BOILER HOUSE DCS AND PLC SPECIFICATIONS

DISTRIBUTED CONTROL SYSTEM (DCS)

And
PROGRAMMABLE LOGIC CONTROLLER FOR
EMEGENCY SHUTDOWN SYSTEM (ESD)
SPECIFICATION

For

HIGH EFFICIENCY BOILERS (HEB) AND ITS

BALANCE OF PLANT (BOP)
BPCL
MUMBAI REFINERY MAHUL

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 1 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

TABLE OF CONTENTS

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Contents
Introduction and plant description
Scope of work for DCS
Scope of work for PLC
Special instructions to vendors for DCS
Special instructions to vendors for PLC
Functional specifications for DCS
Functional specifications for PLC
Data sheets for DCS
Data sheet for PLC
Factory / Site Acceptance test procedure
General terms and conditions
Annexure I - u84 PLC architecture
Annexure II - Existing DCS&PLC hookup diagram
Annexure III - Tentative bill of material
for DCS
Annexure IV-Tentative bill of material for
PLC
Annexure V- List of components to be
removed for DCS
Annexure VI- List of components to be
removed for PLC
Annexure VII- I/O count for DCS and PLC
Annexure VIII- List of documents to be
issued to Vendor
Annexure IX- Control room layout
Annexure x- 24vdc power supply
distribution diagram

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

Page no
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SPECIFICATION

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BOILER HOUSE DCS AND PLC SPECIFICATIONS

LEGENDS:
BMS : Burner Management System
BOP : Balance Of Plant
BPCL : Bharat Petroleum Corporation Limited
CPP : Captive Power Plant
CPU : Central Processing Unit
DCS : Distributed Control System
EFCD : Enhanced Field Control Duplex
ESD : Emergency Shut Down
FAT : Factory Acceptance Test
FLD : Functional Logic Diagram
HEB : High Efficiency Boiler
HRSG : Heat Recovery Steam Generation
IEC : International Electric Commission
ISA : Instruments Society OF America
LBCC : Local Burner Control Console
LCP : Local Control Panel
LED : Light Emitting Diode
L&T : Larsen and Tubro
LSHS: Low Sulphur Heavy Stock
MCB : Miniature Circuit Breaker
MCC : Motor Control Center
MFR : Master Fuel Reset
NC
: Normally Closed
NO : Normally Open
OEM : Original Equipment Manufacturer
PBs : Push Buttons
PDB : Power Distribution Board
PLC : Programmable Logic Controller
POC : Process Operating Console
PTR : Performance Track Record
QAP : Quality Assurance Plan
RTC : Real Time Clock
SAF : Scanner Air Fan

SAT
SIL
SOE
SER
SR
T/C

: Site Acceptance Test

: Safety Integrity Level
: Sequence Of Events
: Sequence Of Event Recording
: Short Residue
: Thermocouple

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 3 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

1.0 INTRODUCTION
The specification defines the minimum requirement of a Distributed Control
System (DCS) and Programmable Logic Controllers (PLC) for Emergency
Shutdown System design for reliable, effective & optimum control and ESD of
High Efficiency Boilers (HEB) & its Balance Of Plant (BOP) in Boiler house area.
The existing M/s Yokogawa make CENTUM XL DCS and general purpose,
YASKAWA make U84 model PLC at BPCL, Mumbai Refinery, required to be
replaced by latest technology, state of the art DCS and ESD system. As the
existing 4 sets of DCS stations with of Process Operators Consoles (POC) & PLC
system shall be replaced in phased manner, vendor to consider the required
additional hardware if any for operating and monitoring the running unit while
submitting the offer.
BPCL, Mumbai refinery Steam load is mainly catered by 3-nos Utility Boilers and
3-nos Heat Recovery Steam Generator (HRSG) boilers. The three numbers of
utility Boilers are termed as High Efficiency Boilers (HEB). Each HEB is designed
to produce High pressure Steam capacity of 1500 MT/D. The Boiler furnace is
fired by either Fuel gas or LSHS or both as fuels. There are 4-nos of Oil burners
and 4-nos of Gas burner with 4-nos pilot gas burners for starting the any of the
respective burners. The High Efficiency Boilers (HEB) are designed to operate
with air from 2-nos FD fans one running and other being in hot standby mode.
Each HEB is controlled and monitored by CENTUM XL EFCD station and the
BMS logic of each boiler is taken care by an independent YASAKAWA make U84
PLC. The Balance OF Plant (BOP) of all the three boilers is controlled by one
CENTUM XL EFCD and the corresponding logic is controlled by a YASAKAWA
make U84 PLC. Monitoring of all the three boilers and BOP is done through three
numbers of Process Operators Consoles (POC) in control room and one remote
console which located around 400 meters away from the control room. The
engineering of all the four DCS stations being done through a common
Engineering station and the Engineering of all the four PLC is done through a
common engineering station. There are three dot matrix printers for alarm and
log printing and one color printer for hardcopy printing.
Each boiler BMS PLC and BOP PLC is connected to the corresponding CENTUM
XL station through MODBUS serial communications. The data of all the three
boilers and BOP is available in IP 21 through a communication gateway unit

which is present in another Domain of CENTUM CS 3000 DCS of CPP.

Refer Annexure I and II for detailed system architecture drawing for existing PLC
and DCS.
BHARAT PETROLEUM CORPN.LTD.
MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 4 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

The objectives of the existing DCS and PLC are

1)
2)
3)
4)
5)
6)
7)

Safe startup of the HEB

Safe shutdown of the HEB
Controlling and monitoring of the HEB
Trending and recording of the events.
Protection of the Boiler under any abnormal condition.
Troubleshooting of the plant trip by using SER.
Communication with DCS and other PLCs for Integration.

The vendor shall not deviate from this specification without the prior written
approval from BPCL. In case of any deviation vendor shall highlight clearly the
deviations of the offered system from the specification with proper justification.
BPCL reserves the right to decide technical acceptability of the system.
1.1

PLANT DESCRIPTION

1.1.0 REFINERY STEAM SUPPLY

Steam produced is mainly used as motive power and process steam. 65% of the
total generation of steam is used as motive power, to run turbines which drive
compressors and pumps. The remaining 35% is used as process steam for
Reboilers, heating coil, steam tracing of lines and stripping in columns.
Sometimes it is used for purging of furnaces, columns, lines etc., for gas freeing
and as fire fighting media
Boiler House plant is one of the utility plant in the BPCL Mumbai refinery, which
is supplying Steam, Instrument air, Process air Fuel oil and drinking water to the
entire refinery. The steam is produced in three independent High Efficiency
boilers and distributed to the plants through the steam distribution header. There
are 8 numbers of instruments air compressors for instrument air and process air
production. Fuel oil is stored in two numbers of tanks and distributed to the plant
through fuel oil pumps. Drinking water taken from BMC is stored in a sump and
pumped to storage tanks. From the storage tank the water is pumped to various
plants of the refinery.
Since all the utilities supplied from boiler house are essential for plant operation,

at any point of time no utility is stopped fully. If this scenario happens, that will

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 5 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

lead to shutdown of the entire refinery. Hence up keeping of the entire boiler
house plant is very essential and critical.
The boiler control and monitoring is done through four numbers of Process
Operators Consoles (POC). The BMS startup and shutdown operation will be
controlled from both local & remote control panel located in the field and control
room respectively with status indication in the control room/local. Switches,
Selector switches and PBs are provided in local/remote to light up each
respective Burner manually. The Switches, Selector switches and PBs are linked
to the burner management system for further logic execution and lighting up the
Burners. The total BMS Logic control system is divided into sixteen main control
sequences namely,
1)
2)
3)
4)
5)
6)
7)
8)
9)

FD FAN-A START / STOP

FD FAN-B START / STOP
S.A FAN-A STARTING / TRIPPING
S.A FAN-B STARTING / TRIPPING
BOILER PURGE / MFR RESET
MFR TRIP
COMMON
PILOT GAS S.O VALVE OPEN / CLOSE
MAIN GAS S.O VALVE OPEN / CLOSE

10) LSHS / SR SHUT-OFF VALVE OPENING / CLOSING

11) PILOT GAS BNR-1 to 4 STARTING
12) PILOT GAS BNR-1 to 4 TRIPPING
13) MAIN GAS BNR-1 to 4 STARTING
14) MAIN GAS BNR-1 to 4 TRIPPING
15) LSHS / SR BNR-1 to 4 START
16) LSHS / SR BNR-1 to 4 SHUT-DOWN.
1.1.1

ABOUT EXISTING DCS/PLC SYSTEM

The entire Boiler house plants is controlled and monitored by M/s YOKOGAWA
make CENTUM XL DCS system. The DCS system is having 4 numbers of control
stations and 4 numbers of Panel operated consoles. Each boiler is controlled and
monitored by independent and dedicated control station (EFCD). The Balance of
plants like, Dearator, fuel oil system, instruments air system, Boiler feed water
pumps, Makeup water pumps, and drinking water pumps, steam distribution
headers etc is controlled and monitored by separate control station. Similarly the

logic part of the each boiler is taken care by an independent YASAKAWA make
U84 PLC and the BOP logic part is controlled by the separated YASAKAWA
make U84 PLC. The monitoring of the entire plant is
BHARAT PETROLEUM CORPN.LTD.
MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 6 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

done through four numbers panel operated consoles, three are in control room
and one is located in remote location (Boiler House officer room) which around
400 meters from control room. Refer Annexure I and II for detailed layout of the
PLC and DCS system components.
Each control stations are mounted in separate cabinets along with bulk power
supply units, signal conditioning units. The analog marshaling cabinet for each
control station is independent and mounted with field termination blocks and
barriers.
Each PLC is mounted in a separate cabinet along with necessary power supply,
I/O cards, relays, I/O Drivers and Modem and terminal strips, Hardware
Consoles, LBCC, LCP and BMS Plaque accommodating Selector switches and
PBs with feedback bulbs. The cabinets are installed in control room.
The new DCS and PLC panels and Consoles need to be installed in the existing
space in the control room. The necessary layout drawing is attached as hard
copy. Refer Annexure IX.
1.1.2

The architecture of the existing Boiler house system

The detailed Architecture for PLC is given in Annexure I and Common

architecture for DCS is given in Annexure II.
1.1.3

GENERAL OPERATION REQUIREMENTS

1. The DCS described in this requisition shall be State- of-the- art

microprocessor based process control and data-acquisition system. The
system shall permit control and data-acquisition functions to be distributed
to remote plant locations with the operator interface consoles located in
the control room.
2. The plant operators shall run the plant through operator consoles
consisting of high resolution Monitors and keyboards. All screens and
keyboards shall be of the same design and shall enable the operator to
view the process, controller outputs, and shutdown status and to
manipulate parameters to control the plant.
3. The overall control system shall be structured to function in an integrated
fashion, comprising of regulatory control and advanced control. The

regulatory control level shall form the foundation for the overall system

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 7 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

with the advanced control level added above the regulatory control. The
regulatory level shall be capable of functioning without the advanced
control.
4. The ESD PLC described in this requisition shall be State- of-the- art
microprocessor based TUV/SIL approved with Fail safe operation. The
system shall be capable of executing complete start-up and shut down
logics pertains to HEBs BMS and BOP.
5. Operator shall start up and shut down the HEB BMS through BMS Plaque,
LBCC and Field/control room selector switches and pushbuttons for
lighting up the burners.
1.1.4

AMBIENT CONDITIONS
The site environmental conditions are as follows
Ambient Conditions: The site environmental conditions are as follows:
1
Maximum ambient temperature (Max./ Min) : 42/ 15 Degree C
2
Relative humidity (Max.): 100% @ 32 Deg.
3
Maximum recorded rainfall: 436.8 mm

1.1.5

PLANT DATA
The plant is electrically hazardous and following philosophy shall be followed
Intrinsic Safety for all Analog Inputs (4-20 mA DC) and Analog Outputs (420mA DC), suitable for Zone-I Gas Groups IIA, IIB as per IEC. All process
switches and solenoid valves shall be explosion proof

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 8 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

2.0 SCOPE OF WORK FOR DCS

The proposed DCS shall replacing the existing M/s.Yokogawa make CENTUM XL
DCS systems with 4 nos of Control stations and four numbers of Process
Operators Consoles manufactured and engineered by M/s YOGOGAWA. The job
includes removal of existing System, Marshaling, PDB panels & associated
hardware consoles and design, engineering, supply, erection installation &
commissioning of new DCS along with associated panels and hardware/software
for the Boiler House plant.
The scope of work shall comprise of the following but not limited to:
1. System Design and Engineering.
2. Manufacture / supply of all hardware and software necessary to
meet specified functional requirements including system
configuration, system integration, factory testing and acceptance of
the system.
3. This HEB DCS System is replacing YOKOGAWA CENTUM-XL
DCS System. Vendor to consider the following while quoting:
1. All related panels of existing YOKOGAWA system for
HEB1,2,3 and BOP is to be removed from base frame.
2. Tag identification of all signals from field before removal of
existing panel and hardware consoles. The I/o count is as
per the attached Annexure VII
3. Existing Ferrule to be replaced with new ferrules as per new
detailed engineering.
4. Removal of field cable terminations.
5. Deglanding of field multicore cable with proper identification
tags.
6. Removal of existing panels along with base frame.
7.

Erection of new panels on new base frames, including

supply and erection of new base frame. General
arrangement drawing of base frame shall be approved by
BPCL before fabrication.

8.

Reglanding of field multicore in the new panel and

retermination of the same with proper identification and
tagging. Supply of weather proof Glands and lock nuts shall
be in the vendors scope.

4. System furniture for Engg PCs, documentation PC, AIMS, HMS,

Consoles, Printers etc.
BHARAT PETROLEUM CORPN.LTD.
MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
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BOILER HOUSE DCS AND PLC SPECIFICATIONS

5. Packing, forwarding, transportation, custom clearance, insurance,
storage etc. of the system.
6. Installation, field testing, loop checking, commissioning and field
acceptance of the system
7. DCS system cabinets shall have hardened plastic transparent doors
to look through various components status without opening the
door.
8. Documentation, training, warranty etc.
9. Installation and commissioning assistance of the free issue if any
(owner supplied) items in the control room.
10. As part of engineering, vendor shall develop documents required
for total system configuration including existing system configuration
and communication hook-up points for new control stations for
HEB1,2,3 and BOP.
11. Vendor shall develop functional schematics, control scheme,
dynamic graphic display drawings and logic diagrams etc.
12. Removed Panels shall be shifted to the location as instructed by
BPCL Engineer in-charge inside the refinery. The list of panels to
be removed is as per Annexure V. The item shown in Annexure V is
only tentative, the actual quantity shall be as per site condition.
13. All control panels / Stations, free issue cabinets and PDBs (UPS
and NON UPS) are to be mounted on new Channel Base.
14. Supply of Hardware 20 window annunciator 3 nos. for HEB1, 2 and
3 shall be vendors scope.
15. New dedicated earth pit shall be provided by BPCL and
That may be connected to the existing earth pit if required. Vendor
to submit the detailed grounding scheme and earth pit drawing to
BPCL.
16. DCS shall be supplied with latest version of system and application
Software, controller Firmware and latest hardware.
17. Vendor's documentation shall be considered part of the global
project documentation to be issued to BPCL at the end of the
Factory Acceptance Test.
18. Tentative Bill Of material attached as per Annexure III.
19. Details of formats to be provided will be defined at Kick off Meeting,
maintaining the following general guidelines:
i. All the documents shall show Client's reference and
document name.
ii. An Index of documents shall be prepared, listing all the

provided documents and their revision number.

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 10 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

iii. Revisions shall be clearly identified on each sheet and erased
at the last issue, which will be labeled as "issued for
construction".
t. Vendor to visit BPCL Control room and understand the job
before submitting the offer. Vendors offer shall not be
considered for technical evaluation in absence of this activity.
2.1 FOREIGN DEVICES INTERFACE
All the foreign interfaces considered for this project shall have
comprehensive diagnostics for serial interface modules / connectivity on
DCS console in the event of any failures.
1. DCS - ESD PLC communication
1) The ESD PLC will be connected to DCS by redundant (or double)
serial link to DCS system or direct connectivity (preferably) on the
DCS network shall be considered which will communicate between
ESD to DCS and visa versa.
2. Communication with Plant Network System
1) The operators shall be able to access entire Plant Information network
through the operator consoles. A gateway from the DCS data highway
and the Ethernet LAN shall be provided, to allow the Plant Information
System to exchange data.
2) This Plant network information system shall collect data from DCS for
data validation, history management, advanced process control,
material balances.
3. Computer Gateway:
1) The gateway will be used for two way communication with computer
(DEC Alpha or Intel Server) for implementing Advanced Process
Control. The gateway will be connected directly to the refinery network
(FDDI) through a switch and will communicate with the computer (also
on the network) using TCP/IP.
(1) Ethernet Port
(2) Communicate Protocol : TCP/IP
2) DCS-Computer Interface
(1) Capable of two way communication

(2) Data scan frequency shall be one minutes for all the tags

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 11 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

c) Interface with Real-Time database software:X/Infoplus.21 from M/s Aspen Tech, USA.

Infoplus-

All the necessary hardware required shall be considered. Hardware firewall

between IP21 server and DCS OPC server must be provided.

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION

MUMBAI-400 074.

SHEET 12 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

3.0 SCOPE OF WORK FOR PLC

The proposed 4 nos PLC systems shall be replacing existing M/s.Yaskawa make
PLC (4 nos) manufactured and engineered by L&T Mumbai and supplied by
M/s.ABB-ABL Calcutta. The job includes removal, replacement of the existing,
PLC and its associated panels & hard wares & design, fabrication, supply,
erection, installation and commissioning of new ESD PLC along with associated
panels and hardware for the Boiler House plant.
The scope of work shall comprise of the following but not limited to:
1.

System Design and Engineering

2.

Manufacture / supply of all hardware and software necessary to

meet specified functional requirements including system
configuration, system integration, factory testing and acceptance of
the system.

3.

PLC shall have latest version of Software, Firmware and hardware.

4.

The PLC shall be TUV AK5 /SIL3 as per IEC61508 certified.

5.

PLC shall have dual redundant processor as a minimum. Additional

redundancy for I/Os/Power supply/Communication network shall be
provided as a minimum requirement

6.

PLC system cabinets shall have hardened plastic doors to look

through the various components system status without opening the
door.

7.

Preferably PLC shall connected to DCS system network, otherwise

serial interfaces between PLC and DCS shall be redundant and
through dedicated controller in DCS.

8.

The software shall include operating system and application

program. The application program shall include software for
performing functions like interlock and shutdown logics,
programming, programming modifications and documentation etc.
The programming format shall be only FLD type using functional

blocks. User defined functional blocks shall be possible to develop.

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 13 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

9.

The system shall be supplied with programming tools and related

accessories.

10.

No two shutdown circuits shall be shared by same I/O modules

unless specified otherwise.

11.

All digital inputs from MCC to PLC and outputs from PLC to MCC
and Solenoid valves and Field lamps as well as Field switches shall
be through interposing relays. All interposing relays shall be
provided with LED indication and minimum one spare contact per
relay shall be free for owner use for future.

12.

The PLC system scan time shall be less than 200ms.

13.

Sequence of Event recording with resolution of 1 mSec scan time

shall be provided as inbuilt feature with PLC.A dedicated PC with
21inch monitor and Ink Jet printer shall be provided in addition to
PLC workstation.

14.

Preferably the entire PLC engineering work station/ SOE station

shall be connected to same network DCS/PLC. In case the distance
between the PLC work station/ SOE station and DCS network
exceeds beyond the allowable limit, necessary hardware viz fibre
optic converter shall be considered.

15.

Application program shall be capable of showing the dynamic

status of the input variables even after respective signal forced.
This feature will facilitate the easy removal of the force after
required maintenance carried out.

16.

24VDC redundant Bulk power supply unit with Diode O ring along
with individual MCBs for individual consumers shall be installed in
Power Distributions (PD) cabinet. The power supply to each of
Marshalling cabinet, Relay Cabinet, Termination cabinet,
Electrical/Instrument Termination cabinet shall be redundant
including in/out MCB.

17.

New dedicated earth pit shall be provided for each PLC system by
BPCL and the same may be interconnected with the existing earth
pit if required. Vendor to submit the details for earth pit requirement

as per system.

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 14 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

18.

Supplier shall include involving qualified Engineers and technicians

for participation in engineering, installation, field testing and
commissioning of PLC system.

19.

Packing, forwarding, transportation, custom clearance, insurance,

storage etc. of the system.

20.

Installation, field testing, loop checking, commissioning and field

acceptance of the system

21.

Documentation, training, warranty etc.

22.

Installation and commissioning assistance of the free issue if any

(owner supplied) items in the control room.

23.

Tentative Bill of Material attached as per Annexure III

3.1 As part of engineering, vendor shall develop documents required for system
configuration for different areas in the unit. Vendor shall develop functional Logic
Diagrams (FLD) etc on the basis of existing Logic schemes which shall be made
available by BPCL Mumbai refinery to the vendor.
3.2 As this HEB PLC System is replacing Yaskawa/L&T make U84 PLC System.
Vendor to consider the following while submitting the offer.
1.

All the existing components along with cabinets/BMS Plaque etc

shall be removed including removal and re-glanding of Field cables,
termination and loop checking of the same. The detailed list is
attached as Annexure VI. The item shown in Annexure VI is only
tentative, the actual quantity shall be as per site condition

2.

Identification of all the loops, replacing the existing ferrule with new
ferrule. The I/O count is as per the attached Annexure VII.
The removed panels shall be shifted to a location shown by BPCL
engineer in charge inside the refinery only.

3.
4.

Vendor to visit BPCL Mumbai Refinery Control room for items to be

removed/replaced as per the above list and understood fully the job
before submitting the offer. Vendors offer shall not be considered
for technical evaluation in absence of this activity.

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 15 OF 129

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3.3 POWER SUPPLY AND ELECTRICAL REQUIREMENTS

110VAC UPS
Supplier shall be provided with redundant feeders of 110VAC from
existing UPS cabinet. Supplier shall consider 100 mtrs approximate
distance from UPS to PDB. However the same shall be reconfirmed
during pre-bid site visit. The cabling from UPS cabinet to Inst PDB is in
vendors scope including sizing of the cables. Supplier to distribute
110VAC to all the consumers from PDB. Complete power consumption
calculation shall be submitted by the vendors and on that basis MCBs
and fuses with appropriate rating shall be provided.
ESD PLC shall include redundancy of DC power supply units / regulators
for internal supply to the electronic cards, with automatic back up, such
that microprocessor controller power supply failure shall not affect loop or
sequence control.
All the MCB shall be mounted in such a way that ON/OFF knob shall be
at the bottom when MCB is kept ON. This will facilitate accidental tripping
of MCB by falling some unforeseen material or force etc.
Electrical power supply to the PLC (ESD) system shall be:
1110 VAC 5%
250 Hz + 1Hz / -1.5 Hz
Electrical power supply to the PLC Modules will be:
24 V DC 2%
Input /Output interrogation voltage shall be 110VDC5%.
Earthing system will be provided strictly as per Vendor standards, the
necessary details to be submitted by vendor for this.

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 16 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

4.0

SPECIAL INSTRUCTIONS TO VENDOR FOR DCS

1. Vendor shall submit the BOM & price schedule with price break-up
including mandatory spares, recommended spares, site services for DCS
shall be clearly separated out for all items.
2. Vendor shall study the existing system configuration of total Boiler house
and propose the system.
3. M/s BPCL will provide the all existing Yokogawa make CENTUM XL
programming documents, by which vendor shall decode the programming
and make the necessary functional schematics which shall be submitted
to M/s BPCL for approval.
4. Vendor shall quote for Alarm Management system which shall be stand
alone system and will be connected to DCS through serial link / other
communication network.
5. PLC related DI/DO signals shall be configured in DCS for alarm purpose.
6. Documentation System Software/hardware for DCS along with printer and
necessary furniture (table and chair) mounted with necessary receptacles
to be considered.
7. As we have segregation of control stations for HEB#1, 2, 3 and BOP,
vendor should also follow the same segregation in new DCS. Accordingly
engineering of control stations, Marshalling panels, PDB power supply
segregation etc. shall be considered in proposed new HEB#1, 2, 3 and
BOP DCS system.
8. Vendor shall take the total DCS backup of existing system configuration
for system engineering and connectivity.
9. Vendor to study the existing HF bus and V-net communication and hook up
scheme for stage wise execution to be submitted for BPCL approval.

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 17 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

10. Vendor shall provide four sets of back-up configuration storage for each
system, containing operating programs, diagnostic programs and system
configuration etc.
11. Vendor to note that the following makes of switches, lamps etc. only used
SR.
NO

TYPE

MAKE

PUSH BOTTON

IDAC ZUMI / FUJI

SELECTOR SWITCH

IDAC ZUMI / FUJI

LAMP

YAMATAKEHONEYWELL
TYPE MICRO

TERMINALS

WAGO TYPE

PC

DELL/HP

BARRIERS

P&F

FUSED TERMINALS

WAGO TYPE

MCBS

MDS

REALYS

OMRON WITH LED JAPA

make

12. All digital input terminal blocks shall be wago type and all digital output
terminal blocks shall be fused wago type.
13. All PCs provided as part of this requisition shall be equipped with the latest
available processor with maximum processing speed.
14. Input - output considerations
1. All cards will be provided with diagnostic features with High diagnostic
coverage per channel at component level, able to detect any failure
and giving a diagnostic alarm. Replacement of I/O cards shall be
possible while the DCS is powered.

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 18 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

2. Removal and insertion of a DCS I/O card shall not affect the supply of
field power to other loops connected to the DCS.
3. Shut down switches will work as follows: when the contact coming from
the switch is OPEN, the shut down sequence will start. This solution
guarantees that plant shut down is initiated only if requested by
operator and not as a consequence of a single hardware failure.
4. Bypass switch will deactivate a cause (or a group of causes, according
to interlock process requirements) only when the contact coming from
the switch is CLOSED. This way if there is a hardware fault interlock
deactivation will not occur.
5. The following type of I/O modules shall be provided for as a minimum
in the DCS but not limited to:
(1) Digital input
(1) Dry contact 110V DC loop Voltage (interrogation voltage
provided by Marshalling) inputs shall be provided with filter and
isolation.
(2) Analogue Inputs/outputs
(1) 4-20 mA dc , 1-5 V dc two wire type
(2) All I/O circuits must be provided with galvanic isolation using
isolating barriers.
(3) Digital Outputs
(1) All digital outputs shall be equipped with protection against
voltage surges caused by inductive loads.
(2) Digital outputs shall be static type, free voltage contacts. The
outputs shall be galvanic ally or optically isolated.
(3) Outputs shall be without any common wiring and no looping in
the terminal end is allowed.
(4) The interposing relays shall be provided in the DCS Marshalling
to match the required ratings.
(i) for Solenoid valves and MOVs 110 V dc - 3 Amps.

(ii) for MCC

BHARAT PETROLEUM CORPN.LTD.
MUMBAI REFINERY, MAHUL,
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110V dc - 5 Amps.
PROJECT NAME : REVAMPING
OF HEB DCS & PLC

SPECIFICATION
SHEET 19 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

(iii) for Shutdown Consoles

110 V dc - 1 Amp.

15. Vendor shall consider IO Modules to be used with 10 % De-rated channel

Density for AI/AO Modules and DI/DO Modules.
16. The following Tagging and Identification philosophy for Equipment, wiring
and terminals shall be followed.
1. Each Cabinet, Workstation, operator station, card file, equipment, shall
have identification label/Nameplate on the front and rear. The
identification label shall be of laminated plastic or approved equal with
white dull surface finish and information engraved in Black. These
labels shall be permanently affixed with fasteners or Bonding to the
Cabinets / equipment. Vendor to provide the Nameplate and labeling
schedules for approval by BPCL.
2. All the instruments, pushbuttons, switches, lamps etc. mounted in the
Cabinets/ Consoles shall be identified by two identical nameplates, one
on the front and one on inside the cabinet/ Console. The nameplates
shall be made of plastic or stainless steel inscribed with tag no. and
service. The nameplates shall be attached with non-corrosive
fasteners.
3. All wires connected to Terminal blocks, including I/O module
termination panels shall be tagged with 2 identification tags. The first
Tag shall (closest to the end of the wire) identify the terminal number to
which the wire is physically connected. The second tag shall identify
the terminal or device number to which the opposite end of the wire is
connected. Wires markers shall be slip-on, heat shrink, permanently
embossed, sleeve type.
4. Each terminal block shall be labeled with a sequential terminal
identification number. Each row or column of terminal blocks shall be
labeled with a unique Identification name or number.
5. Multicore cables with connector plugs shall be labeled with 2
identification tags. The first tag (closest to the plug) shall identify the
cabinet identifier, device and socket to which the plug is to be
connected. The second tag shall identify the cabinet identifier, socket
or device to which the opposite end of the cable is connected.

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 20 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

17. SYSTEM TERMINATIONS

1. The termination in DCS panels have to be segregated per voltage level
and voltage category.
(1) Analog ( Intrinsically safe)
(2) Analog ( Non- intrinsically safe)
(3) Discrete ( Explosion proof)
(4) Power supply cables.
(5) Control signal cables between MCC and control room.
2. Terminals shall be WAGO (spring loaded) type and shall be adequate

for wiring of flexible wires of 1.0 - 1.5 mm section. No double terminal blocks
may be used.

3. Terminal panels with electronic devices and/or relays mounted shall

have a dedicated mechanical protection.
4. Each terminal panel shall have the individual identification tag and
each channel shall be identified by the instrument connected with tag
name.
5. The terminal panel connection to the I/O cards shall be through
prefabricated cable with plug-in connector.
6. The Terminals provided in the Marshalling cabinets shall be single tier
and of suitable size depending upon the current rating and the size of
the cable being terminated.
7. The terminals shall be of Wago type or equivalents with knife edge
isolation with spring loading of the signal from / to field. Individual fuses
and indicating LED/Lamps for indicating signal status shall be provided
for each Digital O/P channel.
8. The digital outputs shall have LED/Lamps for indicating Fuse blown
status.
18. Unauthorized access to the system shall be protected by means of

suitable Hardware Key locks and Software passwords. Different levels of

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 21 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

access shall be provided for the Operators and Engineers by means of
passwords and key locks.
19. COMMUNICATION SUB SYSTEM
1. The Communication sub system cable shall be secured in conduit
inside the control room. In such installations where communication
subsystem extends outdoor and subjected to intermittent exposure to
water or condensed moisture, it must be enclosed in rigid conduit. The
communication subsystem, in such case must perform to the offered
specifications for error rate, signal attenuation, noise immunity etc.
2. DCS Bus shall be fully deterministic based on IEEE802.4.
3. Communication speed on the system bus shall be minimum 100Mpbs
and overall system performance shall not be degraded whether
communication subsystem is 10% loaded or 100% loaded.
4. Vendor must furnish BUS LOADING calculations for each system. I.e.
controller & Data Acquisition subsystem, console subsystem and
communication subsystem. The Loading figures shall be demonstrated
by vendor at FAT and finally during SAT. Vendor quoted Hardware and
software shall meet these loading requirements. In case actual loading
is found to be higher than the specified figure, vendor shall supply
additional hardware / software to meet the requirements of this
requisition without any commercial implications.
5. System bus, subsystem bus and I/O Bus redundancy shall be true
redundant with 2 sets of Bus and redundant Cards.
6. DCS communication sub system shall be OPC compliant.
20. SELF TUNNING
1. It shall be possible to tune control loops automatically on selective
basis. The operator shall either load tuning parameters computed by
the system automatically or manually.

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 22 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

2. The software for the loop tuning may reside / run on any system
hardware including controller and Data acquisition subsystem,
Operator console subsystem, supervisory computer etc. The tuning
package shall ensure that the system not disturbed whenever a loop is
being tuned. Tuning package shall not slow or load the system
performance.
21. POWER SUPPLY
1. Vendor to ensure the DCS component shall not get affected or failed
due to blackouts. Fail Safe Operation of the system to be ensured
under the following conditions.
(1) Total Power failure
(2) Voltage Variation more than 10%
(3) Frequency variation More than 3%
(4) Air conditioning failure resulting in temperature exceeding 40 deg C.
2. 110V AC, 50HZ UPS and 110 V DC redundant feeder shall be made
available to the vendor at one point in UPS room which is around 100
meters from control room.. Any other voltage requirement shall be
derived from the above source by the vendor.
3. Bulk power supply provided by vendor for transmitter power or for any
other application shall have the following specifications:
(1) Bulk power supplies shall be redundant floating with +, - 0.5V
tolerance.
(2) Separate power supplies shall be provided for controller
/subsystem.
(3) Status indication for each power supply at operator console
(4) Switch / Fuse for each loop.
4.

Each power supply shall be sized for 150% of load.

5. The system shall restart without manual intervention after resuming the
power sully with in CPU battery life.
6. Separate Diode O ring/ Isolator unit shall be provided for each bulk
power supply. Scheme attached as per Annexure X

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 23 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

22. EARTHING REQUIREMENT

1. Vendor to specify the earthling requirements and provide the required
drawing as per their standards.
2. Vendor to provide the connectivity of existing or new earth pit and any
additional requirement of earth pit and other details.
23. CABINETS, RACKS AND PANELS
1. All cabinets, panels and racks shall be designed without congestion for
ease of maintenance. Racks / cabinets shall be designed to take care
of the following:
2. No marshalling rack / cabinet have more than 600 terminals in any
case.
3. All the spare cores shall be terminated on the marshalling rack. No
cable / core shall be left unterminated in the rack / cabinet.
4. All spare cores shall be terminated in TBs at top of the each
marshalling cabinets with proper ferrule details.
5. No terminal or terminal strip, MCB shall be located on the side panel of
the rack / cabinet.
6. Quality of all the panels and consoles shall be of highest quality as per
good engineering practice and to the satisfaction of BPCL engineer in
charge.
7. Manufacturer of the panel shall be Rittal or equivalent, this shall be
finalized during detailed engineering.
24. SPARES PHILOSOPHY

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 24 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

1. Installed engineering spares of 10% shall be provided in each
subsystem for each type of module to enhance the system functional
requirements including DCS and hardwired instruments.
2. In addition, the system shall have the following minimum spare
capacity.
(1) The controller and Data acquisition racks, Analog and digital
marshalling racks shall have 20% usable spare space for installing
additional I/O modules for future use.
(2) Each operator console shall contain 20% usable spare group and
related display capability.
(3) The system shall have capability to extend its historical trending,
logging and users memory by 20% to meet future expansion with /
without adding additional memory modules.
(4) I/O racks of DCS shall have 20% usable spare space for installing
additional I/O cards of each type in future. However, internal wiring
for the same shall be connected up to the I/O terminals.
(5) Processor system of DCS shall have capability to execute additional
20% logic. Further it shall be possible to extend the memory by
20% at a later stage.
(6) Usable spare space in cabinets and marshalling racks to install
20% spare hardwire items like barriers, trip amplifiers, and relays
etc. including terminals in future.
3. Mandatory spares shall be 10% of each type of module with minimum
of one module for each type or whichever is higher shall be supplied.
4. System spare capacity shall be provided as follows:
1. Bus capacity
:
2. No. of nodes
:

40%
50%

3. Vendor shall provide Min. 50% expandability on node

connectivity on redundant communication subsystem for
each kind of devices connected to the network.
25. System loading
(1) DCS shall be sized in such a way to guarantee further
expansion to End-User.
(2) Details about software loading of DCS are referred in the
different sections of this specification. They will apply to:
(i) Communication loading
:
60 %

(ii) Mass memory loading :

(iii) Process computations :
BHARAT PETROLEUM CORPN.LTD.
MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

60 %
60 %

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 25 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

(iv) Operator console

60 %

(3) The above software loading figures shall apply to the fully
configured system, comprehensive of spare.
26. Vendor to supply and install 2 Nos. of six pens assignable paperless
recorders and 3 alarm annunciator (4x5 Windows).
27. Vendor has to submit the compliance and deviation statement along
with this offer, without this offer will not be evaluated.
28. Vendor to confirm offered controller card and IO card shall be protected as
per ISA GX CLASS 71.04 corrosive environment protection or better and
relevant certificate shall be enclosed along with the offer.
29. Scope of work for OPC connectivity
1. Vendor to provide necessary Hardware and Software for two way
connectivity between DCS and Supervisory Computer (for Advance
Control System and IP21 database)
2. Vendor to provide OPC Compliant Interface Software. The interface
software should be an OPC Server, which complies with version 1.0a
or version 2.0 OPC Specification developed by the OPC Foundation.
3. Vendor to ensure communication with Aspen techs CIMIO for OPC
which is an interface which communicates with any OPC server that
complies with the version 1.0a or version 2.0 OPC specification
developed by the OPC foundation. The interface communicates with
the OLE 2.0 methods provided by compliant OPC servers.
4. Vendor to ensure that the time zone of the machine on which both the
OPC server and CIMIO for OPC are loaded is set to Indian Standard
Time.
5. Vendor to generate Data buffers, Timers, Switches etc in respective
stations as may be required for developing Advance control logics at
DCS (sequence tables, calculation blocks etc ).
6. Configuring of logics at the DCS (sequence tables, logic tables,
calculation blocks etc) for loops (as per BPCL requirement) to go to
computer mode.
7. To ensure all loops (as per BPCL requirement) have been configured
to go to computer mode.
8. Vendor to develop operator entry graphic screens (as per BPCL
requirement) at the DCS for Advance control purpose.

9. Vendor to establish proper data communication for each loop as per

the logic tables, sequence tables, calculation blocks etc.
BHARAT PETROLEUM CORPN.LTD.
MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 26 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

10. All logic tables, sequence table, calculation blocks etc to be tested for
computer mode operation as well as for backup mode (by simulating
failure conditions).
11. All Data buffers, Timers, Switches etc to be configured in the gateway.
12. The DCS vendor to provide the necessary Hardware / software
specifications for the gateway, as required to access all tags (analog,
digital, data buffers, timers, switches etc) at the frequency of 15 sec.
13. Data transfer should be Bi-directional (i.e.; read data from the DCS and
send data to the DCS).
14. DCS vendor to provide all the necessary Hardware and Software (2
sets) to read and write data from DCS to the supervisory computer.
15. The DCS vendor to ensure that all tag information that is available in
the tuning panel (like tag number, tag description and tag attributes like
PID controls, lead blocks, anti windup status etc) should be accessible
at the supervisory computer.
16. The DCS vendor to incorporate Anti-windup status as a smart data
type parameter at the DCS.
17. The DCS vendor to ensure that all the loops (as per BPCL
requirement) to be configured for accepting remote set value (RSV) or
control valve opening (RMV) as per BPCL requirement.
18. Provision to be made for setting the Basic scan for all manipulated
variable process tags to be set at 1 sec.
19. The OPC server should be able to support minimum 8 clients (all
simultaneously) with no restriction on number of points / groups access
etc.
20. Switches for Advance controls should be 3 point switch (SRVIND):
1. 0 - OFF
2. 1 - ON
3. 2 - FFW
21. Provision for Data buffer ranges changing online.
22. Provision for input Filtering, integral windup status (not antiwindup
status), PID tuning algorithm.
23. Provision to be made for all PID loops to go to CAS, CMP mode.
24. Steam tables to be incorporated in DCS.
30. Vendor to submit PROVEN TRACK RECORD (PTR) for DCS for a period
of minimum two year of continuous successful operation in hydrocarbon

Industry Worldwide. PTR shall be given of the same Model of system

proposed for this project, including all major components like Controller,
CPU, I/O cards, I/O racks, Communication Bus, Operator Station,

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 27 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

Software, etc. The name of the concerned person at customer end with
contact details and installed architecture details should be provided along
with PTR.
5.0

SPECIAL INSTRUCTIONS TO VENDOR FOR PLC

1. The ESD PLC system shall be a high availability Quadruple Modular
Redundant (QMR) PLC / Triple Modular Redundant (TMR) PLC with
Hardware and Software Fault Tolerance.
2. Both processors shall be inline and both shall scan the input, solve logics
and generate outputs. No selection of primary and secondary and no
switching over of primary and secondary concepts are acceptable. The
offered PLC shall be TUV approved for AK5/SIL3 as per IEC61508
3. Safety system shall be protected from Cyber attacks like Virus etc. the
required software/hardware shall be considered.
4. Chassis for Main and Redundant Processor shall not be common and
placed in separate chassis.
5. Identification of field cable inside control room and hooking up to new
marshalling panel is in vendors scope.
6. The ESD system shall be used to continuously monitor the Safety
parameters of the plant and shall take actions to maintain the Safety of the
plants on demand. The ESD system shall provide a dependable and
reliable means of executing the above functions and shall confirm to the
Safety Integrity Level (SIL) 3 of the IEC 61508. The ESD system shall be
TUV approved for class AK5 according to DIN V 19250.Vendor to furnish
the Test certificates & Report of TUV at time of submitting the offer.
7. The ESD system shall operate in a TRIPLE MODE (3 -2 0) redundancy
mode in TMR PLC System OR quadruple (4 -2 0) redundancy mode in
quadruple PLC System.
8. Failure of a card shall not affect with the other parts of the system
9. ESD PLC shall be sized in such a way to guarantee further expansion to
end user.

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 28 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

10. Details about software loading of ESD are referred in the different sections
of this specification. They shall
apply to:
Communication loading
:
60 %
Process computations
:
60 %
11. Hardware loading will be organized to guarantee 10 % spare signals
already installed and wired plus an additional 20 % of free space in the
cabinets.
12. The instrument philosophy used for the plant is Contact CLOSED during
NORMAL or HEALTHY state and OPEN / BREAK to ALARM. Safety and
interlock functions are generally performed by dedicated instruments for
Safety shutdown.
13. Interposing relays for both input/output shall have free wheeling diode
protection for Inductive load.
14. For AI points existing input barriers MTL3046B to be replaced with latest
Barrier /repeater and to be terminated the field signal. One output shall be
retained for DCS indication as existing and other output shall be
connected to PLC AI card. Required installation of AI barrier/Signal
repeater and power supply distribution for the same shall be in vendors
scope.
15. DI/DO relays shall be having 4NO/4NC contacts. Coil Voltage for Input
Relays shall be 110VDC and for output 24VDC.
16. The ESD system shall be capable of accepting signals which may have to
be triplicated / duplicated at the Card level to provide Triple Redundancy /
Dual Redundancy.
17. List of Forced signals shall be displayed in PLC workstation.
18. PLC Workstation and SOE PC along with necessary furniture shall be
provided with insulated anti-virus software and virus protection card to
avoid software corruption.
19. All PCs provided as part of this requisition shall be equipped with the latest
available processor. Unauthorized access to the system shall be protected

by means of suitable Hardware Key locks and Software

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 29 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

passwords. Different levels of access shall be provided for the Operators
and Engineers by means of passwords and key locks
5.1

Scan Time

1. The ESD processors shall continuously scan the inputs, outputs

and program & execute commands to appropriate outputs.
2. The Scan time of the PLC is defined as the total time required for
reading input, program execution and changing the Output state.
3. The vendor shall also state and guarantee at the time of offer the
following
1. Guaranteed Scan time = less than 200msecs
2. The communication time between ESD PLC and DCS = less
than 500 mSecs
3. The vendor shall clearly state and guarantee the offered
Scan time of the Emergency Shutdown System in their offer
based on the figures .Without the above Scan times clearly
stated in the offer and guaranteed the offer would be treated
as incomplete.
4.

Time resolution for SER of ESD PLC shall be less than 1

mSec.

5.2 Vendor to note that the following makes of switches, lamps etc. only
to be supplied and used in this project.
SR.
NO

TYPE

MAKE

PUSH BOTTON

IDAC ZUMI / FUJI

SELECTOR SWITCH

IDAC ZUMI / FUJI

LAMP

YAMATAKE HONEYWELL

TERMINALS

PHOENIX
WEIDMULLER/WAGO

PC

DELL/HP

BARRIERS

P&F

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 30 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

7

FUSED TERMINALS

PHOENIX / WEIDMULLER

MCBS

MDS

REALYS with base

OMRON
WITH
L
(4NO+4NC) JAPAN make

10

BMS Plaque

PHOENIX / WEIDMULLER

5.3 All digital output terminal blocks shall be fused type with LED
indication.
5.4 Input - output considerations
All cards shall be provided with diagnostic features with High diagnostic
coverage per channel at component level, able to detect any failure and
giving a diagnostic alarm. Replacement of I/O cards shall be possible
while the ESD is powered.
1) Removal of a ESD I/O card shall not affect the supply of field power
to other loops connected to the ESD. Online removal/replacement
of all type of cards shall not affect the functionality of PLC.
2) Shut down switches will work as follows: when the contact coming
from the switch is OPEN, the shut down sequence will start. This
solution guarantees that plant shut down is initiated only if
requested by operator and not as a consequence of a single
hardware failure.
3) Bypass switch will deactivate a cause (or a group of causes,
according to interlock process requirements) only when the contact
coming from the switch is CLOSED. This way if there is a hardware
fault interlock deactivation will not occur.
4) The following type of I/O modules shall be provided for as a
minimum in the ESD PLC.
i) Digital input
Dry contact
110V DC loop Voltage (interrogation voltage provided by
ESD Marshalling) inputs Shall be provided with filter and

isolation.
BHARAT PETROLEUM CORPN.LTD.
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PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 31 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

ii)Analogue Inputs
4-20 mA dc, two wire type
iii) Digital Outputs
All digital outputs shall be equipped with protection against
voltage surges caused by inductive loads.
Digital outputs shall be static type, free voltage contacts. The
outputs shall be galvanic ally or optically isolated.
Outputs shall be without any common wiring.
Interposing relays shall be provided in the ESD Marshalling
to match the required ratings.
- For Solenoid valves
110 V DC - 3 Amps.
- For MCC
110 V DC - 5 Amps.
- For Shutdown Consoles
110 V DC - 1 Amp.
Iv) All I/O circuits must be provided with galvanic isolation
using isolating barriers.
5.5 The following Tagging and Identification philosophy for Equipment,
wiring and terminals shall be followed.
1) Each Cabinet, Workstation, operator station, card file, equipment,
shall have identification label/Nameplate on the front and rear. The
identification label shall be of laminated acrylic with white dull
surface finish and information engraved in Black. These labels
shall be permanently affixed with fasteners or Bonding to the
Cabinets / equipment. Vendor to provide the Nameplate and
Labeling schedules for approval by engineer in charge of BPCL
Mumbai refinery
2) All the instruments, pushbuttons, switches, lamps etc. mounted in
the Cabinets/ Consoles shall be identified by two identical
nameplates, one on the front and one on inside the cabinet/
Console. The nameplates shall be made of plastic or stainless
steel inscribed with tag no. and service. The nameplates shall be
attached with non-corrosive fasteners.
3) All wires connected to Terminal blocks, including I/O module

termination panels shall be tagged with 2 identification tags. The

first Tag shall (closest to the end of the wire) identify the terminal
number to which the wire is physically connected. The second tag
BHARAT PETROLEUM CORPN.LTD.
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shall identify the terminal or device number to which the opposite
end of the wire is connected. Wires markers shall be slip-on, heat
shrink, permanently embossed, sleeve type.
4) Each terminal block shall be labeled with a sequential terminal
identification number. Each row or column of terminal blocks shall
be labeled with a unique identification name or number.
5) Multicore cables with connector plugs shall be labeled with 2
identification tags. The first tag (closest to the plug) shall identify
the cabinet identifier, device and socket to which the plug is to be
connected. The second tag shall identify the cabinet identifier,
socket or device to which the opposite end of the cable is
connected.
5.6 SYSTEM TERMINATIONS
The ESD PLC terminal panels have to be segregated per voltage
level and voltage category.
Analog (Intrinsically safe)
Discrete (Explosion proof)
Power supply cables
Terminals shall be screw type / push fit spring loaded type and shall

be adequate for wiring of flexible wires of 1.0 - 1.5 mm section. No

double Decker terminal blocks shall be used.

1. Interconnection between field and control room shall be from

Marshalling rack only. All inter connection between marshalling
and system cabinets shall be through prefabricated cables with
plug in connectors only. The prefab cable shall be installed in
separate cable trays in the control room below false flooring.
Cable trays shall be supported properly with cover on each
cable tray to protect from rates.
2. Following color codes shall be considered.
VOLTAGE

TYPE

COLOR

POWER SUPPLY 110V

AC

PHASE

RED

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SPECIFICATION
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BOILER HOUSE DCS AND PLC SPECIFICATIONS

DCWIRING
24VDC and 110VDC

NEUTRAL

BLACK

EARTH

GREEN

Both POSITIVE
NEGITIVE

ALARM SYSTEM
CONTROL
SHUTDOWN

RED
BLACK
WHITE

&

ANALOG SIGNAL

YELLOW
LIGHT BLUE

3) Power cables to individual barriers, Isolators and Relays shall not

be looped together. Separate wires shall be laid from bus bar to
individual devices.
1)

Identification and Marking

1) All electrical terminations and equipment on the cabinet and
other accessories shall be identified with appropriate tag, cable
marker etc.
2) All terminals in terminal strip shall be identified by their
individual numbers located integral with the terminal itself.
3) Interconnecting multi core cables if any shall be identified by
metal tags.
4) Wiring at terminals shall be identified by the terminal numbers
and termination service at the other end of the wire. Writing at
instruments and accessories like alarm relays, pushbuttons etc
shall have ferrules indicating tag numbers, terminal and the
termination service at the other end of the wire.
5) Ferruling shall be cross and straight both with heat shrink
sleeves.
6) Looping connections if any shall be identified by the termination
services at both ends of the wires.
7) Identification markers as mentioned above shall be repeated in
suppliers drawings also.
8) Sample identification method shall be discussed with engineer
in charge of BPCL Mumbai refinery before finalization.

2)

BMS Plaque Lamps /Switches and PBs.

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BOILER HOUSE DCS AND PLC SPECIFICATIONS

i) Push-buttons
Related push-buttons shall be organized in isles, and a label shall be
provided to identify the general function of each switch
ii) Labels
Close to each switch a plastic label shall be provided and the tag
name of the device shall be indicated on it. Labels shall be black with
white engraving. Size of tag plates shall be finalized before execution
with engineer in charge of BPCL Mumbai refinery
iii) Terminations
Each termination shall be identified with a global label and each
terminal shall be clearly identified through a number/letter (details will
be defined during project development).
4) Lamps
1. Colors will be:
1RED (for alarm)
2GREEN (normal)
3YELLOW (enable/disable of interlock)
2. The lights shall be provided by white multi LED elements, and
the colored caps shall be easily replaceable.
3. Typical connections of lamps shall be as follows:
1-

Two (2) lamps (for valve equipped with two limit

switches): a lamp shall be always lit according to the status
of the valve (green=open; red=closed);

- One (1) lamp (for indication of motor status or valve equipped

with single limit switch indication).
4. Some lamps will be installed inside push-buttons, others will be
independent.
5) Push-buttons and switches
Switch contacts will be wired as follows:

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1- Normally closed: open the contact (2 NOs) to initiate the interlock
and to stop dedicated motors;
2- Normally open: close the contact (2NCs) to disable (bypass) an
interlock sequence.
6) BMS plaque accessories
1) All the switches and lamps shall be wired to a marshalling strip installed
inside the shut down console. The numbers of strips and terminals shall
cover the number of switches and lamps foreseen on the consoles
considering the spares.
2) To allow easy reconfiguration of the console during the plant
commissioning and start-up, all the switches shall have three contacts
per section and internal lamp(s), all wired to the terminal strip.
3) The switches shall be provided with modular components, to guarantee
easy replacement of colored caps, or to allow change from two position
switch to push-button and vice versa. Security covers shall be provided,
to avoid accidental operation of switches and push-button. A mushroom
pull-button for the plant emergency shutdown shall be provided. A lamptest push-button and the necessary diodes and wirings, shall be
provided on the hardwired consoles.
4) Suppliers to consider individual fused terminal strips for power wiring to
barrier, isolators and Relays.
5) Terminal panels with electronic devices and/or relays mounted shall
have a dedicated mechanical protection.
6) Each terminal strip and group of terminal strips shall have the individual
identification tag and each channel shall be identified by the instrument
connected with tag name.
7) The terminal panel connection to the I/O unit shall be through plug-in
connector multiwires cable.
8) The Terminals provided in the Marshalling cabinets shall be single tier
and of suitable size depending upon the current rating and the size of
the cable being terminated. The terminals shall be of Weidmuller type

SAKS or equivalents with knife edge isolation of the signal from / to

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field. Individual fuses and indicating LED/Lamps for indicating signal
status shall be provided for each Digital O/P channel. The digital
outputs shall have LED/Lamps for indicating Fuse blown status.
3) The following points must be taken into consideration for engineering
of PLC
1) Power supply distribution for Processors, inputs and outputs must
be from respective Bus bar only.
2) All power supply distribution shall be designed to have no common
mode failure. Separate DC/ AC feeders shall be used for each
processor and each I/O rack.
3) I/O modules must be segregated shutdown circuit-wise. No more
than 60% of the module I/O capacity shall be utilized.
4) PLC system engineering shall be done by PLC manufacturer at
their works. No subcontracting shall be entertained.
4) The system shall be internally protected against system errors and
hardware damage resulting from: (Detailed write-up / description on
how to achieve this by vendor should be explained)
Electrical transients on power wiring
Electrical transients and signal wiring , and
Connecting and disconnecting devices or removing or inserting
printed circuit boards in the PLC (ESD) system.
5.11 COMMUNICATION SUB SYSTEM
1.

PLC and PLC Bus shall be Fully deterministic based on IEEE802.4

2.

I/O Bus redundancy shall be true redundant with 2 sets of Bus and
redundant Cards.

5.12 For all thermocouple signals, which are connected to PLC (ESD)
system, proper barrier/Converter shall be used for converting T/C to mA
converter to connect to AI Module.
5.13 POWER SUPPLY
1.

Vendor to ensure the equipment not get affected or failed due to

blackouts. Further vendor to indicate the following. Steps to be

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taken for Fail Safe Operation of the system under the following
conditions:
1 Total Power failure
2 Voltage Variation more than 10%
3 Frequency variation More than 3%
4 Air conditioning failure resulting in temp exceeding 40
Deg C
The start up procedure for the system including system databases
loading during start-up and power on shall be submitted. The
system shall restart without manual intervention after resuming the
power supply with in CPU battery life.
2.

110V AC, 50HZ UPS and 110 V DC will be made available to the
vendor at one point in control room. Wherever 24vdc supply
required the same shall be made available by using redundant bulk
power supplies. Separate sets of power supplies shall be used for
each of these applications.

3.

Bulk power supply provided by vendor for transmitter power or for

any other application shall have the following specifications:
1 Bulk power supplies shall be redundant floating with +, 0.5V tolerance.
2 Separate power supplies shall be provided for each
Processor and its associated I/O cards.
3 Status indication for each power supply shall be provided at
DCS.
4 Switch / Fuse for each loop.
5 Each power supply shall be sized for 150% of load.
6 Separate Diode O ring /isolator shall be provided for each
power supply unit. Detailed scheme is as per annexure X

5.14

EARTHING REQUIREMENT
Two separate earth pits will be provided by the BPCL outside the
control room, one for signal grounding (IS) and another for
instrument (SYSTEM) grounding. It may be interconnected with
existing earth pits if required. The earth pit requirement shall be
submitted by vendor for executing the job at site by BPCL Mumbai
refinery.

5.15

CABINETS, RACKS AND PANELS

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BOILER HOUSE DCS AND PLC SPECIFICATIONS

1.

All cabinets, panels and racks shall be designed to avoid

congestion for ease of maintenance. Design shall be as per the
data sheets enclosed. Additionally , racks / cabinets shall be
designed to take care of the following:
1 All the spare cores shall be terminated on the marshalling rack.
No cable / core shall be left unterminated in the rack / cabinet.

5.16

2.

2 No terminal or terminal strip/MCB shall be located on the side

panel of the rack / cabinet.
Quality of the all panels and consoles shall be of highest quality as
per good engineering practice and to the satisfaction of BPCL
Mumbai refinery.

3.

Manufacture of panel shall be Rittal or equivalent, this shall be

finalized with engineer in charge of BPCL.

SPARES PHILOSOPHY
1.

Installed engineering spares of 10% shall be provided in each sub

system for each type of module to enhance the system functional
requirements including PLC and hardwired Instrumentation.

2.

In addition the system shall have the following minimum spare

capacity.

3.

The Processor and I/O cards racks shall have 20% usable
spare space for installing additional I/O modules in future.
However, the Processor and I/O cards shall have additional
20% capacity to handle these I/Os. In addition, internal
wiring for the same shall be completed up to I/O terminals.

I/O racks of PLC shall have 20% usable spare space for
installing additional I/O cards of each type in future.
However, internal wiring for the same shall be connected up
to the I/O terminals.

Processor system of PLC shall have capability to execute

additional 20% logic.

Usable spare space in cabinets and marshalling racks to

install 20% spare hardwire items like barriers, trip amplifiers,
and relays etc. including terminals in future.

Mandatory spare modules of 10% or more module whichever is

higher must be supplied for each type of modules being used

BHARAT PETROLEUM CORPN.LTD.

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BOILER HOUSE DCS AND PLC SPECIFICATIONS

including for consoles. This shall include spare modules for
hardwired instruments. Personnel Computers, PLC etc.
4.

System spares for future shall be provided as follows

Processing capacity
:
40%
No. of Nests/Nodes

50%

Vendor shall provide Min. 50% expandability on node connectivity

on redundant communication subsystem for each kind of devices
connected to the network.
5.17

System loading
PLC (ESD) shall be sized in such a way to guarantee further
expansion to End-User.
Details about software loading of PLC (ESD) are referred in the
different sections of this specification. They will apply to:
Communication loading
Mass memory loading
Process computations
SOE Point Loading

:
:
:
:

60 %
60 %
60 %
60 %

The above software loading figures shall apply to the fully

configured system, comprehensive of spare and uninstalled
interfaces.
5.18
Vendor to submit PROVEN TRACK RECORD (PTR) of two years for
ESD PLC also list of installations in India and aboard. PTR shall be given of the
same Model of system proposed for this project, including all major components
like Controller, CPU, I/O cards, I/O racks, Communication Bus, Operator Station,
Software, etc. The name of the concerned person at customer end with contact
details and installed architecture details should be advised along with PTR.
5.19 DIAGNOSTIC CAPABILITY
1)

The system shall have a High diagnostic coverage per channel.

2) The Diagnostic coverage factor shall be confirmed by the vendor at the time of
offer. The Diagnostic Coverage factor per channel of ESD shall be provided by

the vendor.

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iii) This diagnostic system will be automatic and run on a continuous basis
without maintenance persons intervention. It shall be capable of detecting errors
or fault conditions in any part of the PLC system before system integrity is lost.
The diagnostics shall report the location of the faulty device, the type of device
and the type of malfunction. Faults in the communication system shall also be
identified by the diagnostic routines.
iv) Vendor to detail the diagnostic programs available in the ESD system for the
maintenance people for debugging the system hardware and software faults and
normal maintenance activities.
V) The ESD system diagnostics shall show the following minimum fault / healthy
state status but not limited to:
1 Power feeders healthy
2 Circuit breakers tripped
3 Fuse Failure
4 Battery failure
5 Power supply failure
6 Power supply removed
7 CPU fault
8 Input/ Output Module failure
9 Input/ Output Module removed
10 Communication Failure
11 Each channel failure
12 Panel internal temperature high
13 Others as supplied by the manufacturer.
This status shall be transmitted to DCS via hardwired digital
outputs in addition to serial link. The Fault recovery procedures
for the above faults shall be detailed out by the vendor at the
time of submitting the technical offer.
5.20 Refer Annexure VIII for list of documents issued by BPCL Mumbai refinery
after placement of PO.

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BOILER HOUSE DCS AND PLC SPECIFICATIONS

6.0. FUNCTIONAL SPECIFICATIONS FOR DCS

6.1 FUNCTIONAL REQUIREMENTS
1. The system, as a minimum, shall meet the following requirements without
the supervisory computer:
(1)
(2)
(3)
(4)
(5)
(6)

Control
Data acquisition and monitoring
Alarming
Logging and report generation
Historical data storage
Trending

2. System shall have some free memory space available for the user and
CPU shall have the additional capability to perform advance control
functions, process optimization programs or generate management
reports as specified in job specification in addition to space requirements.
The availability of process control language shall be preferred.
3. Plant process and safety shutdown shall be independently performed by
programmable logic controller. (PLC shall be communicating with other
sub-systems via communication sub-system)
4. Whenever information network is specified, the system shall meet any or
all the following requirements:1. Centralized information system
2. Statistical process control/statistical quality control
3. Computer integrated manufacturing with information transfer to achieve
functions like production and preventive maintenance scheduling and
plant wide coordination etc.
4. Self documentation
5. Asset Management System( AIMS)
6.2 CONTROLLER AND DATA ACQUISITION SUB-SYSTEM
The controller and data acquisition sub system shall be used primarily
for plant control and data acquisition. However, the hardware and software

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used to achieve these functions must meet the following requirements as a
minimum:
6.2.1 Controller sub-system
(1) The control function of the system shall be executed by
microprocessor based multi-loop controller consisting of I/O ports
and a set of algorithms which are easily field configurable using
user friendly software.
(2) The hardware capability of the controller shall primarily be exploited
for regulatory control functions only. However, the sequencing and
interlocking capability shall be used whenever specified in the job
specification.
(3) The controller shall have advanced control algorithms to implement
regulatory and advanced control strategies. These shall include
PID, adaptive, feed forward, dead time, lead-lag, high-low, signal
selection, real time computational capability etc. apart from other
algorithms as specified in the job specification.
(4) Controller shall be able to scan close loop in less than 250msec for
critical loops (30%) and 500 mSec for Non-Critical Loops (70%)
unless otherwise specified in job specifications. The scan time for a
close loop shall be as defined in the data sheets.
(5) Controller shall be capable of accepting process signals from
various process sensors and switches preferably without requiring
external or auxiliary signal conditioning devices. The system inputs
shall include 4-20 mA DC, thermocouple, resistance temperature
detector (RTD) and discrete inputs as a minimum, apart from others
as specified in the job specifications. The controller shall be
capable of processing linear and non-linear analog inputs, providing
square root extraction for flow signals, linearization and
compensation for thermocouple.
(6) The controller shall be able to generate 4-20 mA DC current signals
for analog outputs and potential free contacts for the discrete
outputs as a minimum, apart from others as specified in the job
specification.

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(7) Controller shall be able to operate in either manual, auto, cascade
or computer mode. Mode change-over in either direction shall be
procedure-less and bump-less. It shall be possible to change set
point, tuning constant, operating mode, controller configuration from
the central level i.e. operators interface keyboard and engineers
interface keyboard.
(8) Loop integrity shall be maintained in controller sub-system
architecture in the following way, unless otherwise specified.
(1) By providing one to one controller back-up. In case failure is
detected in the active controller all the control shall be
transferred to back up controller.
(9) The controller sub-system shall have automatic transfer switching
which shall transfer the entire configuration and data base of failed
controller to the back-up controller. Design must ensure that data
integrity is maintained during switch over and no portion of data to
be transferred is corrupted before and during switch over to the
back-up controller. The back-up controller must be dedicated to
perform only control functions. The indication of the failed controller
shall be displayed at local as well as on the central level. The
switch-over time shall be less than 1msecond.
(10)Loop integrity shall also be applicable to closed loop I/O cards and
any other device associated with the controller sub-system
(11)The controller shall have facility for slow and fast ramping of set
point and output. Also all controllers shall have anti-reset wind up
as a standard.
(12)In computer mode, controller shall be able to track computer
generated set point and shall hold the last generated value in case
of computer failure. In such case, controller shall fall back on automode and continue to operate at the last received set point, in
general. Other options like pre-defined set point operation and fail
safe condition shall also be possible. On the resumption of
computer set point again, the controller shall not return to the
computer mode automatically. Computer failure indicator shall be
provided at central and local level.

(13) In cascade loops, the primary controller shall be able to track the
set point of the secondary controller when the secondary controller
is not operating in cascade mode.
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(14)All controller and input/output racks shall be provided with

redundant floating power supply.
6.2.2 DATA ACQUISITION SUB-SYSTEM
1) Data acquisition sub-system shall interface and multiplex analog
and discrete inputs from open loops. The inputs shall include 4-20 mA
DC, thermocouple, resistance temperature detector (RTD) and discrete
contacts, as a minimum, apart from others as specified in the job
specifications.
2) The system shall be capable of processing linear and non-linear
analog inputs, linearization and compensation for thermocouple,
linearization of RTD inputs, and square root extraction for flow inputs
apart from others as specified in the job specifications.
3) No. of inputs per I/O module shall not exceed either of the
following :SL.NO.
1
2
3

TYPE OF INPUT
Analog
Analog output
Discrete

NO. OF I/O PER MODULE

16
8
32

4) In case, an I/O module is capable of handling both discrete

inputs/outputs, only either type of inputs shall be connected to such
modules.
5) Redundancy must be provided for the data acquisition sub-system
processor. The redundant component shall takeover in case of main
component failure automatically. Design must ensure that the integrity
of the data to be transferred is maintained before and during switch
over. The switch over time shall be less than 1 mSec.
6) The system shall have capability to provide analog outputs for
driving indicator/recorders. In addition it shall provide contact outputs
suitable for connecting this to alarm annunciation. The analog outputs
shall be of 4 to 20 mA DC unless otherwise specified

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7) The critical open loop inputs shall be scanned at maximum of 500
mSec. interval in case of non-critical open loop shall be scanned at
maximum of 1 sec.
8) All data acquisition cabinets shall be provided with redundant
floating power supply.
9) It shall be possible to display all variables in the data acquisition
sub-system on the operator consoles on addressing from keyboard.
6.2.3 CONTROLLER AND DATA ACQUISITION SUBSYSTEM
LOADING:
(1) The system loading for controller and data acquisition
subsystem shall not exceed 60%. The loading as indicated here
is the worst case of high system activity referred to the use of
memory, CPU time and communication capacity for this subsystem.
6.3 OPERATOR INTERFACE SUB-SYSTEM
6.3.1 GENERAL
1) The operator interface sub-system shall provide the centralized
information to the plant operator/Engineer in the following fields:
(2) Indication of all analog and digital process variables of control
loops, open loops and all loop related parameters.
(3) Manipulation of control loops including changing set point, mode
output, configuration, tuning and computational constants.
(4) Alarm displays and annunciation
(5) Graphic displays and status indication
(6) Logging and trending including historical trend recording
(7) Trend recording on assignable trend recorders
(8) Self diagnostic messages
2) The operator interface sub-system shall consist of operator
consoles. Number of operator consoles shall be three numbers in
control room and one number at remote location.

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3) Touch screen feature shall be provided for the entire operator
console.
4) Each operator console shall consist of three set stacked monitor and
three set of keyboards, each driven by independent electronics or
common redundant electronics. The operator console as a minimum
shall also have one logging printer, one alarm and event printer and a
hardcopy unit unless otherwise specified in job specifications. In case
of each electronics drives two monitors the operation of peripherals
shall remain unaffected by the failure of one electronics.
5) The system shall have global data base available at each operator
console electronics at operator console. However in case distributed
data base/console functions are offered, each data base electronics
must be dual.
6) All the displays on all the monitors of an operator console shall be
interchangeable. However, under normal operating condition, each
MONITOR in the operator console shall be able to assign a specific
task, for example, one may display on overview of the plant, second
might display a specific point or group and third may be dedicated to
display alarm summary.
7) All the functions of monitors and keyboards on an operator console
shall be fully interchangeable. Further any change made in the data
base of one MONITOR shall automatically update the data base of
other monitors of the same console.
8) The real time clock of each operator console shall be crystal
controlled one which shall be independent of line frequency.
9) All the real time clocks in the system shall be synchronized with
master clock.
10) Each MONITOR shall have an industrial high resolution 21 color
screen capable of displaying alpha-numeric and graphic displays.
Multiple colors shall be used to distinguish parameters such as control,
information, process and alarms etc.
11) Each monitor screen shall be able to display the full alpha-numeric

tag number of a process variable. A minimum of eight (8) digits shall

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be required for the tag number and 24 digits for the process
description.
12) Data display update rate shall not be more than one (1) second.
6.3.2 KEY BOARD
1) Keyboard shall be self explanatory, easy to operate and shall meet
all the functions to configure, operate and maintain the system.
Conventional user friendly software shall be used for operation,
configuration and maintenance of system.
2) Key board shall preferably be touch sensitive membrane type. Each
key board entry shall be registered with an audio beep. However, if
press type key board is provided it shall be ensured that the key board
is not susceptible to dust and moisture.
3) The operator, as a minimum, shall have access to the following
through the operator key board at all times:
1 Selection of all the displays including the direct selection of loop
in alarm, page turning facility, overview, group view and loop
view selection etc.
2 Selection of loop for operation.
3 To acknowledge alarms as and when they are annunciated on
the operator console.
4 Facility to enter any changed parameter like set point,
manipulated variable, digital commands and to cancel any
wrong entry while making such change.
5 Facility for easy positioning of cursor for the selection of any
parameter.
6 Selection of hardcopy printout, logging printout, alarm history
printout and assignable trend recorder points.
7 Auto/manual/cascade/computer mode changeover of each
controller.
4) In addition to above keyboard shall have the following capabilities
for restricted user/engineer through a key-lock.
1 Data base configuration including overview, group, loop, multiloop and multi-variable control configuration.
2 Group or multi-group alarm inhibit from a plant under
maintenance.
3 Reconfiguration of alarm settings and their values, addition and

deletion of components in a loop.

BHARAT PETROLEUM CORPN.LTD.
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MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
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BOILER HOUSE DCS AND PLC SPECIFICATIONS

1 Tuning of control loops including change of P.I.D. dead time etc.
2 On-line compilation of graphic displays using standard user
defined symbols.
3 Changing of parameters to be logged
4 Setting of real time clock
5 Assigning of parameters for historical trending
6 To call detailed self diagnostic for maintenance
5) Any change made for any parameter for an input from any display
shall be automatically updated on all displays configured for that input.
6) It shall not be possible to override any process variable or digital
status from operator keyboard.
7) Each keyboard shall have a set of dual function user configurable
keys minimum 64. These keys shall be configured to access important
pages in single key stroke. Also keys shall have LEDs which flash on
pre-configured alarm conditions.
6.3.3.0 ALARM MONITORING AND DISPLAY
1) It shall be possible to display process as well as system alarms on
the operator console for operators attention and action. Alarms shall
appear immediately on the operator console as and when they occur.
2) It shall be possible to set process alarm limits from the engineering
keyboard i.e. alarm limits on absolute value of measured variable, rate
of change of measured variable, high and low deviation set points, and
high, extra-high and low, extra-low points on process variable and
output. In addition, it shall be possible to derive alarm conditions on the
basis of few calculations performed by the system.
3) Alarm messages shall be displayed by flashing the page and group
number of the input under alarm irrespective of type of display. It shall
be possible to access the group or tag in alarm condition with a
maximum of two key-strokes of operators console keyboard. The plant
overview display, operator guided message display in addition to
display alarm message, shall also be able to provide warning by
changing color of excessive deviation of process variable from their set
value.

BHARAT PETROLEUM CORPN.LTD.

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PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
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4) All alarms shall be displayed as they occur or generated with change

in the color of display in the following sequence, activating an audio
signal:
i.
Continuous flashing
: Un-acknowledg
ii.
Steady display
: Acknowledged
5) The system shall not put off the audio alarm and visual flashing
even after the condition returns to normal unless it is acknowledged by
the operator.
6) In addition to alarms appearing on the different displays, the system
shall also be able to display alarm summary and alarm history as per
data sheets.
6.3.3.1 Alarm Information Management System (AIMS).
1. The package shall have the following minimum features.
1. Logical processing of events and alarms and present in an efficient
way for analysis.
2. The offered package shall have the facility to analyze frequency of
occurrence of events in pre defined period.
3. AIMS system shall be stand alone system with server PC connected
to DCS. The connectivity to DCS shall be through one of the operator
station printer port. This system shall have one MONITOR
minimum. AIMS shall store the collected alarms from the DCS for
minimum of one year and facility of archival on to disc.
2. The report print of alarms shall be possible as and when required in the
user defined format.
3. The AIMS package shall be M/s IMAC or equivalent proven make. In
case, the vendor offers other than IMAC package, it shall have proven
track record of running references satisfactorily for minimum period of
2 year.
4. If the offered AIMS functionality is a part of DCS functionality, it must
not affect the system performance and shall meet the above mentioned
points. It shall be provided with separate monitor and shall not utilize the
operator stations /monitor.
6.3.3.2 Alarm summary display

BHARAT PETROLEUM CORPN.LTD.

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PROJECT NAME : REVAMPING

OF HEB DCS & PLC

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1. It shall be possible to display summary of all alarms in the sequence
of their occurrence and shall disappear from display only when they are
acknowledged and cleared. The alarm display shall list the following for
each alarm as a minimum.
(9) The date and time of occurrence
(10) Point identification (i.e. Tag number)
(11) Point description
(12) Type of alarm (absolute value or deviation)
(m)Serial number of alarm in the sequence of its occurrence
2. The system shall be able to display on alarm summary a minimum
of 1000 alarms.
3. Alarms shall be listed, in the form of alarm list like current, List I, List
II etc. The minimum number of alarms per list shall be 1000.
6.3.3.3 ALARM HISTORY
1. The history of alarm conditions shall be maintained in the data base
for alarm history display and printed on shift wise basis for the
parameters specified in the job specifications. The alarm display and
print out shall list the following for each alarm as a minimum:(1)
(2)
3)
4)
5)
6)
7)

The date and time of occurrence

Point identification (i.e. Tag number)
Point description
Type of alarm (absolute value or deviation)
Time of acknowledgement
Time of return to normal
Serial number, of alarm in the sequence of occurrence

2. The system shall be able to display and print out the alarm history of
minimum of 10000 alarms.
3. Alarms shall be listed in the form of alarm lists like List I, List II, List
III etc. The minimum number of alarm points per list shall be 1000.
6.3.3.4 SYSTEM ALARM
1. System shall have capability of on-line self diagnostics and to be
displayed to operator as a system alarm.

BHARAT PETROLEUM CORPN.LTD.

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PROJECT NAME : REVAMPING

OF HEB DCS & PLC

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2. Any abnormal conditions in and sub-system or any other functional
device shall be displayed as system alarm message on the operator
console irrespective of the display selected.
6.3.3.5 ALARM AND ANNUNCIATION SYSTEM
1. Alarm and annunciation system shall be modular and programmable
and it shall be possible to program by the engineer.
2. Lamps shall be LED based and replaceable from the front. Hooter in
general, shall be solid state type with audibility 100 db at a distance of
3 meters. Hooter shall have provision to set different tone for different
functions.
3. An interruption of power supply of 20 mSec or less shall not affect
the function of Annunciator.
6.4 CONFIGURATION DISPLAY
1. Configuration display shall provide a separate detailed display for
each loop indicating the configuration of that loop. When control
requires more than one loop, all interrelated loops shall also be
displayed. Following information is required to be available for
configuration display:
1) Loop configuration giving designation of each block.
2) Control block interconnection showing soft wiring or hardwiring value
of each block parameter like P&ID, ratio, bias, dead-time, lead-time
etc.
ii) It shall be possible to configure and reconfigure the loops from this
view using user friendly software.
6.5 LOGGING FUNCTION
1. It shall be possible to log all measured and computed parameters,
operator actions, alarms etc. from operator consoles.
2. Logs shall be required on hourly, shift wise (8 hourly) and daily basis
and some cases for weekly and monthly basis as specified in job
specification.

BHARAT PETROLEUM CORPN.LTD.

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PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
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3. All parameters required for logging shall be stored in memory in
accordance with data base update rate. However it shall be possible to
perform basic arithmetic calculations such as averaging, summing,
efficiency calculations etc. priority logging.
4. The log format shall be user definable, in general. However the
typical log formats for hourly, daily and shift wise reports shall be as
defined in the job specifications. For extended logging like weekly and
monthly reports, system shall have capability of writing programs in
high level language. High level language compiler software, sufficient
free memory space and necessary hardware shall be provided.
5. Number of log reports shall be as per number of log formats defined
like hourly report format, daily reports format etc. Number of pages in
each log report shall be sufficient to accommodate all the parameters
for logging as defined in the job specifications.
6. Hourly report shall be printed only as and when initiated on demand
by the operator and shall not be printed automatically at the end of the
pre-defined time as well as on demand by the operator. The maximum
storage time for log information shall be 15 minutes after the predefined print out time for a format.
7. Logging hardware
1) Logging printer
(1) Printing of hourly shift wise and daily log
(2) Shutdown report printing
2) Alarm and even printer
1) Alarm printer shall log the process and system alarm messages
as and when they occur and alarm history for every shift of
operation or on demand from operator console.
2) Print out shall show as a minimum the tag number, description,
date and time of occurrence, time of acknowledgement and time of
return to normal.

BHARAT PETROLEUM CORPN.LTD.

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MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

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6.6 SELF DIAGNOSTICS
1) The self diagnostic message for a subsystem failure shall appear on
the operator console irrespective of display selected. The choice of the
detailed self diagnostic displays shall be made by a key-lock switch.

2) The system shall have an extensive set of self-diagnostic routines

which shall locate and identify the system failure at least up to module
level including redundant components.
3) At the local level, failure of a module in a sub-system shall be
identified by an individual LED display.
4) Failure of sub-system shall be annunciated with the change in
colour. To aid system maintenance and for effective fault location,
following displays shall be provided as a minimum.
6.6.1 Communication system status display
The display shall show on overview of different sub-systems
connected over the communication sub-system showing status
of each sub-system. When a failure is detected by the system
self diagnostic routine, the display shall indicate the location and
nature of malfunction. Display shall as a minimum have
1) Type of sub-system
2) Failure of communication bus/link with the sub-system
6.6.2 Sub-system diagnostic display
1. One display page shall be available for each sub-system on
the communication sub-system, which can be called on
demand.
2. The display as a minimum shall contain:
1) Sub-system number and type
2) Error code and description
3) Details of failed module

BHARAT PETROLEUM CORPN.LTD.

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OF HEB DCS & PLC

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6.7 DATA STORAGE, ARCHIVAL AND RETRIEVAL
1) Historical data shall be stored on a non-volatile memory device like
hard disc which can be subsequently recalled by operator on any
screen.
2) It shall also be possible to store and retrieve this data on removable
mass storage media like Compact Disc, cartridge or tape etc.
6.8 HARD COPY UNIT
1) Hard copy unit shall be used to make permanent copy of any
graphics page and when demanded through the operator
console/Engineer console.
(2) Graphics page shall not be locked for more than 1 second while
taking the video-copy.
(3) Copies of display shall be in full color.
6.9 ENGINEER INTERFACE SUB-SYSTEM
(1) Engineer interface sub-system shall be primarily an engineers
interface which shall normally be used for configuring, tuning and
maintenance of the Distributed Control System.
(2) It shall consist of an engineering console. In general engineering
console shall be able to perform all engineering functions required
for each operator console and its related sub-system.
(3) Each engineering console shall consist of single or multiple color
monitors, each provided with one operator key-board and one
engineering keyboard. This, as a minimum shall also have one
configuration and maintenance printer.
(4) Engineering console shall have, as a minimum, the same capability
as operator console. However, the operation of the plant shall not
be possible from this console except in tuning mode. All the plant
views as specified under operator console shall also be available
on engineering console.
(5) Engineering console like any other system shall be capable to
communicating with all other sub-systems over the communication
sub-system.
(6) Engineering console can have either common or individual

electronics.

BHARAT PETROLEUM CORPN.LTD.

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OF HEB DCS & PLC

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(7) It shall be possible to .perform all system configuration functions
from the engineering console typically.
(8) Data base configuration including overview, group, loop, multiloop
and multi-variable control configuration.
(9) Group or multi group alarm inhibit from the plant under
maintenance
(10)Configuration or re-configuration of alarm settings, their values,
addition or deletion of any control block or component in a loop.
(11)Tuning of control loops like changing, P.I.D. dead time values etc.
(12)Compilation of graphic displays
(13)Setting of real time clock
(14)Compilation of logs/reports/historical trend points
(15)To call detailed self diagnostic displays for maintenance aid
(16)Tuning of a control loop shall be possible from engineering as well
as from operator console, the location shall be selected by the
operator using a Tuning mode key-lock switch provided on the
operator console. In Tuning mode it shall be possible to operate
only the loop under tuning from engineering console. In case of
simultaneous commands from operator and engineering consoles,
operator console shall over-ride.
(17)During the normal operation, the engineering console, in no case,
shall interfere with the process operation or system software.
However any change in the configuration shall be down loaded into
the system with proper knowledge of the operator.
(18)All detailed diagnostics of the system shall appear on the
engineering console with a print out on the configuration and
maintenance (CM) printer. A common diagnostic message on the
operator console shall indicate the need of the maintenance.
(19)To aid the system maintenance and effective fault location following
displays shall appear on the engineering console :
(1) Communication system status display
(2) Device diagnostic display and system diagnostics up to module
level should be possible from the diagnostic software.
(20)Printer shall be used for printing the configuration made or
configuration changes, printing system alarms as and when they
appear and to print out any engineers command from engineering
console.
(21)Hard copy unit, if specified, shall be used to take hard copy of the

engineers console.
(22)Accesses to the engineering station shall be protected by using
soft key or hard key.
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6.10 COMMUNICATION SUB-SYSTEM

1. The communication sub-system shall be a digital communication
bus, that provides a high speed data transfer rapidly and reliably
between the operator consoles, process I/O devices, process computer
and other devices connected to it.
2. Communication system shall be full deterministic based on
IEEE802.4, dual redundant, consisting of two separate communication
buses and two separate communication system interfaces for each
device. In case of systems having traffic directors, redundant traffic
directors shall also be provided.
3. Communication speed on the communication bus shall be sufficient
to update the operator console data base once in every second. The
overall system performance shall not be degraded whether
communication sub-system is 10% loaded or 100% loaded.
4. In case of main bus failure or any communication device failure, the
transfer to the back up device or bus shall be automatic without
interrupting the system operation and without any operators
intervention. Information about the failed device/bus shall be displayed
on the operator console.
5. It shall be possible to switch over the communication from main bus
to the redundant bus manually without disturbing the system operation.
6. It shall be possible to connect or disconnect a device from the
system without disturbing the operation.
7. The mechanism used by the communication system for error checks
and control shall be transparent to the application information. Error
checking on all data transfer shall be done by cyclic redundancy check
(CRC) and other advanced codes.

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7.0 FUNCTIONAL SPECIFICATIONS OF ESD PLC

System configuration shall be as per the job specifications. However the basic
system shall consists of the following major sub-system:
7.1 PROCESSOR MODULE:
1) The processor module shall have capability to implement all the
control functions to implement logic scheme attached along with, as
logic diagram.
2) The processor memory shall be capable of dealing with all types of
discrete inputs / outputs and shall be sufficient for storage of the
program instructions required to implement the logic functions.
Offer shall indicate the amount of memory capacity utilized by
actual program and space available for later modifications and
additions.
3) Memory shall be non- volatile. However in case of volatile memory
is provided, battery backup shall be provided. Battery life shall
minimum 5 years and the memory contents holding time shall be at
least 1 year at 27 deg C. Battery drain indication shall be provided
at least one month before the battery gets discharged. A potential
free contact shall be provided for hardwired annunciation in the
control room.
4) The processor shall be capable of implementing all logic functions
such as arithmetic operations, double precision arithmetic, relays,
timers( on-delay/off-delay timers), counters(up/down), square root
arithmetic, MATRIX (AND, OR, NOR, XOR, COMP, etc) operations.
5) The programming type shall be of Functional Block Diagram (FLD)
type only.
7.2 Diagnostic functions
Minimum following diagnostic features are required:
1) Battery monitoring
2) Watch dog timer shall be provided. The healthiness of processors

shall be continuously monitored by watch dog timer. Any

software/hardware problem in the processor system, which shall
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include CPU, Memory, communication systems, power supply,
etc., shall cause the watch dog timer to report processor failure.
3) Reference number checking
4) CPU/memory diagnostics.
6) Incase of dual redundant processor, both processor shall be
energizing the outputs. Secondary Means OF De-energization
(SMOD) features shall be provided through watchdog timer.
7) It shall be possible to manually switch over from main processor to
standby processor without interrupting the system function if
required.
8) The redundancy shall be provided for complete processor system
including CPU, memory, and power supply and communication
subsystem.
9) Failure of single processor shall not affect the system. Incase of
failure of complete processor system failure i.e. both processors in
case of quadruple configuration and two or more in case of triple
redundant system outputs shall take fail safe state automatically.
10) It shall be possible to generate first out alarm contact by the PLC in
case where group of parameters are likely to trip a system.
11) CPU module shall have visible indication to indicate the healthiness
of the processor module.
7.3

Input / output system

1) Maximum number of input/output per I/O module shall be not more than
sixteen.
2) Each I/O shall be isolated from external control circuit by suitable means. The
minimum isolation level between I/O and logic circuit shall be 1000 volts DC.
3) Each I/O shall be protected against the reversal of polarity of the power
voltage to I/O.
4) Each I/O module shall have a status LED per channel to indicate the status of
each input and output.
5) Response time for I/O (ON to OFF and OFF to ON) shall be 10ms maximum.
6) Each input shall be provided with filters to filter out any noise in the input line
and contact bouncing noise.
7) The PLC inputs shall be provided with only dry contacts (potential contacts)
unless otherwise specified, all inputs shall preferably be double ended. i.e.
two wires per input and not with common return for all inputs.

8) The interrogation voltage to the input contacts shall be powered from separate
power supply/supplies or shall be part of PLC.

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9) Each I/O shall be short circuit proof and protected by fuse. Visual inspection
of fuse blown shall be provided for each module.
10) The communication of I/O system with central processor shall be carried out
redundant.
11) PLC shall have interposing relays at both input side and output side.
12) Hardwired bypass switches shall be provided for selected inputs (which are
trip logic) with key lock arrangement and lamp ON indication.
13) All the inputs shall be routed through diode terminals. Each output shall be
short circuit proof and protected by fuse. Visual indication of fuse blown must
be provided for each module.
14) The communication of I/O system with central processor shall be carried out
redundant with complete error checking.
7.4 PLC /SOE CONSOLE
1) Programming terminal shall be used for programming, program storing,
altering, deleting, adding, fault diagnostic, and alarm monitoring.
2) It shall consist of 21 size TFT screen and one programming keyboard and
printer.
3) The keyboard shall preferably be touch sensitive sealed type. It shall be
provided with a lock and key to prevent any unintentional program
modifications.
4) Manual forcing of any input or output contact connected to PLC shall be
possible from PLC console key board.
5) It shall be possible to modify, add, and delete the application program
online without affecting the outputs and process.
6) All illegal entries shall be rejected by terminal and shall be identified by
warning signal on TFT.
7) PLC console monitor shall display logic and/or ladder diagram indicating
power flow and shall show description and status of each input and output
and other elements used in the ladder diagram.
8) It shall be possible to display I/O map in user defined format.
9) PLC console shall be provided with self diagnostics feature which shall
display error messages and initiate an audible alarm if the fault is
detected.
10) Dedicated screens/displays shall be available in the PLC console for the
diagnostics of the PLC system. The displays shall show all components
modules status including the redundant equipment and communication
system.

11) It shall be possible to print out the ladder/ logic diagram on the dedicated
PLC printer. The printer in addition shall also print out:

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9. All diagnostic messages as and when generated and diagnostic
reports, when called for.
35. Process alarm connected to the PLC as and when they appear and
alarm report whenever initiated.
61. The I/O maps showing status of all inputs and corresponding
outputs in a user defined format.
7.5

PLC COMMUNICATION SUBSYSTEM

1) The PLC communication subsystem shall be a digital
communication bus that provides a high speed data transfer rapidly
and reliably between processor, I/O subsystems, PLC console and
other devices connected in the PLC system.
2) Redundancy in PLC communication system shall be provided as
Follows:
1. For dual I/O processor configuration, each I/O subset shall
have a separate communication interface and bus for
connecting to PLC processor.
2. The communication sub-system between processor and PLC
console shall be dual redundant, consisting of two separate
communication interfaces and two communication buses.
3. Incase of redundant PLC communication subsystem, on the
failure of the active device, the redundant device shall take
over automatically without interrupting the system operation.
4. It shall be possible to switchover from main bus/device to
redundant bus/device without interrupting any system
function.
3) Interface with Distributed Digital Control System:
The PLC system should have the facility to interface it with DCS. A
suitable interface shall be offered in order to achieve the following
functions:
1. To display diagnostic messages of PLC.
2. Display of all input points under alarm/first out alarm
connected to PLC and outputs generated by PLC on
operator console.
4) The communication interface between PLC and DCS shall be dual
redundant.

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7.6 SYSTEM SOFTWARE
1) The system software shall include all programs for the PLC and PLC console,
which are required to perform all PLC functions including communication and
self-diagnostics. A soft copy of the system software shall be delivered in
triplicate with the system.
2) Soft copy of the logic program shall be delivered in triplicate together with the
system.
7.7 FIELD TESTING
All the equipment shall be checked thoroughly after its receipt at site. The
Tests. As a minimum shall include,
1) Visual and mechanical testing.
2) Demonstration of all system diagnostics features.
3) Checking of communication between DCS and PLC and PLC and
Programming unit.
4) Checking of changeover of redundant devices.
5) Demonstration of all system functions.
6) Checking of proper functioning of PLC programming unit, PLC printer.
7) Complete checking of PLC system.

7.8 The output contact rating shall be as follows:

S.NO.

APPLICABLE FOR

1.

All output cards driving solenoid valve and

alarm annunciator system unless otherwise
specified.
All LT motor/pumps/compressor output
240 VAC.
cards unless otherwise specified.
All HT motors/pumps/compressor (6.6 KV 229 V DC.
Inductive and above) output cards unless
otherwise specified.

2.
3.

VOLTAGE
RATING
110 V D.C.

CURRENT
RATING
3A /1A
5.0 A
2.0 A

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7.9

INSTALLATION, TESTING AND COMMISSIONG

1. Vendor shall offer the services of the installation team which would
install the equipment in the control room , lay the interconnecting
cabling inside the control room , check out , test and commission the
system
2. All technical personnel assigned to site by the vendor shall be fully
conversant with the supplies system and software package, and shall
have both hardware and software capability to bring the system on line
quickly and efficiently with a minimum of interface with other concurrent
construction and commissioning activities.
3. Vendors responsibility at site shall include all activities necessary to be
performed to complete the job as per material requisition including
1. Receipt of Hardware / software and checking for Completeness of
supplies
2. Installation of the system including free supply equipment and field
cable termination in the system
3. Check out of the equipment installation
4. Identification of field cables and Termination of the same.
5. Necessary Interpanel cabling to be carried out .Supply of cables in
BPCL Mumbai refinery scope.
6. Checking of interconnection, hardware & software configuration,
overhaul system functioning etc.
7. Loop checking
8. Liaison with vendors home office
9. Field test
10. Commissioning and On line debugging of the system
11. Performance of final acceptance test.
12. All civil works in the control room including false flooring
13. Cable laying and identification of field cables
4. Loop Checking
1. Loop check shall be carried out by the vendor and checking of
interconnection configuration and over all system functioning.
2. Loop checking shall be carried out to check the functional
performance of all elements comprising the loop and thereby
ensuring proper configuration, functioning and interconnection.
3. Vendor shall co-ordinate with field contractor for smooth and proper
loop checking. If any discrepancy found during checking shall be

brought to the notice of Engineer in Charge. All readings shall be

recorded on a suitable format and shall be submitted for approval.
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BOILER HOUSE DCS AND PLC SPECIFICATIONS

4. After loop checking is completed, Vendor shall connect back any
terminals and connections removed for loop checking.
5. Field Testing
All the equipment shall be checking thoroughly after its receipt at site.
The tests, as a minimum shall include
1.
2.
3.
4.
5.
6.
7.
8.

Visual and mechanical testing

Complete system configuration loading
Demonstration of all system functions
Checking of loop configuration
Checking of MONITOR displays
Checking of correct functioning of all keyboards
Demonstration of all system diagnostics
Checking of Correct change over of redundant devices

9. Checking of communication between PLC , PLC and other foreign

devices
10. Checking of Bus- degradation
11. Checking of proper functioning of all printers and hard copy units,
ample printing of all log reports, shutdown reports and MIS reports
12. Checking of all disc drives, historical trending points, alarm
summary and alarm history.
13. Complete checking of shutdown system
14. Complete checking of hardwired instruments
15. Demonstration of proper operation of the system at specified power
supply specifications
16. Loading of users program and check out results.
6. Final Acceptance Test
The owner will take over the system from the vendor after the final
acceptance test, which is defined as successful uninterrupted
operation of the integrated system for three weeks for all units of the
plant. Vendors personnel shall be present during the test. Any
malfunctioning of the system components shall be replaced / Repaired
as required. Once the system failure is detected, the acceptance test
shall all over again from the beginning. The warranty period
commences from the day owner takes over the System

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 64 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

8.0 DATA SHEETS FOR DCS

Type of system distribution
: Functional
Location
: Control room
System size
Closed loops
a.
: Ref Annexure VII
Open loops
b.
: Ref Annexure VII
Digital loops
c.
: Ref Annexure VII
4.
System availability for the specified: 99.99%
Configuration
5. Maximum permissible communication bus length:
: ________ (to be filled by Vendor)
Standard
: _______ (to be filled by Vendor)
With expander
6. Max. Number of sub system on the communication sub system:
(to be filled by Vendor)
1.
2.
13

No. OF NODES
STANDARD
WITH
BUS
EXPANSION
7.

No.
CONSOLES

OF COMPUTER
INTERFACE

OTHER
SYSTEM

Type of sub system

a. Controller &Data-acquisition Subsystem : Required: Model no.__________
Controller subsystem
b.
:
Data-acquisition sub system
c.
:
Communication sub system
d.
Required Model no.___
5.
Operator Interface Subsystem: Required
f.
Engineer interface subsystem : Required
Model
no._____________
7.
Programmable Logic Controller (PLC) Not Required
Supervisory computer &workstations :
h.
N.A
(For Advanced Control)
Foreign Device Interface :
i.
Required
Model
no._____________
Personal Computer
j.
: Required Model
no._____________

k.

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

Hardwired Instruments :

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

Required
Model
no._____________

SPECIFICATION
SHEET 65 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

8.

Standard
Interface
available
for
Supervisory Computers: Vendor to specify.

9.
10.

Online self-diagnostic message

: Required
Redundant Floating Power Supply Required Cabinet-wise for:
a. Controller & Data-acquisition Subsystem: Required
Model
no._____________
b. Controller subsystem
:
N.A
c. Data-acquisition sub system
:
N.A
d. Communication sub system
:
Required
Model no._____________
e. Operator Interface Subsystem
: Not Required
(Individual Power supply)
f. Engineer interface subsystem
:
Required
Model no._____________
(Individual Power supply)
g. Programmable Logic Controller (PLC)
: Not Required
(Individual Power supply)
h. Supervisory computer &workstations
:
N.A
(For Advanced Control)
i. Foreign Device Interface
: Required
Model no._____________
j. Personal Computer
: Required
Model no._____________
k. Hardwired Instruments
:
Required

11.Power Supply availability:

a.

AC Voltage for the System:

DESCRIPTION
VOLTAGE(V)
FREQUENCY(Hz)
MAXIMUM STATIC
TRANSFER
TIME(ms)
b.
c.

SUPPLIED
110 +,- 10% UPS
50 +,- 3%
5

PERMISSABLE
110 + 10% -15%
50 +3%- 6%
20

DC Voltage for Output Devices

AC Voltage for Lighting/fan

REMARKS

: 110V +, - 10%
: 110V AC, 50 Hz.

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 66 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

12.

13.

Total power requirement :_________( to be

Earthing Requirements:
a.Type of earthing system

TYPE
OF REQUIRE
EARTHING SYSTEMS
D
ZENER
BARRIER
EARTH
SYSTEM EARTH
ELECTRICAL EARTH
PLC EARTH

:
RESISTANCE UPTO EARTH
PIT
1 OHMS OR LESS

15.

: Vendor to specify.

Installation details
Type of foundation required
a.
Max. Loading for foundation design
b.
Operating Environment
Temperatura
Humidity

REMARKS

1 OHMS OR LESS
1 OHMS OR LESS
1 OHMS OR LESS

b.No. Of Earth pits

14.

filled by Vendor)

: On false flooring
:592 kg/m3

: Control room Safe area

o
o
:25 C +, - 2 C
:50 +, - 5 %

8.1 COMMUNICATION SUB SYSTEM

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Communication Topology
: Open-ended
Redundancy in Communication
: Required
Type of Bus Redundancy
: Active
Switchover of Communication buses
: Auto & Manual
Type of communication Bus
: Full Deterministic
Type of Communication
: Floating Master
Type of Protocol
: Token Passing
Communication Speed
: Min. 100 MBPS
Message error checking
CRC : Required
Bus controller
: Not required
Redundant Communication Interfaces required for:
Controller & Data Acquisition Sub system : Required
a.
Controller sub system
b.
:Not required
Data acquisition sub system
c.
:Not required

d.

Operator Interface sub system

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

: Required

SPECIFICATION
SHEET 67 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

12.

Engineers Interface sub system

e.
: Required
Programmable logic controller
f.
: Required
Foreign device interface
g.
: Required
Switchover to redundant Communication Interface: Auto and
Manual
13. Power supply for Communication Interface redundant Floating
14.
15.

Communication Bus Model No.

Max. No of nodes on the bus

:________________
: _________________

8.2 CONTROLLER AND DATA ACQUISITION SUB SYSTEM

8.2.1
Offered System Details
: Required
Combined controller and Data acquisition
Type of Controller
Multi loop : As Required
2.
a. Controller Sub System
3.
: Model no. ______________
2. Data Acquisition subsystem : Model no. ______________
3. Controller & Data Acquisition when offered combined
1:
Model
no.
______________
GENERAL
1.

8.2.2

1.
2.
3.
4.
5.

Number of Controllers per 19 racks (Nest) : Vendor to specify

Number of 19 racks (nests) per cabinet
: Vendor to specify
Number of Controller Cabinets
:________( to be
filled by Vendor)
Cabinet-wise MTBF
:________( to be
filled by Vendor)
Cabinet-Wise MTTR
:________( to be
filled by Vendor)

8.2.3 SPECIFICATION
Type
1.
2.

Enclosure

Microprocessor Based 32 bit

Configurable type

: Required
: Required
: General purpose

8.2.4

1.
2.

Type of controller
Multi loop Controller
Indicating
Display

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

: Multi Loop
: Blind
: Not Required

SPECIFICATION
SHEET 68 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

3.

Number of Inputs / Output per Processor: Vendor to

specify
: Rack
:_______To be
filled by vendor
With 60% of

Mounting
No of loops per Controller

loading.
Backup Controller
Switchover Time
Scan time (closed loops)
loopsMax.250 mS. For other loops max. 500 ms.
Configuration from

Conformal coating for

MTBF
MTTR

Control Mode

4.

Tuning Constants
TUNING
CONSTANT
PROPORTIONAL
BAND
INTEGRAL RATE
DERIVATIVE
DEAD TIME

Manual
Auto
Cascade
Computer

REQUIRED
1-180 %
0.05-100
REPEATS
PER MIN
0.01 10 MIN
0.07 10 MIN

: Required For ONE

to ONE
: 1 mSec.
: For critical
: Central Level
(From Operating
Station)
: Required for
Corrosive
atmosphere
:______(to be filled
by Vendor)
:______(to be filled
by Vendor)
: Required
: Required
: Required
: Required

OFFERED

REMARKS

LEAD LAG TIME

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

0.005 10 MIN

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 69 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

6.
7.
8.

9.

Direct / Reverse Selection

Anti Reset wind up feature
Output Status on controller failure FLUNK
FREEZE
Engg. CONFIGURABLE
Self Tuned Controller Function

: Required
: Required
: Required
: Required
: Required
:Required for
all Ctrls.

8.2.5 DATA ACUISITION SUB SYSTEM

1.
2.

3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Mounting
: Rack Mounting
Number of Inputs per Processor
Analog
: Max. 16 points
Digital
: Max 32 Points.
Conformal coating : Required for Corrosive
atmosphere
Processor Redundancy
: Required ONE to ONE.
Processor Switch- over time
: 1 mSec.
Control Cycle time
:______( to be filled by Vendor)
Configuration from
: Central level (from Operator
Station)
MTBF
:______( to be filled by Vendor)
MTTR
:______( to be filled by Vendor)
Model No
:______(to be filled by Vendor)
Input Isolation
:Required (galvanic / optical)
Output Isolation
:Required (galvanic / optical)
TYPE OF INPUT MODULES

TYPE
OF
MODULE

INPUT MODEL
NO.

ISOLATIO NO. OF MODULE

N
INPUT
AVAILBLE
PER
MODULE

4-20mA DC (2 WIRE)

IS
BARRIER

4-20ma Dc ( non 2 wire)

IS
BARRIER

1-5 V DC ( 2 WIRE)

IS

MODULE
OFFERE
D

BARRIER
THERMOCOUPLE

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

IS

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 70 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

TYPE J,K,R,

BARRIER

GROUNDED
GROUNDED
ANSI MC 96.1

&
AS

UN
PER

RTD

IS
BARRIER

TYPE :-PT 100

3 WIRE AS PER DIN
43760
CONTACT
TYPE
FREE

N.A

:-

POTENTIAL

RS 232 / R485
13TYPE OF ANALOG OUTPUT MODULES
TYPE
OF
OUTPUT MODEL ISOLATION
MODULE
NO.

4-20mA DC (2 WIRE)

14

MODULE
OFFERE
D

IS.
BARRIER

TYPE OF DISCRETE INPUT/OUTPUTS MODULES

TYPE OF
MODULE

POTENTIAL
CONTACT

DISCRETE MODEL
NO.

ISOLATIO
N

NO.
OF MODULE
INPUT
AVAILBL
PER
E
MODULE

FREE

15 Power supply for Transmitter 24 v DC

16

NO. OF MODULE
INPUT
AVAILBLE
PER
MODULE

Intrinsically safe

: Required
: Yes

17 A/D Converter Resolution 1500 steps (Min.) : Required __

19 D/A Converter Resolution 1500 Steps (Min) : Required _________

MODULE
OFFERE
D

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 71 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

20 Load Driving Capability for output 750 Ohms: Required ________
21 Load driving capability 650 Ohms of Transmitter at 24 V DC:
Required
22 Max. allowable source resistance T/C input Module: Required
_____________
RTD input Module

:Required _____________

23. Online Diagnostic available at local

Centralized level

: Required
: Required

24 Memory Type for Configuration

IF
RETENTIVE

OFFERED
BY
VENDOR

IF VOLATILE

ERASIVE

BATTERY BACK UP

NON
ERASIVE

BATTERY LIFE

ERASING BY

BATTERY TYPE

OFFERED BY
VENDOR

CHARGEBLE
CONTINUOUS
CHARGE

TRICKLE

CONFIGURATION
72
HRS.PROTECTION
TIME(
INCASE OF POWER FAILURE)
BATTERY DRAIN INDICATION.
25

ALGORITHMS

ALORITHIMS

REQUIRED

PID FUNCTIONS

a. PID BASIC CONTROLLER

b. PID CASCADE
c. PID BIAS
d. PID DIFFERNTIAL GAP

OFFEREDBY
VENDOR

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 72 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

e. PID NON-LINEAR
f. PID SELF TUNING
g. EXTERNAL OUTPUT TRACKING
h. RESET LIMITING
BASIC FUNCTIONS

a. MANUAL LOADER
b. CASCADE ( WITH SET POINT
TRACKING)
HIGH ALARM LIMIT
c. EXTRA HIGH ALARM
d. LOW ALARM
e. EXTRA LOW ALARM
f. RATE OF CHANGE ALARM
g. DEVIATION ALARM

CONTROL
ALORITHMS

a. PROPORTIONAL CONTROL
b. PI
c. ERROR SQUARE PID
d. ADAPTIVE GAIN
e. RATIO CONTROL
f. PID WITH DEAD BAND

ARITHMETIC
FUNCTIONS

a. ADDITION / SUBTRACTION
b. DIFFERENCE
c. MULTIPLICATION
d. DIVISION
e. ABSOLUTE VALUE
f. SQUARE ROOT
h. SQUARE
i. AVERAGE
j. SUMMATION(INTEGRATION)
k. BIAS

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION

MUMBAI-400 074.

SHEET 73 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

l. RAMP FUNCTION
m. EXPONENTIAL
n. LOGARITHM
LINEARISATION

a. SQUARE ROOT EXTRACTION

b. FLOW COMPUTATION (PR&TEMP.
COMPENSATION)
c. THERMOCOUPLE
d.LINEARISATION&COLD
JUNCTION COMPENSATION
e. RTD LINEARISATION
f. POLYNOMIAL

DYNAMIC FUNCTIONS

a. LEAD / LAG
b. DEAD TIME
c. TIMER
d. FEED FORWARD
e. VELOCITY LIMIT
f. TOTALIZE

LIMITER

a. LOW OUTPUT LIMITER

b. HIGH OUTPUT LIMITER
c. ALARM LIMITER
d. SET POINT LIMITER

COMPARISON

a. GREATER THAN
b. LESS THAN
c. GREATER OR EQUAL
e. LESSER OR EQUAL
d. EQUAL
e. NOT EQUAL

SELETOR

a. LOW SELECTOR
b. HIGH SELECTOR

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION

MUMBAI-400 074.

SHEET 74 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

c. MEAN VALUE SELECTOR
d. AUTO RANGING FOR DUAL for
TRANSMITTERS
e. OVER RIDE
LOGIC FUNCTION

a. AND
b. OR
c. NOR
e. NOT
f. XOR
g. ON / OFF DELAY
h. FLIP-FLOP
i. PULSE

SEQUENCE
FUNCTION

a. SET BLOCK ON / OFF, AUTO /

MAN.
b. SET ALARM LIMITS
c. SET POINTS
d. SET RAMP RATES,RAMP ON/OFF
e. GET / SET BLOCK PARAMETERS
f. ACTIVATE / ABORT SEQUENCES
g. OPEN/CLOSE VALVES
h. START / STOP PUMPS / MOTORS

MISCELLANEOUS
FUNCTIONS

a.

BUMPLESS
TRANSFERS
BETWEEN ALL CONTROL MODES

b. RAMP TO SET POINT

c. RAMP OF OUTPUT
d. RAMP OF CACULATED VALUES
e. DIRECT OR REVERSE OUTPUTS

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION

MUMBAI-400 074.

SHEET 75 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

8.2.6

ENGINEER INTERFACE SUB SYSTEM

A. GENERAL

1.

No. of engineering console

: One

2.

No. of MONITOR per Engg. Console

: One

3.

Type of Electronics Individual per MONITOR : Required

4.

Microprocessor type

: 32 Bit

5.

Microprocessor make / Model No.

:________( to be filled by
Vendor)

6.

Memory size

:Min 1 GB

7.

No. of Engg key Board

: One per MONITOR

8.

No. of Operation key Board

: One per MONITOR

9.

Maintenance Key Board

: Required

10. Functional Capability

: Same as Operator

11. Basic functions of Engg. Console

1.

System Configuration and Reconfiguration : Required

b.

Group &Multi Groups alarm inhibiting

: Required

c.

Plant views with / without plant operation

: Required

d.

Graphic page Compilation

: Required

e.

Setting/resetting of real time clock

: Required

f.

Loop Tuning on selectable basis

: Required

g.

System Maintenance and diagnostics

: Required

12.

MONITOR specification

: As per Operator Console Sheet

13.

Key board Specifications

: As per Operator Console Sheet

14.

High Voltage Isolation Protection

Type

15.

: Required
: Optical
Barrier

Peripheral requirements
a.

Printer (Laser)

: Required

b.

Hard Copy Unit Color

: Required

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 76 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

8.2.7 LOGGING PRINTER

1. Type of printer Line / High Speed serial

: Required
Offered _________

2. Number of Character type Approx. 96 Characters : Required

Offered ______ ASCII
3. Printing speed 300 Lines per minute

: Required
Offered _________

4. No. of print columns Min 132 Character per line

: Required
Offered ___________

5. Paper width Approx. 381 mm

: Required
Offered __________

6. Paper type Continuous fan fold

: Required
Offered __________

7. No. copies

8. Bi-directional printing feature

: Not required

9. Acoustic cover

: Required
Offered __________

10. Paper feed

Pin feed

: Required
Offered __________

11. Test pattern generation

12. Cord length offered

: Required
As Read.

: Required
Offered ___________

13. Mounting self Contained with Integral stand

: Required
Offered ___________

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 77 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

14. Noise level (in DBA) while printing at 1 Meter distance

OFFERED
LESS THAN

WITH COVER

45 DBA

WITHOUT COVER

15. No. printers

: ONE Model no.___________

8.2.8 ALARM / EVENT PRINTER

1. Type of printer Line / High Speed serial

: Required
Offered __________

2. Number of Character type Approx. 96 Characters

: Required

Offered___________
3. Printing speed 300 Lines per minute

: Required
Offered___________

4. No. of print columns Min 132 Character per line

: Required

Offered ___________
5. Paper width

Approx. 381 mm

: Required
Offered___________

6. Paper type

Continuous fan fold

: Required
Offered ___________

7. No. copies

:( to be filled by
Vendor)

8. Bi-directional printing feature

: Required

9. Acoustic cover

: Required
Offered ___________

10. Paper feed

Pin feed

:Required
Offered ___________

11. Test pattern generation

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,

:Required

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION

MUMBAI-400 074.

SHEET 78 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

12. Cord length offered As Reqd.

:Required
Offered ___________

13. Mounting

self Contained with Integral stand

: Required

Offered ___________
14. Noise level (in DBA) while printing at 1 Meter distance

REQUIRED

OFFERED

LESS THAN

WITH COVER

45 DBA

WITHOUT COVER

15. No. printers

: One
Model no.___________

8.2.9 CONFIGURATION AND MAINTENACE PRINTER (LASER TYPE)

1. Type of printer Line / High Speed serial
2. Number of Character type

: Required
Offered ___________

Approx. 96 Characters
: Required
Offered ___________

3. Printing speed 300 Lines per minute

: Required
Offered ___________

4. No. of print columns Min 132 Character per line

: Required
Offered ___________
5. Paper width Approx. 381 mm

: Required
Offered ___________

6. Paper type Continuous

: Required
Offered ___________

7. No. copies

8. Bi-directional printing feature

: Not
Required

9. Acoustic cover
10. Paper feed

: Required
Offered ___________
Pin feed

: Required
Offered ___________

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 79 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

11. Test pattern generation

: Required

12. Cord length offered

As Reqd.
: Required
Offered ___________

13. Mountingself Contained with Integral stand

: Required
Offered ___________

14. Noise level (in DBA) while printing at 1 Meter distance

15.

REQUIRED

OFFERED

LESS THAN

WITH COVER

45 DBA

WITHOUT COVER
:ONE

No. printers

Model no.___________
8.2.10 COLOR HARD COPY UNIT
1.Type of Hard copy unit

: Laser type

2. Screen Lockout time Max.2 SEC.

: Required
Offered ____________

3. Screen Selection from Operator consoles & Engg console

1:
Required
Offered ____________
4. Max. distance from Operator Console

As per control room layout

: Required\
Offered ____________

5. No. channels from any operating consoles

: Required
Offered ____________

REQUIRED

OFFERED

Printer type
Paper size
Resolution640 dots / line
High voltage protection Reqd.

BHARAT PETROLEUM CORPN.LTD.

PROJECT NAME : REVAMPING

SPECIFICATION

MUMBAI REFINERY, MAHUL,

MUMBAI-400 074.

OF HEB DCS & PLC

SHEET 80 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

Paper type
Connection to Multiple Monitors
Copier swathing Auto / Manual
Noise level
Acoustic cover Reqd.
Max. No. Channels offered
6.Card length Offered

As Reqd.

: Required
Offered __________

7.Mounting self contained with Integral Stand

: Required
Offered __________

8.3.0 FOREGIN DEVICE INTERFACE

8.3.1

INTERFACE-WITH-PLC

1. Type of interface

SERIAL

2. Type of Redundancy DUAL REDUNDANT

Processor system

ACTIVE

: Vendor to specify
: Required
: Required

3. Standard Interface software available for MODBUS PROTOCOL

1:
Vendor
specify
4. Functional Requirements Type of Communication

to

: DUPLEX

Automatic time Synchronization : Required

Interface with PLC diagnostic messages : Required
Interface diagnostics available at : Central Level (at
And LOCAL LEVEL)
5. DCS operator station
The Resetting of activated interlocks shall be done through the DCS
operator station. The status of all the inputs, interlocks, Bypass
switches and the diagnostics of the ESD shall be reported on the DCS
for monitoring and alarming

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 81 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

8.3.2 INERFACE WITH SUPERVISORY (ALPHA) COMPUTER

1.

Type of interface

IEEE 802.3

ETHERNET

Communication Protocol

: Required
: Required

2.

No. of Interfaces per System

: Min ONE.

3.

Input Capability All the Tags in DCS

: Analog & digital

4.

Functional Requirements Type of Communication

: DUPLEX

Automatic time Synchronization

: Required

5 Proven Interface software available for the following Supervisory

computers : Make DEC VAX
: Model No.__________
Make DEC ALPHA :
Model No.__________

6. Time Taken to transfer Data from supervisory Computer to DCS

1:
1 Sec
Offered By vendor____________
8.4 Constructional details
1. control panel Front plate CRCA 3 mm THICK STEEL Welded to frame
1:
Required
2. System cabinets Front door: transparent shutter proof Glass Panel Color
1:
Vendor to specify
c. Door panel thickness : CRCA 2 mm THICK
Concealed hinges

: Required

Flush pull handle

: Required

Both sides hinges

: Required

d. Frame angle size

: 50 x 50 x 4 mm

Lifting Bolt

: Required

e. Card rack size 19

Type

: Required

: Fixed

f) Ventilation

: Yes, required with fan and filters Also

Fan failure Alarm

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BOILER HOUSE DCS AND PLC SPECIFICATIONS

shall and Cabinet Temperature
High alarm shall be
provided in DCS.

8.5 Wiring
110v AC UPS Wiring
I.

External to Cabinet / panel Min. 3 x 2.5 Sq.mm copper

Conductor PVC insulated

II.

Inside the cabinet / panel Min 19 strnds,16 AWG

:Required
Copper Conductor PVC Insulated
230v AC Wiring2.5 Sq.mm. copper
:Required
Conductor PVC insulated
Low Voltage Internal to cabinet / panel Min 19 strnds,16 AWG: Required
Copper Conductor PVC Insulated

III.
IV.

:Required

8.5.1 SIGNAL WIRING

1. External to Cabinet / panel

Min2 x 1.5 Sq.mm copper : Required

Conductor PVC insulated with Overall drain

PVC insulated armoured
2. inside the cabinet / panel Min 7x20 AWG

: Required

Copper Conductor PVC Insulated twin shielded

8.5.2 TERIMINALS TYPE
Wago type with pressure plate

: Required

Terminal size for signal

: Suitable for 2.5Sq.mm

For power dist.

: Suitable for 4. 0Sq.mm

Terminal block Clip-on Channel Mounted Stack type : Required

8.5.3 WIRING COLOR CODE
VOLTAGE

TYPE

POWER SUPPLY 110V PHASE

AC

COLOR
RED

NEUTRAL

BLACK

EARTH

GREEN

OFFERED

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DC WIRING (24VDC)
DI SIGNAL
DO SIGNAL (WET)
DO SIGNAL (POTEN.
FREE)
RTD SIGNAL
ANALOG I/O SIGNAL

8.6

POSITIVE

RED

NEGITIVE

BLACK

POSITIVE

YELLOW

NEGITIVE

YELLOW

POSITIVE

RED

NEGITIVE

BLACK

POSITIVE

WHITE

NEGITIVE

BLACK

POSITIVE

WHITE, WHITE

NEGITIVE

BLUE

POSITIVE

BLUE

NEGITIVE

WHITE

Engineering Guidelines

As a general rule, push-buttons and lamps shall be organized according to the

plant areas they are related to, and according to plant handling needs:
a. Push-buttons
Related push-buttons shall be organized in isles, and a label shall
be provided to identify the general function of each switch.
2. Labels:
(1) Close to each switch an Acrylic engraved label shall be provided
and the tag name, description of the device shall be indicated on
it.
(2) Labels shall be black with white engraving.
3. Terminations
(1) Each termination shall be identified with a global label and each
terminal shall be clearly identified through a number/letter
(details will be defined during project development).
4. Lamps Colors
will be:
(1) RED
(2) GREEN
(3) YELLOW (enable/disable of interlock)

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5. The lights shall be provided by white multi-LED elements, and the
colored caps shall be easily replaceable.
6. Typical connections of lamps shall be as follows:
(a) Two (2) lamps (for valve equipped with two limit switches): a
lamp shall be always lit according to the status of the valve
(green=open; red=closed);
(2) One (1) lamp (for indication of motor status or valve equipped
with single limit switch indication).
(3) Some lamps will be installed inside push-buttons, others will be
independent.
7. Push-buttons and switches
(1) Switch contacts will be wired as follows:
(1) Normally closed: open the contact ( 2 NOs)to initiate the
interlock and to stop dedicated motors;
(2) Normally open: close the contact (2NCs) to disable (bypass) an
interlock sequence.
(2) All the switches and lamps shall be wired to a marshalling strip
installed inside the hardwired console. The numbers of strips and
terminals shall cover the number of switches and lamps foreseen
on the consoles considering the spares.
(3) To allow easy reconfiguration of the console during the plant
commissioning and start-up, all the switches shall have three
contacts per section and internal lamp(s), all wired to the terminal
strip.
(4) The switches shall be realized with modular components, to
guarantee easy replacement of colored caps, or to allow change
from two position switch to push-button and vice versa.
(5) Security covers shall be provided, to avoid accidental operation of
switches and push-button.
(6) A push-button for the plant emergency shutdown shall be provided.
(7) A lamp-test push-button and the necessary diodes and wirings,
shall be provided on the hardwired consoles.

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9.0 DATA SHEET FOR PLC

9.1 FUNCTIONAL REQUIREMENT
To execute all Burner Management System (BMS) shutdown logic and
interlocks with Interposing relays at input and output levels and also sequence
recording function as a part of the PLC system.
9.2 SYSTEM CONFIGURATION TYPE
PLC Configuration shall be QMR and redundant dual I/O with built in
Diagnostic features for Processors and I/O or TMR Configuration. PLC shall be
monitored by Watch Dog and in the event of any discrepancy found by the Watch
Dog, it shall supersede the CPU outputs and De-energize the outputs to bring the
plant to Safe Operation. All the Processor shall read the Inputs, Solve the
Application logics and generate Outputs and energize the Output modules in
parallel.
9.3 TUV-CERTIFICATION /SIL
1. Required (class AK-5 minimum/SIL3) as per IEC61508and the copy of the
certification shall be enclosed with the bid.
9.4 PROCESSOR SYSTEM
1) Functional Capability
1. Logic functions
2. Timer function (Both off-delay and on-delay timer) Range 0 to
99,999 Sec. least count: 0.1 sec
3. Counter functions: (up/ down counter)
2) Interfacing Capability
1.
2.
3.
4.
5.

With I/O racks

With DCS
With PLC console
With SOE PC
With printer of PLC Console and SOE PC

: required
: required
: required
: required
: required

c) Memory Type
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Flash Memory

: required

d) Memory Capacity

: vendor to specify

e) Memory Capacity Used

: vendor to specify

f) Spare Memory Available

: should be >50%

g) Memory type

: Volatile / Nonvolatile (vendor to specify)

h) Memory If Volatile

: Vendor has to
specify the following

1.
2.
3.
4.
5.
6.

Battery backup
Battery life
Battery type
Chargeable
Battery drain indication
Incase of power Failure
protection of configuration required

: required
: (vendor to specify)
: (vendor to specify)
: yes, required
: required
: Minimum 72 hours

i) Maximum scan time 200 ms or less

: required
offered __________

j) Power supply redundancy

: required
offered __________

k) Output on processor system failure

: vendor to specify

l) Max. Distance between processor & PLC console

: vendor to specify

m) System Clock

: RTC

n) SOE

: User Defined SOE

o) Time Stamp for SOE

: 1 mSec

p) Processor loading philosophy

: 60% (maximum)

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17)
Online Downloading feature shall be provided. The same shall
be possible for all the functions viz Addition/Deletion of System and I/O
Modules, Addition/Deletion of all the Variables, Addition/ Deletion of FLDs
including Functional Blocks etc.
9.5 INPUT / OUTPUT SYSTEM:
1) Type
Discrete
Analog

: required with LED for Module

and I/O status.
: required with High speed A/D
conversion.
: required with Channel to
Channel isolation

b) Dual I/O configuration

: required

c) On line replacement of I/O modules : required

d) I/O Status indication

: required (both on PLC I/O cards

with LED for
Module and status and in PLC
workstation)

e) Input isolation

: required (optical isolation)

f) Output isolation

: required (optical isolation)

g) Auto testing of I/O

h) Power supply to I/O rack

: required
: Dual redundant power supply

i) I/O rack to processor comm. Link

: Dual redundant

j) Maximum number inputs per module : max. 16 (offered: vendor to

specify)
k) INPUT MODULE:
Input type
: potential free contact rated
110VDC,1A required

Analog input : Intrinsic Safe required

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l) Input interrogation voltage

m) I/O Capacity

: 110VDC/ 24VDC (vendor to

specify)

: Refer attached Annexure VII.

n) Output Module
Output type
1) Output capable of driving 110VDC, 23W solenoid valves
through interposing relays, indicating lamps etc.
2) Output for communication with centum DCS system.
3) Output capable for energizing ignition transformer
(transformer input supply is 110VAC)
4) Potential free contact outputs for alarm annunciation
o) Max. Number of outputs per output module

p)
q)
r)

: 16
(Offered:
vendor to specify)

Maximum distance between processor and I/O rack

: (vendor to
specify)
Mounting rack
: 19 rack.
Process input bypass switch (Rotary)
: required
(hardwired with indication lamps)

9.6 PLC /SOE CONSOLE:

a)

Installation Location

: Indoor and Control room

b)

Monitor

: 21 inch TFT color

(Independent PC shall be provided, capable of communicating with

both the CPU. The necessary hardware and software shall be provided.)
c) Redundant communication link between processor and PLC/SOE
console
: required
d) Keyboard : required

e) Printer

: required

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f) Type of printer (laser/monochromatic/color)

: vendor to
specify

g) Printer speed

: vendor to
Specify

h) Printer power supply

: 110VAC, 50

Hz (UPS)

i) System boot-up on power on : Automatic

j) Password protection for opening the file
: required
k) Password protection for modifying/forcing/Unforcing the inputs/outputs
(Edit mode) : required
l) Programme storage
: required
(USB /CD)
m) Online programming facility : required
n) Online programming modification
: required
o) Disable / enable facility : required
p) Power flow indication on ladder / logic : required
q) Self diagnostics : required
r) I/O mapping
: required
s) List of forced signal shall be displayed in PLC work station : required
t) Forced signal field dynamic status displayed : required
u) Alarm printing
: required
v) Function Logic Diagrams/Ladder logic monitoring : required
w) paper width for printing : 381 mm
(Vendor to specify)
9.7 SYSTEM/APPLICATION SOFTWARE:
1) All the software to be supplied shall be of latest version.
2) Software shall be Engineer friendly for ease of configuration and
troubleshooting.
9.8 INTERFACE WITH DCS:
1) Type of communication
Serial /Bidirectional/RS232C interface

: vendor to
specify

b) Communication protocol: vendor to

specify
c) Total time for displaying alarm generated by PLC on DCS : vendor to
specify.
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9.9 POWER SUPPLY:

110VAC will be made available to PDB cabinet. AC voltage and DC
voltage distribution (110VAC/110VDC and 24VDC) distribution inside the PLC
cabinet will be in vendors scope. Also the voltage conversion from 110VAC to 24
or 5VDC will be in vendors scope.
a)

Power supply available for PLC system

50Hz (+/-3%)
Interrogation voltages for switches
(vendor to state)
Energizing voltage for solenoid valves
Energizing voltage for indicating lamps
(vendor to state)
Voltage output for energizing ignition Transformer
Power supply available for PLC /SOE console
AC and 110V/24VDC/5VDC voltage distribution

b)
c)
d)
e)
f)
g)

: 110VAC+/-10%,
: 110DC/24VDC
: 110 VDC
: 110VDC/24VDC
: 110VAC
: 110VAC (UPS)
: vendors scope

9.10 DIAGNOSTIC CAPABILITY:

The system shall have a high diagnostic coverage. This diagnostic system
will be automatic and run on continuous basis without operator intervention. It
shall be capable of detecting errors or fault conditions in any part of the control
system before system integrity is lost. Fault in the communication system shall
also be identified by the diagnostic routines.
Vendor should detail the diagnostic programs available in the PLC system
for the debugging the system hardware and software faults and normal
maintenance activities.
The PLC system shall have minimum following diagnostic features. These
false contact output shall be hardwired to DCS addition to serial link
communication.
1.
2.
3.
4.

Power feeders trouble

Power supply failure
Fuse failure
Battery failure

5. CPU fault.
6. Input/ output module fault
7. Communication bus failure etc.
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9.11 PLC CABINET:

1) Location : Control room
Flooring
: False flooring
Air Conditioning
: Available
2) General details
a) Type of cabinet
Self supported
: yes
Free standing
: yes
Enclosed cubicle
: yes
b) Lighting
: Yes, required inside the panel / cabinet
Door switch : yes, required
Power supply: 230 VAC, 50 Hz
c) Ventilation
: Yes, required with fan and filters
Also Fan failure Alarm
shall and Cabinet Temperature
High alarm shall be
provided in DCS/PLC.
d) Doors : Required (both front and rear doors
required) Doors
should be provided with door locks.
e) Special features
Cable entry : bottom
Cable gland : required
6)Space available for mounting PLC cabinet in the control room
1:
Yes
g) Panel painting: vendor to submit panel/console
painting color /type of painting and the approval shall
be taken from BPCL Mumbai
refinery.
h) Constructional details:
control panel
Front plate
Welded to frame

: 3mm Thick steel

: required

Panel thickness
Flush pull handle
Channel base
Lifting bolt
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: 2mm thick CRCA

: required
: CRCA
: required
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3) WIRING:

Cable Entry : Bottom

Receptacles : For 110VAC/230VAC,
Telephone socket : required.

a) 110VAC power supply wiring

b) Signal wiring

: min.19 strands, 16 AWG

copper conductor, and low
voltage inside panel PVC
insulated.

: minimum 7 strand, 20

AWG copper conductors

with PVC insulation.

c) Wiring color code

110 VAC
PHASE
NEUTRAL
EARTH

: RED
: BLACK
: GREEN

DC WIRING
POSITIVE : RED
NEGATIVE : BLACK
ALARM SYSTEM : WHITE
CONTROL/SHUTDOWN CABLE : YELLOW
MCC WIRING
: GREY
d) Terminal block

: clip-on channel mounted

stack type
e) Terminal size for power cable : suitable for 2.5 sqmm
cable
f) Terminals type
: Screw clamp type with
pressure plat

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10.0 FACTORY/SIT ACCEPTANCE TEST PROCEDURE

10.1.0 INTRODUCTION
10.1.1

General

This document specifies Factory Acceptance Test (hardware and

software) and procedure to be performed before accepting the system,
the certificates (if any) to be presented by Vendor, the assistance to be
guaranteed as a minimum during testing, shipping and installation and
Vendor's responsibilities.
This document shall be checked and integrated by Control System
Vendor during the project development to include additional tests, or to
modify some of them below described to match the requirements of the
system.
The document will be revised at a meeting prior to the F.A.T. to include
these additional comments. As a general rule, anyhow, test defined in
this document's revision shall be considered mandatory.
10.1.2 Factory Acceptance Test
The Factory Acceptance Test (F.A.T.) will concern all the equipments and
SW activities that are within Control System Manufacturer's scope of
supply.
During the System development, it will be agreed if the test will be
performed on the complete Control System (DCS and PLC, Cabinets), or
if separate tests will be conducted on each item, performing a final
integration test (for example at the end of the FAT) with a suitable subset
of the other equipment.
In this case, the present procedure shall be applied to the item under
test, unless otherwise specified. In any case Vendor is requested to
propose, a procedure to perform F.A.T. without marshalling cabinets.
Prior the F.A.T. all the equipment shall be fully assembled, wired and
properly connected each other, to test all the functionalities of the

package.

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Supplier shall perform a complete system functional test before advising

the Purchaser that the system is available for witnessed testing.
The entire Control System shall be submitted to a complete shop
acceptance test prior to shipment at Vendor's workshop by Vendor's
technicians in presence of BPCL Mumbai refinery.
Major objective of the test is to get confidence that the System will work
on site as foreseen during engineering activities; positive result of this
test does not release Vendor from his responsibilities to provide a system
completely working and to perform all the modifications which could be
necessary to assure system correct working in the field.
This document outlines a procedure for Factory acceptance Test (FAT) to
be witnessed by the BPCL Mumbai refinery; it is not intended to explain
the hardware and software tests which are part of Vendor internal testing
procedures. It covers vital system functionality tests
The F.A.T. procedure shall be considered as an addition to Vendor's
standard procedure to clarify and define tests which BPCL Mumbai
refinery considers necessary: they form the minimum list of check to be
performed and they do not substitute the checks foreseen by Vendor.
In case of discrepancy between this document and Vendor's internal FAT
procedure, BPCL Mumbai refinery engineers will decide which document
shall be followed, and the decision will be reported in the FAT report.
Anyway, as a general rule, this document shall be considered prevailing
on Vendor procedure.
All defects detected during Supply testing, shall be corrected by Vendor
at its own expense prior the end of testing, if possible, or at least before
shipment.
10.1.3 Packing
System packing and shipment shall be done as per BPCL Mumbai
refinery procedures, defined at the Purchase Order.
10.1.4 Shipping and Installation

Control System shipping details will be defined during project

development; Vendor is required to evaluate the possibility (and the
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costs) to ship Control System complete or to divide shipping in different
phases (e.g. marshalling cabinets, PLC (ESD) cabinets and DCS
cabinets at different time).
Control System Vendor's qualified personnel will be present to check
system installation and to supervise the initial system power up activities.
Checks listed in chapters 3 and 4 will be repeated during the Site
Acceptance Test in the field. These tests are intended to re-check control
system's functionalities to verify no problems arose during packing,
shipping and installation.
BPCL engineers will define for each test if the complete check or a
representative subset, will be repeated.
Vendor's technicians will be on site during field test
10.2.0 F.A.T. ORGANIZATION
10.2.1 Facilities
Factory Acceptance test shall be organized by Vendor at their staging
area.
Vendor shall assign qualified personnel during the entire test period to
perform all kind of tests and operations on the system and to assist
BPCL Mumbai refinery
The proposed staging area shall satisfy the following minimum
requirements:
1. Area dimensions shall be enough to easily accommodate all
cabinets inside supply and equipments supplied by other Parts if
they will be necessary to the complete test.
2. A warehouse containing at least one item per device type in the
supply shall be available to change within one working day any
device found defective during the test.
3. An office (key-locked) shall be available to accommodate
engineers, to keep documentation necessary during the test, to
arrange meetings; this room shall have a telephone line available.
4. The area where cabinets are placed shall be organized to avoid that
other people present in the staging area can overlook the test; a
couple of desks shall be available near the DCS and PLC consoles.

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5. Power supply lines for system equipments shall be suitable for
testing purposes; in addition power supply lines shall be available to
power a Personal Computer (not in Vendor's scope) both in the
meeting room and near the system under test.
6. Auxiliary tools to perform a complete test shall be provided by
Vendor. In addition to the tools necessary for system working, at
least the following shall be provided.
1. Digital multimeter;
2. 4 to 20 mA signal generators;
3. 1 to 5 V signal generators;
4. Potentiometers to simulate different readings for analogue signals
powered by PLC (ESD)
5. Decades resistances box to simulate RTDs readings;
6. Simulation panel for digital inputs and outputs;
7. Tool kit (with screwdrivers, jumpers, etc.).
10.3.0 Test procedure
Duration will depend upon the real status which will be checked at the
factory acceptance test beginning; if system conditions request more
time to complete the test in the foreseen period, BPCL Mumbai refinery
will request to Vendor to provide additional assistance and, if necessary,
also out of normal working time.
Vendor shall communicate He is ready to test the system two weeks prior
the scheduled start beginning. Failure to this communication will result in
an automatic delay of the F.A.T. beginning, due to Vendor's problems.
Exact time schedule will be defined at the F.A.T. kick of meeting to be
attended by Vendor's representatives the first day of F.A.T. The actual
time period will depend upon the actual progress during F.A.T.
Each day an informal meeting will be held to state:
1- Progress;
2- pending points;
3- Modifications (due to configuration errors, specification
changes, etc.);
1- Re-scheduling of activities (if needed).
At the end of the meeting a "punch list" stating activities to be performed,

due date and final approval of change (if any) shall be issued by Control
System Manufacturer and submitted to Buyer.

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10.4.0 HARDWARE TEST

Factory tests shall be performed using hard-wired simulated inputs, with
simulators to be provided by the Supplier.
The system shall be tested with all the inputs and outputs wired to the
simulators.
During the test, the system shall perform as required by Material
Requisition, System specifications and engineering documents provided
by BPCL Mumbai refinery. Control System Vendor shall provide monitors
and equipment to determine the performance of the system under test
with respect to the loading and response time requirements
The following table details the applicability of the Hardware tests to the
items under scope of supply.
Test

DCS

PLC

Check of supply completeness

Check of proper change-over of the back-up

units in case of unit failure

Demonstration of diagnostic features

Power off and power on of any single unit

Check of auxiliary devices

Check of correct functionality of keyboards

Testing of proper working of the printers

Simulation of power-off and restart

Test of system interfaces working

Check of power supply load

Check of analogue channels accuracy

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NOTES:
X = test to be performed for all the equipment
S = test to be performed as sample
10.5.0

SOFTWARE TEST

All the functions both standard and specific for the project will be
checked to verify that the system will work as desired and needed
by process requirements to give BPCL Mumbai refinery effective
and friendly means to handle the plant.
The following table details the applicability of the Software tests to the
items under scope of supply.
Test Description

DCS

PLC

Check of database configuration

Check of batch sequences (if any) and

interlocks configuration

Check of MONITOR displays (all kind of

displays)

Check of all kind of reports

Check of system internal loading (processors,

communication system, etc.)

Check of printing functions (alarm, reports, etc.)

Check of time stamping and continuous

operation after year 1999

Scan time checking

NOTES:
X = test to be performed for all the equipment
S = test to be performed as sample

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 99 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

10.6.0 INTEGRATION TEST
Part of the Hardware and Software tests listed in the previous
paragraphs, does not require the presence of the complete system, but
could be performed separately on any single component of the system.
In any case, those "individual" tests require the completeness of the item
under test: for example, during the DCS/PLC FAT all the equipment
composing the system (Processors, Operator Consoles, I/Os, serial
cards, gateways, cabinets, remote racks, etc...) shall be present, wired
and properly working.
10.7.0 DOCUMENTATION
Prior to FAT, Vendor shall prepare documentation and deliver one copy of
it to BPCL Mumbai refinery two weeks before FAT beginning.
The following list of documents to be provided before test shall be
considered as a minimum.
- System database: -One copy on removable media to BPCL Mumbai
refinery.
-One copy on paper at FAT beginning in testing area
(database and system configuration).
- Application Data Base- One copy on removable media to BPCL
Mumbai refinery.
-One copy on paper at FAT beginning in testing area
(database and system configuration).
- Logic diagrams : - One copy on paper (printout from system) to BPCL
Mumbai refinery
- One copy at FAT beginning in testing area.
After Factory Acceptance Test, Vendor shall provide to BPCL Mumbai
refinery, PLC (ESD) configuration /Logic diagram on soft and hard copy
one each.

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 100 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

10.8.0 TESTING ACTIVITIES
10.8.1

General

The following points outline the tests which will be performed during the
Factory Acceptance Test and how they will be carried out. The system
shall be always under power during the entire check period with one
printer always on line to print any kind of errors which could occur (where
applicable). The print out can be attached to the Factory Acceptance Test
report.
The applicability of the following tests is for reference only and shall be
integrated with all the Software functions detailed by the system
documentation.
10.8.2

Completeness of Supply and documentation consistency

1) Visual check of hardware against Manufacturer's documentation
2) Item list check:
1. number of Item's modules
2. quantities of auxiliary equipments
3. quantities of switches and push buttons
4. check of system documentation
5. quantities of consumable
3) System drawings check:
1.
System cabling and wiring check

10.8.3

System hardware check

The usual standard check defined by Vendor in His procedures will be

performed; they will include at least the following:
1)
2)
3)
4)

Power loss Simulation

Shut Down of Operator Stations and their Reloading
Shut Down of Process Stations and their Reloading
Fail on (for redundant systems):
1. Processor
MASTER CARD
2. Communication MASTER CARD
3. Power Supply
MASTER CARD

4. Processor
BACK-UP CARD
5. Communication BACK-UP CARD
6. Power Supply
BACK-UP CARD
BHARAT PETROLEUM CORPN.LTD.
MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 101 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

6.2.2
Communication
fail:
For
redundant
Cables/Busses and Serial links:
1) Master line and relevant switch over
Reserve line and relevant system alarm
1- For single Serial Links and Ethernet:
12 . Communication fail and relevant system
behavior.
10.8.4 Input output working
Analogue (4-20 mA) Inputs check
Analogue (4-20mA) output
Digital Inputs check
Digital Outputs check
The proper correspondence between electrical signals and internal
indications will be checked. All the points are checked against
detailed engineering documentation.
10.8.5 System configuration check
1) Database configuration check (comprehensive of serial data)
2) All the points are checked against detailed engineering
documentation.
10.8.6 Internal programs test
1) Energy measures check.
3) Flow compensation formulas check.
4) Optimization programs check: the proper working of the
programs and their ease of handling will be verified.
5) Special control algorithms check.
6) Special functions check: all the functions implemented inside
the system (i.e. data reconciliation checks, discrepancies,
Mass balance, etc...)
7) Interlocks checks: the proper working of all the interlock
schemes will be checked against Engineering Contractor's
documentation using external simulators to simulate the field.
8) The following connections shall be provided:
2- Analogue inputs:
Each signal shall be connected to an external potentiometer to

easily modify input readings and to simulate different values;

Digital outputs to one solenoid valve:
Output shall be wired to input corresponding to "OPEN" position.
BHARAT PETROLEUM CORPN.LTD.
MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 102 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

1- Digital outputs for motors:
start and stop output shall be wired to a motor starter simulator
(hard-wire or software) whose output signal is in turn connected to
motor status input.
2- Digital inputs not related to valves or motors:
Simulation panel shall be provided to simulate their state.
10.8.7 Auxiliary devices
1) The proper working of printers is to be checked.
2) The proper working of trip amplifiers, temperature converters,
relays, etc is to be checked.

10.9

3) The proper working of other special modules (if any) is to be

checked and software which are related functioning of the
DCS/PLC system. Prior to F.A.T. the system shall be fully
assembled, wired and properly connected to test all the functioning
of the system. Vendor shall perform a complete system functional
test before advising
Site Acceptance Test (SAT)

Procedure for carrying out SAT shall be submitter by vendor for BPCL approval.
All the equipment shall be checked thoroughly after its installation and
commissioning. The Tests. As a minimum shall include,
1 Visual and mechanical testing.
2 Redundancy checking of all the redundant units like, Controller,
Communication bus, Sub communication I/O modules, power supply unit
etc.
3 Demonstration of all system diagnostics features.
4 Checking of communication between DCS and PLC and PLC and
Programming unit.
5 Checking of changeover of redundant devices.
6 Demonstration of all system functions.
7 Checking of proper functioning of DCS/PLC programming unit, PLC
printer.
8 Complete checking of DCS/PLC system.
9 Complete engineering configuration of DCS and PLC including Graphics
tuning, FLD.
11.1 GENERAL TERMS AND CONDITIONS.

11.2 General

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 103 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

On the basis of guidelines specified in these specifications, vendor
shall submit their own testing installation, commissioning and acceptance
procedure. For hardware, the procedures shall include purpose of test, testing
definition of input, procedure, results expected and acceptance criteria. The
testing and acceptance of the system shall be carried out on the mutually agreed
procedures and criteria based on these guidelines and vendor standard
procedures.
11.2 FACTORY ACCEPTANCE TESTING (FAT) & ACCEPTANCE and SAT
Vendor shall demonstrate functional integrity of the system hardware and
software. No material or equipment shall be transported until all required
tests are successfully completed and certified Ready for Shipment by
BPCL Mumbai refinery.
BPCL Mumbai refinery reserves the right to involve and satisfy himself at
each and every stage of testing. They shall be free to request any specific
test on equipment considered necessary by him, although not listed in this
specification.
SAT shall be carried out as per mutually agreed approved SAT procedures.
The cost of performing all tests shall be borne by the vendor. Second phase
of testing shall systematically, fully and functionally test all hardware and
software in the presence of representative from BPCL Mumbai refinery. All
sub-system shall be interconnected to simulate, as close as possible, the
total integrated system.
Following minimum testing shall be carried out :
1) Visual and mechanical testing
2) Functional testing
3) Vendor shall notify the owner at least three weeks prior to factory
acceptance test. In the event that representative arrives and the
system is not ready for testing, the vendor will be liable for back
charges for any extra time and expenses incurred.
11.3 Installation, Testing & Commissioning :
Vendor shall offer the services of the installation team, which would install the
equipment, lay the interconnecting cabling check out, test and commission the

system.

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 104 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

1 Vendors responsibility at site shall include all activities necessary to be
performed to complete the job including :
1) Receipt of hardware/software and checking of completeness of
supplies
2) Installation of the system.
3) Field cable identification before removal of marshalling panel.
4) Field cable termination.
5) Check out equipment installation
6) Loop checking
7) Commissioning and online debugging of the system.
8) Involvement during plant commissioning and performance of final
acceptance test.
11.4 SPARE PARTS:
1) Vendor shall indicate spares, consumable including special tools,
test equipment etc. for commissioning and operating the system
smoothly. The same shall be supplied free of cost as a part of the
contract. The vendor also to supply free of cost the consumable
spares for at least six months operation after taking over the
system.
2) In addition, Vendor has to quote for comprehensive list of spares
with unit price information for post warranty Maintenance of
Automation System.
3) The successful vendor shall warrant that spare parts for the system
would be available for a minimum of fifteen years.
4) Vendor to consider Six Sets of Crocodile clip/ earthing clamp with
Cable as spares.
11.5 Documentation:
1) Vendor shall furnish all manuals & engineering drawing as required
review/approval after order as per agreed QAP.
2) Vendor shall provide four sets of back-up configuration storage for
each system, containing operating programs, diagnostic programs
and system configuration etc.
3) Final as built documents shall be furnished within one month of final
field acceptance after incorporating all modifications at site, if any.
Numbers of copies of documents/drawings required for the above

mentioned shall be four plus one set of soft copy. Vendor to provide
following as built documents.

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 105 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

1 Operating and maintenance manuals
2 Software manuals, soft application data and soft copy of as
built drawings
3 Work sheets, engineering drawings, and documentation
prepared for the
Configuration of the offered system.
1 Loop drawings containing full information of each loop with
field termination, junction box nos., cables No., device
address, power supply connection etc.
2 All these documentation shall be furnished in hard cover
loose ring folders in A4 size (216 mm x 239 mm).
11.6 Warranty:
1) Vendor shall be responsible for the manufacture in respect of
proper design, quality, workmanship, and operation of all
equipment, accessories etc. supplied by vendor for a period of
12months from the date of taking over by the owner at site.
2) It may be noted that during the defect liability / warranty period,
vendor will take complete responsibility for any defect observed in
the system.
3) Further, vendor shall provide written guarantee that the back-up
engineering, maintenance and spare parts shall be available for a
minimum of 15 years.
4) It shall be obligatory on the part of vendor to modify and/or replace
any hardware and modify the operating, application and
diagnostic software
free of cost, in case any malfunction is
revealed even during
online operation after taking over within the
warranty period.
5) Vendor shall provide the total maintenance of system during
warranty period including replacement of equipment / component at
no extra cost.
6) Vendor to provide extended warranty for all supplied hardware and
software for a minimum period of 4 years trouble free operation for
DCS and PLC. This extended warranty period shall commence from
expiry of standard warranty of 12 months. On any failure, Service
Engineer shall report to the site within 24 hours.

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 106 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

11.7 Packing & Shipping

All the materials used for packing, wrapping seals, moisture resistant
barriers and corrosion prevention shall be of recognised brands and shall confirm
to the best standards for the article, which are packed.
1) Workmanship shall be in accordance with best commercial
practices and requirements of applicable specifications.
2) There shall be no defects, imperfections or omissions, which would
tend to impair the protection offered by the system as a whole.
3) The packing shall be suitable for storing in tropicalised conditions,
as specified in data sheets.
Shipment shall be thoroughly checked for completeness before final
packing and shipment. Vendor shall be fully responsible for any delay in
installation or commissioning schedule because of incomplete supply of
equipment.
11.8 Rejection:
Vendor shall make his offer in detail with respect to every item of the
purchasers specs. Any offer not conforming to this shall be summarily rejected.
11.9 Vendor data requirements & documentation along with offer:
Following shall be submitted as a Minimum:
a) Catalogues for each equipment covering technical specification,
principle of operation, design features, performance data, dimensional
and monitoring details, power and heat dissipation etc.
2) System description.
3) General specification.
4) Systems configuration diagram.
5) Vendors organ gram involved for this project.
6) Test plan.
7) QAP.
8) Post Warranty Spares list with part no & unit price information.

9) Certificate from statutory bodies.

BHARAT PETROLEUM CORPN.LTD.
MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 107 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

10) Loop schemes.
11) Bill of Materials.
12) Recommended spare parts for :
1. Commissioning
2. Post Warranty Annual Maintenance
Any other drawings not mentioned above but required for erection,
commissioning or re-configuration of system.
The following documents/drawings shall be supplied as a minimum for
owner/engineer review/approval, after placement of order and along with
shipment:
1) Functional design, specification of DCS/PLC, system and application
software.
b) Engineering drawings documents consisting of detailed configuration
diagrams, wiring diagrams, loop schemes, power supply distribution
diagrams, grounding arrangement, assembly and installation diagrams.
3) As built documentation covering hardware, software uses, installation
and maintenance manuals for all equipment.
d) Inspection and test plans, FAT, SAT and Test Plan procedures.
5) Quality assurance/quality control documents/rewards.
6) All report generation print outs.
7) Numbers of copies of documents/drawings required for the above
mentioned shall be TWO.
8) Vendor shall note that the approval of drawings/documents as per
vendor data requirements does not absolve vendor from the
responsibility of providing safe efficient and functional system fully
meeting the requirement.
11.10 Training of DCS/PLC:
This training shall be conducted at vendors/OEM works. All the training are to be
imparted by the manufacturers experts in the respective fields.
Efforts shall be made to arrange factory training for the BPCL personnel
at manufacturer works prior to factory acceptance test.
The training requirements for ESD PLC and DCS shall be as follows

1) Engineering, Maintenance and trouble shooting training for DCS 20

Man weeks.
BHARAT PETROLEUM CORPN.LTD.
MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 108 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

2) Engineering, Maintenance and trouble shooting training for PLC 20
Man weeks.
3) Site Training shall be carried out by the vendor for 10 Trainer man days
for the operator.
4) Operator training shall be 10 Man weeks for DCS.
11.11 Vendor shall submit the following calculation sheets along with the offer.
1.
2.
3.
4.
5.

DCS/PLC loading calculation

Historical trend memory utilisation
power/load calculation sheet
HVAC calculation sheet
Air quality requirement

6. list of Sub-vendor/ manufacturer for BPCL engineer in charge

approval
11.12 Special Notes
1) Before submitting the offer, vendor to visit the site and understand all the
jobs in detail then to submit the offer. This will enable minimum deviation
from the BPCL Mumbai refinery specification and easy of technical
evaluation further. Failing which vendors offer shall not be considered for
technical evaluation.
2) The UPS calculation sheet must indicate: actual UPS load under normal and
start up condition. (consider all loads are powered on simultaneously)
3) No new UPS has been envisaged at this stage, however vendor to check
the adequacy of the existing UPS w.r.t new load (which is to be furnished
by the vendor) and to confirm the same in their offer.
4) Vendor shall be responsible for their recommendations regarding UPS
requirement.
5) Vendor to ensure any equipment supplied by them shall not be damaged
due to blackouts/ brown outs. Further, vendor to indicate the following:
(1) Steps to be taken for fail safe operation of the system under the
following conditions:
1. Power Failure
2. Voltage variation more than +/- 10 %
3. Frequency variation more than +/- 3 %
4. Air-conditioning failure
(2) The start-up procedure for the system including system data

base loading during start-up, and power on.

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 109 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

6) Vendor to furnish information related to their and / or their principals
experience and the proven ness of the equipment (computers, hardwares,
softwares etc.) in the PROVEN TRACK RECORD The information should
specifically be related to the similar applications. Vendor should submit
documentary evidence to substantiate above along with their quotation.
Vendor is wholly responsible for the correctness of the information
submitted or provided otherwise by them as a part of their bid. BPCL
reserves the right to verify the correctness of documentary evidence
furnished by the Vendor.
7) Vendor to produce documentary evidence for service support and
supply of spares for minimum 15 years. Vendor shall have full-fledged
service support team; the detail of the service support team shall be
submitted along with the offer.
8) Vendor shall furnish a certificate for providing necessary support services.
The certificate shall be duly signed by them and their principal(s)
9) Certificate from sub vendors for systems such as computers, printers etc.
shall also be furnished. The certificate issued by the local agents shall not
be acceptable.
10) Vendor has to submit the compliance and deviation statement for each
and every clause of this offer including general terms and conditions,
along with this offer, without this offer will not be evaluated.
11) Vendor to confirm offered Processor and IO card shall be protected as per
ISA GX CLASS 71.04 corrosive environment protection or better and
relevant certificate shall be enclosed along with the offer.
12) Vendor to consider Supply of all installation material including trays
,conduits, fasteners, supports, base-channel frames, glands ,earth
electrodes, earthing cables and other accessories as necessary.

13) The storage of equipment at site shall be vendor's responsibility for all the
equipments supplied by them. Non air-conditioned space could be
provided to the vendor if the control room is not ready at the time of
equipment receipt at site.
14) All necessary hardware/software/licenses and engineering required for
successful augmentation/ up-gradation / extension of present system
without affecting the existing system shall be provided by the vendor.
15) Vendor to note that all hard discs of server/ PC grade machines shall be
sized with at least 50% spare availability for application area.
16) As a execution methodology vendor shall prepare a detailed work
schedule for the phase wise installation and commissioning of the system
which shall be approved by BPCL..

17) As a part of engineering, testing, loop checking, pre-commissioning and

commissioning of the system, vendor shall ensure the following as a part
of their scope of work;
BHARAT PETROLEUM CORPN.LTD.
MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
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BOILER HOUSE DCS AND PLC SPECIFICATIONS

1. Any consequential changes in hardware / software configuration
and / or necessary engineering
2. Any changes necessary in the system during pre-commissioning
and loop checking because of either inadequate information, wrong
engineering, front desk engineering etc related to operational and
maintenance requirements like configuration change, graphic
change, I/O reassignment, termination modifications, addition of
input / outputs within the scope of specification.
11.13. Proposal of Vendors offer.
a) The proposal shall comprise of the following sections:
SECTION I- Synopsis of the Proposal
SECTION II- Vendor's Capability
SECTION III- Project Execution
SECTION IV- System Description/ Operation
SECTION V- Technical Specifications
SECTION VI- Deviations
SECTION VII- Quality Assurance, Factory Testing and Field
Acceptance
SECTION VIII- Price Details
2) Section I and II shall be used by the vendor to establish their capability in
the field of Distributed Control Systems/PLC. The details shall be
forwarded as under:
1 Introduction
2 Company profile
3 Vendor's experience (in PTR format)
4 System engineering capability
5 Sub-vendor list (for all bought-out items)
6 Vendors Organization chart
7 Miscellaneous
3) Section III shall be used by the vendor to provide details about execution
of the project. . The details shall be forwarded as:
1
Proposed project management
2
Man-power Deployment Chart
3
Bio-data of Key persons
4

Estimated engineering and delivery schedule including

bar chart.

5
6

Methodology of execution
Vendors responsibility

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 111 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

1

Sub-vendors Responsibility Chart To be filled separately for

each bought-out item.

4) Section IV shall include the following details separately for each system
item i.e. DCS, PLC etc.
1 System proven-ness
2 A drawing showing the offered system architecture and all
subsystems offered by the vendor.
3 A single line diagram showing interconnection of all hardware
functional modules subsystem-wise, e.g. I/O modules, controller
modules, communication subsystem interface module etc. for
each system item.
4 Detailed functional description for each system item explaining
how the system meets each of the functional requirements
specified in the requisition.
5 Vendor to explain redundancy levels and methodology of
change-over at each
6 processor level i.e. I/O module, Processor module and
communication at Processor and network level (for controller,
console)
7 Vendor to explain availability of Diagnostics at various levels
with the system.
8 Vendor to explain data storage and retrieval capability of the
system.
9 Vendor to explain with respect to offered add-on hardware and
software explaining how Time Synchronization of Complete
System from external clock is achieved.
10 Vendor to forward detailed explanation as to how they propose
to meet the 20% future expansion requirements with respect to
hardware and software
5) Section V shall include the following details separately for DCS./PLC
Vendor shall include printed literature to support and clearly explain as to how
each subsystem fits into the functional requirements specified in the
requisition.
1) Vendor to furnish the following documents
9) Sizing calculation for controller and data acquisition
sub-system considering loading and scan time
requirements specified in the detailed specification.
Considering the additional I/O are in each system.

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 112 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

Sizing calculation for PLC processor considering loading and
scan time requirements.
3) Communication network sizing calculation.
2) Storage Capacity
2)

Trending Capability (No. of points with respect to sample time

and maximum storage time.
1. Real-time Trend
2. Historical Trend
3) Data Base and History Memory Sizing
1)

4) Calculations for 30 days Historical Trending for all analog points at the
rate of 1 (one) minute sample time.
5) Vendor to specifically indicate the availability of the following system
alarms:
For DCS and PLC
1 Channel failure alarm of main as well as back-up I/O module.
2 Module failure alarm of main as well as back-up module.
3 Availability of PLC system alarms on DCS operator console.
4 Power supply failure alarm.
5 Fan failure and cabinet temperature high alarm
6 Main and redundant bus failure alarm
7 I/O channel latent fault (permanent open / short) detection and
alarming
8 for PLC only.
9 Barrier failure diagnostic
10 Disc failure alarm. In case of dual disc configuration, Main as
well as Redundant disc.
11 Redundant device failed to take-up
6)Vendor to furnish following details
1) Update rate on DCS console.
2) Update rate for data from PLC to DCS console and vice versa.
3) Console switch over time in case of Redundant Console
electronic type systems.
7) Vendor shall include any other information not mentioned in the data
sheets but important or required to be furnished to support and explain
the functional requirements for the system. The additional information
shall be provided on separate sheets and shall be attached to appropriate
data sheet.

8) Vendor shall furnish all the data and drawing required . Vendor shall
also furnish data for power consumption, ventilation and air conditioning

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 113 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

requirements. Since this information is being used for engineering, vendor
must certify the correctness of the data provided.
9)
Vendor to clearly indicate the G classification as per ISA for each
of the subsystem offered by them against this job. The information shall
be given in the form of a Table indicating all sub-systems and systems and
their corresponding G class offered. In case any hardware is not listed in
the , it shall be construed to have been complying minimum of G3
classification.
10)
Vendor shall include the detailed description and capabilities of
all the software offered.
11) Vendor shall include separate lists for mandatory spares,
recommended spares for two (2) years normal operation, test equipment
and tools, and consumables.
6) Section VI shall list out deviations, if any separately. The list shall indicate
Document name, Document no., Page no., Clause no., Requirement, Deviation
asked, Technical reason for Deviation, Remarks, if any.
Vendor should not give any explanation or comment on the specification.
7) Section VII shall include - Quality Assurance, Factory Testing and Field
Acceptance Vendor shall enclose "Vendor Standard" procedures including the
test facilities available with them to perform the following:
Quality Assurance
Factory Acceptance
Field Testing
Field Acceptance
Vendor to provide procedure being adopted by them to demonstrate scan
time, loading etc. Vendor shall enclose the details of simulation method of
all process inputs. Vendor shall also enclose the detailed schedule for
factory testing, installation, loop checking, field testing, commissioning and
field acceptance of the system.
h) Section VIII shall contain all the pricing information including Bill of Materials,
as per the requirements of this requisition. Bidder shall submit the price details
against each item.

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 114 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

Annexure I - u84 PLC Architecture

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION

MUMBAI-400 074.

SHEET 115 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION

MUMBAI-400 074.

SHEET 116 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

Annexure - III
Tentative Bill of Material- DCS
S/N

1.
2.
3.
4.

5.

6.

7.
8.
9.

10.
11.
12.

Description
Removal of Existing Centum XL DCS along with complete
System, Analog and Digital marshalling and PDB Cabinets,
Relays and accessories etc. as per annexure V.
Supply of Redundant DCS Rack, CPU, Communications
Modules etc.
Supply of Redundant I/O modules (AI,DI,DO,T/C & RTD)
details as per Annexure VII.
Supply of System cabinets
(2200mmHx1200mmWx1200mmD) with Glass door along
with all the required accessories
Supply of Analog and Digital Marshalling and Relay Cabinets
with all the accessories like Relays/barriers, Converters etc
mounted. And wired.
(2200mmHx1200mmWx1200mmD)
Supply of PDB cabinet (2200mmHx1200mmWx1200mmD)
with Voltmeter, Ammeter, MCBs, Bus Bar with inter-panel
wiring and termination etc.
Supply of HWC along with PBS, Selector switches, Feedback
lamps and terminal blocks including inter-panel wiring etc

UOM

Lot
4 set
Lot
4 set

Lot

Lot

Lot

Supply of LED base Annunciator with inter-panel wiring and

termination etc.
Supply of Relays For DI/DO and Barriers, Converters and
Signal repeaters etc including Signal Conditioning , wiring etc
For Analog Inputs and Outputs.
Supply of Field Termination Assembly for AI, AO, and DI and
DO Modules as per project requirement.
Supply of System cables, Prefab cables, Communication
cables etc required for complete Integrity of the System

3 set

Supply of Redundant Bulk Power supply

Unit(110VAC/24VDC)

Lot

Lot

Lot
Lot

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 117 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

13.

14.

15.

16

17.

18.

19.

20.

Supply of Operator Station, Remote Operator Station for DCS

with Latest model and Latest O.S with 21 TFT Monitor etc
along with printer necessary furniture (table and chair)
mounted with necessary receptacles.
Supply of OPC Server Client Station for DCS with Latest
model and Latest O.S with 21 TFT Monitor etc along with
printer necessary furniture (table and chair) mounted with
necessary receptacles. OPC system shall be supplied with
necessary Hardware firewall (is must) for protecting the
system from cyber attack.
Supply of Engineering Station for DCS with Latest model and
Latest O.S with 21 TFT Monitor etc along with printer
necessary furniture (table and chair) mounted with necessary
receptacles.
Supply of Documentation System Software/hardware for DCS
with Latest model and Latest O.S with 21 TFT Monitor etc
along with printer necessary furniture (table and chair)
mounted with necessary receptacles.
Supply of Alarm Management System Software/hardware for
DCS with Latest model and Latest O.S with 21 TFT Monitor
etc along with printer necessary furniture (table and chair)
mounted with necessary receptacles.
Supply of Latest Version Software
a) System Software
b) Application Software
c) Communication Software
d) OPC Client Software
e) AMS Software
e) PC s latest O.S
f) Documentation Software.
g) Any other essential software to make the system functional
as per specification.

4 set

Identification of Existing Field cables in Control room, Deglanding the same and Glanding to New Cabinets, Including
Ferruling and Termination as per new Engineering.
Laying of Power and Signal cables for Inter-panel wiring
including cable supply. Supply and laying of power cable as

Lot

1 set

2 set

1 set

1 set

Lot

Lot

per load requirement from UPS room to control room (

Distance approx 100 meters)

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 118 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

21.

Lot

23.

Detailed Engineering service including generation of, DCS

Engineering, Functional logic diagram and Project
Engineering services etc
Erection Installation and Commissioning of Complete system
after removal of all the existing cabinets termination, Loop
checking and Handing over the system in totality to BPCL.
Training as per Tender

24.

Factory Acceptance Test

Lot

25.

Site Acceptance Test

Lot

26.

Complete as built Documentation like Manuals, Engineering

documents like i/o allocation, Loop wiring drawing etc
Furniture project needs/specification.

Lot

22.

29

Lot

Lot

Lot

Note:
1. The above BOM is indicative only. Vendor to quote as per their terms
and condition. However make sure that all the above items are covered.
2. For Sr.13, 14 and 15 the furniture shall be mutually decided after
discussing available options and suitability conditions etc.

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 119 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

Annexure - IV
S/N

Tentative Bill of Material- PLC (Total 4-nos)

Description

UOM

Removal of Existing General Purpose PLC along with complete

Cabinets, BMS Plaque Panel, PDB, Relays and accessories
etc. for detailed list refer Annexure VI
Supply of Redundant PLC Rack, CPU, Communications
Modules etc. as per project requirement.
Supply of Redundant I/O modules (AI,DI,DO) as per I/O count
listed in annexure VII.
Supply of System cabinets (2200mmHx1200mmWx1200mmD)
with transparent hardened plastic door along with all the
required accessories.
Supply of PDB cabinet (2200mmHx1200mmWx1200mmD)
with Voltmeter, Ammeter, MCBs, Bus Bar with inter-panel
wiring and termination etc. as per project requirement.
Supply of Marshalling and Relay Cabinets with all the
accessories like Relays/barriers etc mounted.
(2200mmHx1200mmWx1200mmD) as per project requirement.
Supply of BMS Plaque panel along with PBS, Selector
switches, Feedback lamps and terminal blocks including interpanel wiring etc
Supply of Relays For DI/DO and For AI- Barriers, Converters
and Signal repeaters etc including Signal Conditioning , wiring
etc as per project requirement
Supply of Field Termination Assembly for AI,DI and DO
Modules as per project requirement
Supply of System cables, Prefab cables, Communication
cables etc required for complete Integrity of the System

Lot

11.

Supply of Redundant Bulk Power supply Unit(110VAC/24VDc)

Lot

12.

Supply of Engineering Station for PLC with Latest model and

Latest O.S with 21 TFT Monitor etc along with printer
necessary furniture (table and chair) mounted with necessary

2 sets

1.
2.
3.
4.

5.

6.

7.

8.

9.
10.

4 set
Lot
4 set

Lot

Lot

3 set

Lot

Lot
Lot

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 120 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

receptacles.
13. Supply of SOE Station for PLC with Latest model and Latest
O.S with 21 TFT Monitor etc along with printer necessary
furniture (table and chair) mounted with necessary receptacles.
14. Supply of Latest Version Software
a) System Software
b) Application Software
c) Communication Software
d) SOE Software
e) PC s latest O.S
f) Documentation Software.
g) Any other essential software for system functionality as per
project specification.

2 set

15. Identification of Existing Field cables in Control room, Deglanding the same and Glanding to New Cabinets, Including
Ferruling and Termination as per new Engineering
16. Laying of Power and Signal cables for Inter-panel wiring
including cable supply. Supply and laying of power cable as
per load requirement from UPS room to control room (
Distance approx 100 meters)
17. Detailed Engineering service including generation of Functional
Logic Diagrams, PLC Engineering and Project Engineering
services etc
18. Erection Installation and Commissioning of Complete system
after removal of all the existing cabinets, termination, Loop
checking and Handing over the system in totality to BPCL.
19. Establishing Communication with existing DCS with required
Hardware and Software etc.

Lot

20. Training as per Tender

Lot

21. Factory Acceptance Test

Lot

22. Site Acceptance Test

Lot

23. Complete as built Documentation like Manuals, Engineering

documents like i/o allocation, Loop wiring drawing etc ( Soft
+hard copy)

Lot

Lot

Lot

Lot

Lot

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 121 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

24 Furniture

Lot

Note: The above BOM is indicative only. Vendor to quote as per their terms and
condition. However make sure that all the above items are covered.
ANNEXURE V

Sl
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

List of Component to be removed for DCS

Item
DCS
cabinets

Designation
and
I/O Cabinets with Cards and
Terminals etc
Cabinets along with all the
Relay Cabinets
Relays Terminals etc
Power
Distribution Cabinet along with MCBs and
Cabinets
Terminals etc
Cabinets with Cards and
SER cabinet
Terminals etc
Cabinets with Cards and
SKYD
Terminals etc
Process
operators Cabinets with Cards and
Console
Terminals etc
Cabinets with Cards and
Hardware console
Terminals etc
Cabinets with Cards and
Engineering PC
Terminals etc
Omron relay
with
base
For BOP DCS and PLC
TB16 card
BOP digital i/p card
Bus bar
110 V dc and 24 Vdc
MCB
PDB and other Cabinets
Terminal strips
SER unit
SER system
Bulk power supply
For system cabinets
SKYD
Alarm setter unit
TE08
Digital o/p
PS33
Processor power supply
Processor rack cards FCS processor rack cards
PS31
I/O rack power supply card

Quantity
6 set
2 set
2 set
1 set
1 set
4 set
3 sets
1 set
525
34
12
80
1300
1 set
5
48
6
8
28
50

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 122 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

21
22
23
24
25
26
27
28

I/o cards
PS40
EX1/EA2
Barriers
Printer
Recorder
SLPC
Prefab cable

Open, close, digital and serial

interface
Signal condition power supply
Signal conditioning unit
Open loop/temp/close loop
Alarm, log, hard copy and engg
BOP loops

170
8
35 set
570
4
2 sets
10
200

Note: The above list is indicative only; However the actual

items/list/quantity shall be as per actual site condition.

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION

MUMBAI-400 074.

SHEET 123 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

ANNEXURE VI

Sl
No.
1.
2.
3.
4
5

List of Component to be removed for PLC

Item
PLC
cabinets

Designation
andI/O Cabinets with Cards and
Terminals etc
Cabinets along with all the
Relay Cabinets
Relays Terminals etc
Power
Distribution Cabinet along with MCBs and
Cabinets
Terminals etc
Power Supply
A1PS, A2PS, A6PS, A7PS
A3PS to A4PS
CPU
U84-224
Power Supply
P8101
Power Supply
P8054
Switch Module
C8150
Comm. Module
C8110
Aux Comm. module
Remote I/O driver
C8130
local I/O Receiver
C8125
I/O Buffer
B1010
Mount Base
A1BP
Mount Base
A2BP
Mount Base
2A1BP, 3A1BP
2A2BP,
3A2BP,
2A4BP,
Mount Base
3A4BP
Mount Base
2A3BP, 3A3BP
I/P Module
B1057A
O/P module
B1056A
Cable
W1013-1
Cable
W1014-2
Cable
W1011-2

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

Quantity
7 set
5 set
16 pc
8 pc
8 pc
12 pc
16 pc
4 pc
4 pc
4 pc
4 pc
8 pc
8 pc
4 pc
4 pc
8 pc
16 pc
8 pc
155 pc
100 pc
8 set
8 set
8 set

SPECIFICATION

MUMBAI-400 074.

SHEET 124 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

Cable
Cable
Cable
Cable
Cable
Modem
Bus bar

7
8

Illumination lamp
Fuse

9
10
11
12

Lamps
Contactor
Switch Toggle

13
14
15
16
17
18

MCB
O/E/N Relay Board
Socket Switch
Door limit Switch
Transformer

19
20

Cable
Terminals
Double
Terminal
Switch Toggle

21

BMS Plaque panel

22

Annunciator

Deck

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,

W-1022
W1017-T01
WE02-15
WE17-15
WE14
J1078
BB1, BB3, BB5, BB7, BB9
BB2, BB4, BB6, BB8, BB10
E11-E13
F1, F2
F3
F4, F5
H1 to H7
K111
Q1, Q2
Q3
Q4
Q5
Q6
Q7
Q8
Q9
Q10
RD1-RD30
S30
S50 to S52
T1
T2, T3
X1 to X4

24 set
8 set
8 set
8 set
4 set
16 pc
20 set
20 set
24 pc
8 pc
4 pc
8 pc
28 pc
4 pc
8 pc
4 pc
8 pc
8 pc
8 pc
8 pc
8 pc
8 pc
8 pc
120 set
8 pc
12 pc
4 pc
8 pc
800 set
4pc
1500 pc
8 pc

S1, S2
Complete BMS Plaque Panel
along with its wiring, Selector
switches
and pushbuttons,
bulbs etc.
3-set
IIC make Annunciator
5x4
window
3-set

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION

MUMBAI-400 074.

SHEET 125 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

Note: The above list is indicative only, however the actual
items/list/quantity shall be as per actual site condition.

ANNEXURE VII
I/O COUNT FOR DCS AND PLC
DCS I/O COUNTS - PER BOILER

20%
TYPES QTY/BOLIER SPARE
AI
100
AO
35
DI
40
DO
16
DCS I/O COUNTS - BOP
20%
TYPES QTY
SPARE
AI
214
AO
36
DI
180
DO
16
PLC I/O COUNTS - PER BOILER.
20%
TYPES QTY
SPARES
AI
20
DI
285
DO
175
PLC I/O COUNTS - BOP
20%
TYPES QTY
SPARES
DI
125
DO
48

20
7
8
4

43
9
36
4

4
57
35

25
10

TOTAL
QTY/BOILER

TOTAL
COUNTS

TOTAL
QTY/BOILER

TOTAL
QTY/BOILER

120
42
48
20

257
45
216
20

24
342
210

150
58

TOTAL
COUNTSFOR
THREE
BOILERS

360
126
144
60

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 126 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

Note: 1.Control Station shall be segregated boiler wise i.e. three control
stations for three boilers and one separate Control station shall be for BOP.

2. PLC shall be separate for each Boiler i.e. three PLC for three boilers and
one separate PLC shall be for BOP.

Annexure VIII
List of Documents to be issued after placement of P.O by BPCL.
1. Cable/Junction Box Schedule
2. Functional Logic Schematics
3. Back up of existing Ladder Logics
4. Existing Panel/Relay Arrangement Drawing
5. Back up of DCS system/application software.
6. Loop drawing of DCS and PLC.
7. Existing Control room layout.

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,
MUMBAI-400 074.

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION
SHEET 127 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

Annexure IX

Control room layout drawing

Softcopy/Hardcopy shall be provided on request.

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION

MUMBAI-400 074.

SHEET 128 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

BHARAT PETROLEUM CORPN.LTD.

MUMBAI REFINERY, MAHUL,

PROJECT NAME : REVAMPING

OF HEB DCS & PLC

SPECIFICATION

MUMBAI-400 074.

SHEET 129 OF 129

BOILER HOUSE DCS AND PLC SPECIFICATIONS

Note:
The above scheme of 24VDC power supply distribution dwg is only for
reference / guidance. However actual rating of MCB and wiring shall be as
per project requirement

BHARAT PETROLEUM CORPN.LTD.

PROJECT NAME : REVAMPING

SPECIFICATION

MUMBAI REFINERY, MAHUL,

MUMBAI-400 074.

OF HEB DCS & PLC

SHEET 130 OF 129

(To be executed on plain paper and applicable for all tenders of value above
Rs. 1 crore)
INTEGRITY PACT
Between
Bharat Petroleum Corporation Limited (BPCL) hereinafter referred to as "The
Principal",
And
..hereinafter
Bidder/Contractor/Supplier"

referred

to

as

"The

Preamble
The Principal intends to award, under laid down organization procedures,
contract/s for ..The Principal values full compliance with all
relevant laws and regulations, and the principles of economic use of
resources, and of fairness and transparency in its relations with its Bidder/s,
Contractor/s and Supplier/s.
In order to achieve these goals, the Principal cooperates with the renowned
international Non-Governmental Organisation "Transparency International"
(TI). Following TI's national and international experience, the Principal will
appoint an Independent External Monitor who will monitor the tender process
and the execution of the contract for compliance with the principles
mentioned above.
Section 1 - Commitments of the Principal

(1) The Principal commits itself to take all measures necessary to prevent
corruption and to observe the following principles:
1) No employee of the Principal, personally or through family
members, will in connection with the tender, or the execution of the
contract, demand, take a promise for or accept, for himself/herself
or third person, any material or immaterial benefit which he/she is
not legally entitled to.
2) The Principal will, during the tender process, treat all Bidders with
equity and reason. The Principal will, in particular, before and
during the tender process, provide to all Bidders the same
information and will not provide to any Bidder confidential /

additional information through which the Bidder could obtain an

advantage in relation to the tender process or the contract
execution.

1-

1-

3) The Principal will exclude from the process all known prejudiced
persons.
(2) If the Principal obtains information on the conduct of any of its employees

which is a criminal offence under the relevant Anti-Corruption Laws of India,

or if there be a substantive suspicion in this regard, the Principal will inform
its Vigilance Office and in addition can initiate disciplinary actions.

Section 2 - Commitments of the Bidder / Contractor/Supplier

(1) The Bidder / Contractor/Supplier commits itself to take all measures

necessary to prevent corruption. He commits himself to observe the
following principles during his participation in the tender process and
during the contract execution.
1) The Bidder / Contractor/Supplier will not, directly or through any
other person or firm, offer, promise or give to any of the Principal's
employees involved in the tender process or the execution of the
contract or to any third person, any material or immaterial benefit
which he/she is not legally entitled to, in order to obtain in
exchange, any advantage of any kind whatsoever during the tender
process or during the execution of the contract.
2) The Bidder / Contractor/Supplier will not enter with other Bidders
into any undisclosed agreement or understanding, whether formal
or informal. This applies in particular to prices, specifications,
certifications, subsidiary contracts, submission or non-submission
of bids or any other actions to restrict competitiveness or to
introduce cartelisation in the bidding process.
3) The Bidder / Contractor/Supplier will not commit any offence under

the relevant Anti-Corruption Laws of India; further the Bidder /

Contractor/Supplier will not use improperly, for purposes of
competition or personal gain, or pass on to others, any information or
document provided by the Principal as part of the business
relationship, regarding plans, technical proposals and business
details, including information contained or transmitted electronically.

4) The Bidder / Contractor/Supplier will, when presenting his bid,

disclose any and all payments he has made, is committed to, or
intends to make to agents, brokers or any other intermediaries in
connection with the award of the contract.
(2) The Bidder / Contractor/Supplier will not instigate third persons to
commit offences outlined above or be an accessory to such offences.

1-

2-

Section 3 - Disqualification from tender process and exclusion

from future contracts
If the Bidder, before contract award, has committed a transgression through
a violation of Section 2 or in any other form such as to put his reliability or
credibility as Bidder into question, the Principal is entitled to disqualify the
Bidder from the tender process or to terminate the contract, if already signed,
for such reason.

(1) If the Bidder/Contractor/Supplier has committed a transgression through

a violation of Section 2 such as to put his reliability or credibility into
question, the Principal is also entitled to exclude the Bidder /
Contractor/Supplier from future contract award processes. The imposition
and duration of the exclusion will be determined by the severity of the
transgression. The severity will be determined by the circumstances of
the case, in particular the number of transgressions, the position of the
transgressors within the company hierarchy of the Bidder and the amount
of the damage. The exclusion will be imposed for a minimum of 6 months
and maximum of 3 years.
(2) A transgression is considered to have occurred if the Principal after due
consideration of the available evidences, concludes that no reasonable
doubt is possible.
(3) The Bidder accepts and undertakes to respect and uphold the Principal's
absolute right to resort to and impose such exclusion and further accepts
and undertakes not to challenge or question such exclusion on any
ground, including the lack of any hearing before the decision to resort to
such exclusion is taken. This undertaking is given freely and after
obtaining independent legal advice.
(4) If the Bidder / Contractor/Supplier can prove that he has restored /
recouped the damage caused by him and has installed a suitable
corruption prevention system, the Principal may revoke the exclusion
prematurely.
Section 4 - Compensation for Damages

(1) If the Principal has disqualified the Bidder from the tender process prior
to the award according to Section 3, the Principal is entitled to demand
and recover from the Bidder liquidated damages equivalent to Earnest
Money Deposit/Bid Security.
(2) If the Principal has terminated the contract according to Section 3, or if
the Principal is entitled to terminate the contract according to Section 3,

the Principal shall be entitled to demand and recover from the

Contractor/Supplier liquidated damages equivalent to Security Deposit /
Performance Bank Guarantee.

1-

3-

(3) The Bidder agrees and undertakes to pay the said amounts without protest
or demur subject only to condition that if the Bidder / Contractor/Supplier can
prove and establish that the exclusion of the Bidder from the tender process
or the termination of the contract after the contract award has caused no
damage or less damage than the amount of the liquidated damages, the
Bidder / Contractor/Supplier shall compensate the Principal only to the extent
of the damage in the amount proved.

Section 5 - Previous Transgression

(1) The Bidder declares that no previous transgression occurred in the last 3
years with any other Company in any country conforming to the TI
approach or with any other Public Sector Enterprise in India that could
justify his exclusion from the tender process.
(2) If the Bidder makes incorrect statement on this subject, he can be
disqualified from the tender process or the contract, if already awarded,
can be terminated for such reason.
Section 6 - Equal treatment of all Bidders / Contractors
/Suppliers/ Subcontractors

(1) The Bidder/Contractor/Supplier undertakes to demand from all

subcontractors a commitment in conformity with this Integrity Pact, and to
submit it to the Principal before contract signing.
(2) The Principal will enter into agreements with identical conditions as this
one with all Bidders, Contractors/Suppliers and Subcontractors.
(3) The Principal will disqualify from the tender process all Bidders who do
not sign this Pact or violate its provisions.

Section 7 Punitive Action against violating Bidders / Contractors

/ Suppliers/Subcontractors
If the Principal obtains knowledge of conduct of a Bidder, Contractor,
Supplier or Subcontractor, or of an employee or a representative or an
associate of a Bidder, Contractor, Supplier or Subcontractor which
constitutes corruption, or if the Principal has substantive suspicion in this
regard, the Principal will inform the Vigilance Office.

-4-

Section 8 - Independent External Monitors

(1) The Principal has appointed competent and credible Independent

External Monitors for this Pact. The task of the Monitor is to review
independently and objectively, whether and to what extent the parties
comply with the obligations under this agreement.
(2) The Monitor is not subject to instructions by the representatives of the
parties and performs his functions neutrally and independently. He
reports to the Chairperson of the Board of the Principal.
(3) The Bidder/Contractor/Supplier accepts that the Monitor has the right to
access without restriction to all Project documentation of the Principal
including that provided by the Bidder/Contractor/Supplier. The
Bidder/Contractor/Supplier will also grant the Monitor, upon his request
and demonstration of a valid interest, unrestricted and unconditional
access to this project documentation. The same is applicable to
Subcontractors. The Monitor is under contractual obligation to treat the
information and documents of the Bidder/Contractor/Supplier/
Subcontractor with confidentially.
(4) The Principal will provide to the Monitor sufficient information about all
meetings among the parties related to the Project provided such
meetings could have an impact on the contractual relations between the
Principal and the Bidder/Contractor/Supplier. The parties offer to the
Monitor the option to participate in such meetings.
(5) As soon as the Monitor notices, or believes to notice, a violation of this
agreement, he will so inform the Management of the Principal and
request the Management to discontinue or heal the violation, or to take
other relevant action. The Monitor can in this regard submit non-binding
recommendation. Beyond this, the Monitor has no right to demand from
the parties that they act in a specific manner, refrain from action or
tolerate action. However, the Independent External Monitor shall give an
opportunity to the Bidder/Contractor/Supplier to present its case before
making its recommendations to the Principal.
(6) The Monitor will submit a written report to the Chairperson of the Board
of the Principal within 8 to 10 weeks from the date of reference or
intimation to him by the 'Principal' and, should the occasion arise, submit
proposals for correcting problematic situations.
(7) If the Monitor has reported to the Chairperson of the Board a
substantiated suspicion of an offence under relevant Anti-Corruption
Laws of India, and the Chairperson has not, within reasonable time, taken
visible action to proceed against such offence or reported it to the

Vigilance Office, the Monitor may also transmit this information directly to
the Central Vigilance Commissioner, Government of India.

(8) The word 'Monitor' would include both singular and plural.

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Section 9 - Pact Duration

This Pact begins when both parties have legally signed it. It expires for the
Contractor/Supplier 12 months after the last payment under the respective
contract, and for all other Bidders 6 months after the contract has been
awarded.
If any claim is made / lodged during this time, the same shall be binding and
continue to be valid despite the lapse of this pact as specified above, unless
it is discharged / determined by Chairperson of the Principal.
Section 10 - Other provisions

(1) This agreement is subject to Indian Law. Place of performance and

jurisdiction is the Registered Office of the Principal, i.e. Mumbai. The
Arbitration clause provided in the main tender document / contract shall
not be applicable for any issue / dispute arising under Integrity Pact.
(2) Changes and supplements as well as termination notices need to be
made in writing. Side agreements have not been made.
(3) If the Bidder/Contractor/Supplier is a partnership or a consortium, this
agreement must be signed by all partners or consortium members.
(4) Should one or several provisions of this agreement turn out to be invalid,
the remainder of this agreement remains valid. In this case, the parties
will strive to come to an agreement to their original intentions.

For the Principal
For the Bidder/Contractor/
Supplier
Place Witness 1 :
(Signature/Name/Address)
Date . Witness 2 :
(Signature/Name/Address)

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