven model manufactured preferably and shall be supplied
on turnkey basis.
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distance whichever is
greater
8. Repeatability : better than 1mm
9. Ambient temperature effect : 0.2 mm/K
10. Update interval : < 1 sec
11. Reference condition : 298 K and ambient pressure
in IPA
12. Microwave output power : 0.3mW to 45 mW
13. Display : Integral digital display to
be provided to display the level
14. Output : 2 wire, 4 to 20 mA analog output
and HART signal
superimposed on analog output
15. Power supply : 16-42 VDC
16. Probe type : Coaxial/Flexible with centring disc
17. Material : SS316L
18. Process connection : 2” Flange, ANSI 150# CL
19. Housing material : Polyurethene covered
aluminium
20. Ingress protection : NEMA 4X and IP 66
21. Hazardous Location : Intrinsically safe certified
ATEX II 2G Ex ia IIC T6.
22. Vibration resistance : Housing : IEC 60770-1
Level1
23. Electromagnetic compatibility : Emission and immunity
:EN61326-1:1997
2.1. Fabrication
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The pipe bends may be employed in lieu of elbow fittings wherever
possible. The bending process shall produce wrinkle-free bends.
Unless specified otherwise, the radius of curvature measured to the
centre-line of the pipes shall be equal to 3 times the nominal pipe
size (diameter). The bending shall normally be done in cold
condition. However, hot bending may be resorted to in certain
cases with the approval from the Department.
2.1.2. Welding
2.1.3. Tests
The following tests shall be performed after fabrication of pipe-
lines:
a. Dye penetrant test: All the butt and mitre welded joints shall be
subjected to DPT at the root pass.
b. Radio-graphic test: All the (full) SS butt welded joints shall be
subject to radio-graphic test to 2% equivalent sensitivity.
Generally, the radio-graphic tests shall be done with X-rays.
Alternatively, the gamma rays may be used in locations where
the joint is inaccessible to X-ray equipments. All the radio-
graphic films shall be submitted to the Department.
c. Pressure test: All the fabricated pipe-lines shall be subject to
pressure test with hydraulic medium at 1.5 times the MAWP.
Alternatively, in pipe-lines, where the presence of water is
intolerable, the pressure test may be done with pneumatic
medium at 1.1 times the MAWP.
d. Pneumatic leak test: All the pipe-lines, except those for water
medium, after attaching all components shall be subject to leak
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test with GN2 or dry Air at 0.85 times the MAWP to validate
bubble-tightness.
e. Surface oil contamination test: The surface oil content of the
pipe-lines shall be measured by transferring the oil contaminant
into a solvent by mopping the surface and analyzing with
Spectro Fluoro photometer. The permissible surface oil
contamination shall be 200 mg/m2.
2.1.4. Cleaning
The fabricated SS pipe-lines shall be cleaned as per the following
procedure:
a. Mechanical cleaning: All the metallic surfaces with scales and
newly welded surfaces shall be cleaned by scrubbing with SS
wire brush. The loose particles generated by mechanical
cleaning shall be removed by blowing with compressed air,
sucking or washing with water.
b. De-greasing: The oil and grease adherent to the surface shall be
removed by vapour phase de-greasing with Tri Chloro Ethylene
(TCE) or Per Chloro Ethylene (PCE), followed by liquid phase
de-greasing with TCE or PCE.
HF : 5 % by mass
HNO3 : 15 to 20 %
Water : Remainder
This is followed by rinsing with water.
HNO3 : 25 % by volume
Water : Remainder
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Duration : 2 hours
This is followed by rinsing with De-mineralised water.
2.1.5. Painting
2.2. Erection
The minor civil works shall be done with Plain Cement Concrete
(PCC), Reinforced Cement Concrete (RCC) and brick masonry, as
required. The minor civil works are required for
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a. Grouting of equipments, pipe supports, structural works, etc
b. Breaking and making holes across walls for laying pipe-lines
c. Excavation and levelling of ground wherever required for laying
the pipe-lines and providing pipe supports. In some locations, it
may be required to break and excavate already laid PCC/ RCC
pavements for grouting
d. 2 coats of white washing of the concrete surfaces after
plastering.
All the materials such as torr-steel reinforcement rods, binding
wires, brick, cement, sand, gravel, etc shall be arranged by the
Contractor. The composition of concrete shall be as follows:
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2.3. Commissioning
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2.3.1. Qualification tests
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equipments to be carried out by the Contractor shall specifically address
essential safety provisions both in-built and external. Reliability is a prime
factor, which has to be embedded in the process of realization of the systems.
To ensure that the sub-system design, development, selection of equipment,
components, material, etc are in compliance with the standard engineering
practices, it is necessary to follow established design codes and standards.
The relevant standards applicable to the scope of work described in this
document are furnished here under. Wherever specific mention is not made
for particular application, the relevant and applicable procedures shall be
followed after mutual agreement between the Department and the
Contractor.
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The Contractor must look for the quality factors individually
attributed to engineering developments, redundancy philosophy adopted,
selection of equipments and components, test and acceptance procedures
followed, repetitive performance achieved, risk analysis carried out, etc.
For the purpose of confirmation of the above aspects, the documents such as
functional documents and mathematical formulation document shall be
prepared and reviewed wherever applicable.
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The flow components, pipes, pipe fittings, etc used for the fluid circuits shall
be made of compatible materials like SS 304L/ 316L/ 321, etc.
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4. DOCUMENTATION
j. List of sub-contractors
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4.3. Fabrication
During the Pre-Shipment Review (PSR), the following documents shall
be submitted:
a. As-built fabrication drawings
b. Test certificates and inspection reports of the materials such as
equipments, flow components, pipes, pipe fittings, instruments
(including the calibration certificates), etc
4.4. Erection
4.5. Commissioning
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Maintenance (routine, preventive and break-down)
Trouble-shooting
SS pipes
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5.3 Flexible Hoses
Valves
Valves may be procured from the sub with a suitable collar flange.
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9 M/s Flow serve India Controls Pvt. Ltd. Bangalore
10 M/s Samson Controls Pvt Ltd, Pune, India
11 M/s MIL control Ltd., Aluva P.O., Cochin
12 M/s. GE Energy (Dresser Valve India Pvt Ltd), Coimbatore
13 M/s Instruemntation Ltd. Palakkad, Kerala, India
M/s Indus vacuum & Cryogenic systems (STOHR
14
Germany) , Vadodara
15 M/S. Emerson Process Management Chennai Pvt Ltd, India
16 M/s. Severn Glocon India Pvt. Ltd. Chennai
17 M/s VELAN , Coimbatore,India)
5.4.2 Filters
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5.4.3 Burst-Discs
1 M/s BS &B System (India) Ltd. 9 Cathedral Road,Chennai
2 M/s Fike Corporation
3 M/s Rembe GmbH
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5.4.6 Instrument Valve(Needle Type globe valve)
1. M/s Swagelok
2. M/s Parker
3. M/s Hoke
4. M/s FITOK GmbH
5. M/s DK LOK, Korea
6. M/s Microfinish Valves, Hubli
7. M/s L&T, Chennai
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5.4.9 Pump
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6 The Anup Engg Ltd, Gujarat
7 M/s Artson Engg Ltd, Mumbai
8 M/s L & T, Mumbai
9 M/s INOX India Pvt. Ltd., Vadodara
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S.No Items Recommended Vendors/Brands
5 Solenoid valve M/s Asco, Chennai
M/s Parker
M/s Herion
M/s Rotex
6 Junction boxes M/s
1. Thomson
Legrand
2. Standard Metal Industries
3. Chemin controls , Pondicherry.
4. M/s Baliga Lighting Equipments
Ltd
5. M/s Flame Proof Equipments Pvt.
Ltd
6. M/s. Stahl, Chennai
7. M/s CEAG Flame Proof Control
Gears (P) Ltd
8. M/s FCG Power Industries Pvt. Ltd
9. M/S. EX Protecta
10. M/S. Pepperl+Fuchs Pvt Ltd.
11. Weidmuller
7 PVC cables 1. Delton Cables, New Delhi
20AWG 2 core armoured 2. Paramount communication Ltd., New
cable Delhi
20AWG 4 core armoured 3. NICCO corporation limited, Kolkata
cable 4. Cable Corporation of India, New Delhi
18AWG 2 core armoured 5. CMI LTD, New Delhi
cable 6. Incom Cables
18AWG 64 Core Cable 7. Thermo cables Limited,Chennai.
8. Advance Cables, Bangalore
20AWG 64 Core Cable
9. Tempsens Instruments Pvt Ltd, Udaipur.
18/20 AWG Single core
PTFE wire (for internal
rack wiring)
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S.No Items Recommended Vendors/Brands
9 Structural materials
10 Isolators Make: Pepperl + Fuchs &
Isolators for MTL
transmitters.
Isolators for status
11 Relays Make: Phoenix
Power Supply
24V ±10% - 10 A- SMPS Make: Phoneix, Weidmuller, Lambda, Kepco
12
(Low ripple)
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S.No Items Recommended Vendors/Brands
22 Guided wave radar Vega, E+H, Rosemount
based level sensor
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AC Asbestos Cement
BG Bank Guarantee
BS British Standard
CI Cast Iron
CS Cast Steel
CR Control Room
DG Diesel Generator
DN Diameter Nominal
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DP Differential Pressure
EP Electro-Pneumatic (valve)
FH Fire Hydrant
GI Galvanised Iron
ID Inside Diameter
IS Indian Standard
LD Liquidated Damages
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MS Mild Steel
NC Normally Closed
NH National Highway
NO Normally Open
OD Outside Diameter
PN Pressure Nominal
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QC Quality Control
RF Raised Face
SL Sea Level
SS Sub-Station
SS Stainless Steel
Sch Schedule
TC Thermo Couple
WT Wall Thickness
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