HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT

HINDUSTAN PETROLEUM CORPORATION LIMITED

ENGINEERING & PROJECTS
GRESHAM HOUSE ( 2 ND FLOOR),
SIR P. M. ROAD, FORT,
MUMBAI -400 001.

TENDER DOCUMENT
FOR

TERMINAL AUTOMATION SYSTEM PROJECT

AT

BHATINDA TERMINAL, PUNJAB

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SPECIAL CONDITIONS
OF
CONTRACT
(SCC)

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SPECIAL CONDITIONS OF CONTRACT
1.

Completion period: 7 months from the date of issue of LOI / Work order .
This excludes the stabilization period.

2.

Water required for construction purposes, if any, would be made available if

possible, by HPCL within the Installation at one source, free of cost, the
vendor shall be responsible for taking the same to the place of work as
required. In case of interruption in availability of construction water, vendor
shall make his own arrangements for progressing with the works and no
claim for additional work/time can be made on this account.

3.

Power required for the project works shall be arranged by the vendor at
his own cost either thru a temporary power connection from the local
Electric Supply Authority or by means of a DG Set of required capacity.

4.

The contract shall be executed on a unit rate basis. The unit rates shall
remain firm except otherwise if stated specifically in the General Terms &
Conditions of the tender.

5.

The Contractor shall provide and maintain at his own expenses all lights,
guards, fencing and watching when and wherever deemed necessary by
the site-in-charge for protection of the work, equipments, instruments,
accessories or for safety and convenience of those employed on the works
or public.

6.

The Contractor shall provide and maintain proper temporary sheds of

adequate capacity for storage of all materials and his own store in good
and water tight conditions at site. Any damage / loss of materials in the
contractors custody will be to his account and will be recovered from his
running bills.

7.

TERMS OF PAYMENT :
Subject to the provisions under the General Terms & Conditions of the
Contract for deduction of taxes at source, retention money, Liquidated
Damages etc. the following payment terms shall prevail;

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7.1

For Supply items:

7.1.1 80% of the quoted rates shall be paid on receipt of the material at site based
on the certification of HPCL/PMC along with submission of the following
documents;

7.2

a)

Copies of invoices showing goods description, quantity, unit

price and total amount.

b)

Railway receipt / Lorry Receipt / delivery challan duly

acknowledged by the Consignee.

c)

Manufactures Guarantee Certificate

d)

Inspection Certificate and dispatch clearance issued by the

nominated Inspection Agency and suppliers factory
inspection report.

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

successful commissioning (SITE ACCEPTANCE TEST).

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

Stabilisation Period.
7.2

For Erection Items

7.2.1 80% of the quoted rates shall be paid basis on physical progress of work
certified by Site Engineer of HPCL / PMC as per the approved billing
schedule and upon submission of the following documents.

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a)

Copies of invoices

b)

Copy of certified progress of work

c)

Proof of payment of ESI and deposition of EPF etc.

d)

Wage Sheet

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e)

Certified time sheet

7.2.2 10% of the quoted rates shall be paid on completion of erection and
successful commissioning (SITE ACCEPTANCE TEST)
7.2.3 Balance 10% of the quoted rates shall be on completion of the
Stabilization Period
8

For Testing and commissioning Items : 100 % of the quoted rates shall
be paid on completion of erection and successful commissioning (SITE
ACCEPTANCE TEST)
Successful commissioning is defined as compliance of all SAT punch points
by bidder and accepted by HPCL

8.2

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

completion of Training

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

charges shall be quoted in absolute amount (not in %).However the CAMC
charges for 5 years shall be at least 10 % of the total Capital cost to ensure
that the system is maintained throughout the CAMC period as envisaged. If
the Vendor quotes less than 10% as AMC charges, minimum of 10% of the
total capital cost for 5 years period shall be considered as AMC charges,
keeping the total cost (Total capital cost + CAMC) as quoted by the vendor.
In case the vendor quotes higher amount of CAMC, the quoted amount shall
be retained. The composite rate quoted by vendor for 5 years CAMC period
shall be split year wise in the following percentage for payment purpose
Year 1 :
10% of CAMC cost of 5 years
Year 2 :
15% of CAMC cost of 5 years
Year 3 :
20% of CAMC cost of 5 years
Year 4 :
25% of CAMC cost of 5 years
Year 5 :
30% of CAMC cost of 5 years

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9

Bidders are required to accept the payment terms given above without
any deviations. In case of deviations, Bidders will be given one opportunity
to withdraw the same without any revision in prices failing which the offer is
liable to be rejected.

10

Receipt of unconditional acceptance of order and security deposit as per

GTC is a pre-condition for release of any payments.

11

The final payment will be made on completion of all the work and on
fulfillment by the contractor of all his liabilities under the contract duly
backed up by a completion & no claim certificate.

12

Site shall mean the Bhatinda Terminal project site.

13

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

14

DEFECT LIABILITY PERIOD/Warranty Period

In addition to clause No.11 & 5n of GTC, the entire system including all
supplied materials shall be warranted for another 12 months. Thus the
total period of warranty/guarantee will be for 24 months starting from
date of acceptance of the system (ie date of compliance of punch points
of SITE ACCEPTANCE OF THE SYSTEM by HPCL). During warranty period
the contractor shall be liable to replace / rectify any item/ equipment
found defective. All spares and consumables required during the warranty
period shall be under the scope of the contractor. However printer
cartridge and stationery will be outside the scope of warranty
replenishment.

15

Bids will be evaluated taking into account the charges towards CAMC for 5
years. However HPCL reserves the right to award the CAMC contract
subsequently at the end of the warranty period or earlier.

16

In case of deviations, Bidders will be given one opportunity to withdraw the

same without any revision in prices, failing which offer shall be liable to be
rejected.

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17

The above Special conditions shall be read in conjunction with General

Conditions of Contract and Instructions to bidders. If any provision in
these special conditions is at variance with that of the aforesaid
documents, the Special Conditions shall be deemed to take precedence
there over.

18

No conditions should be mentioned in the price bid. Conditional price bid

shall be liable for rejection.

19. CONFIDENTIALITY:
The Bidders are requested to handle/respond the tender in utmost
confidentiality and shall not copy documents/information of the
Corporation
and
shall
not
divulge/distribute/share
any
documents/information or knowledge of things or process which Bidder
comes to know or acquires during the tendering/execution process. HPCL
also reserves the right to initiate appropriate legal action against Bidder
for breach of this condition or any copy right or infringement of
intellectual property of HPCL disclosed to Bidder during the
tendering/execution process.
18

General :

No idle time charges shall be payable by HPCL ,in any case what so ever.

In the absence of any specifications covering any material, design of work

(s) the same shall be performed / supplies / executed in accordance with
Standard Engineering Practice as per the instructions / directions of the
Engineer-in-Charge, which will be binding on the bidder. These have to be
completed at no extra cost to HPCL.

It is the clear understanding of the bidder that the complete scope as

defined or as may be required for the intended objective of this tender is
included in the quoted price. No extra payment apart from the quoted
price will be made in order to achieve the intended objectives. Reasons

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like, bidder having not envisaged / considered a particular activity or
element of cost required to be carried out for achieving the intended
objective or some activity not specifically mentioned in the tender
enquiry/tender but required to be carried out for achieving the intended
objective, will not form basis for considering extra payments.

No extra payments will be made for working on extended hours /

Saturdays / Sundays / Holidays to meet the committed/required time
schedules.

19.0 SOLE RIGHTS TO TEMPLATES / DOCUMENTATION /

PROCESSES

HPCL will have the sole rights to the templates / documentation /

processes / solution model etc. developed in the course of implementation
and the Successful Bidder and/or their partners will not be allowed to use
them without the explicit prior permission of HPCL in writing.

20

SUCCESSFUL BIDDERS RESPONSIBILITY

Successful Bidder will be wholly and solely responsible and liable for all the
jobs carried out by them / services provided by them. HPCL acceptance
having signed off a particular milestone will not exonerate the Successful
Bidder from his prime responsibilities to have done a correct job as per the
requirement of the job/contract and as per international practices in the
first instance itself. If required, Successful Bidder will be required to revisit
those milestones which are already signed off and will be required to
make suitable corrections at no extra cost to HPCL.

21.

PATENT /COPYRIGHT PROTECTION

If any third party claims that a Product/Service(s) supplied by the bidder in

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connection with this contract here under infringes a patent or copyright,
the bidder will defend HPCL against that claim at Bidders expense and pay
all costs, damages, and attorneys fees etc. and it would be the sole
responsibility of the successful bidder to comply with all instructions that a
Court finally awards.

If such a claim is made or is likely to be made, Bidder to enable HPCL to

continue to use, or to modify or replace the Product. If none of these
alternatives is acceptable to HPCL, the Bidder will give HPCL a credit for
such Product. as well as for all resultant consequential losses, resulting out
of the non-availability of the product for HPCLs use.

22.

COMPLIANCE TO TENDER ENQUIRY DOCUMENT

Tender quoted should be in compliance to the tender enquiry conditions.
All Annexure duly filled up along with necessary documentation as
requested in the tender enquiry and / or required to support Successful
Bidders claim must be enclosed with the tender in the first instance itself.
Any willful attempts by the Successful Bidder to camouflage the deviations
by not mentioning them in the prescribed format may render the bid itself
non responsive. Only the deviations which are mentioned on the format
attached in tender or in the datasheets will be taken during evaluation and
remaining offer shall be considered as exact compliance to tender enquiry.

23.0 Limitation of Liability :

1) In no event shall either Party to the contract be responsible for or
obligated in any manner to pay any special , exemplary, punitive,
consequential or other indirect damages( whether under tort, negligence
or strict liability ) in respect of any loss, damage, claim or demand asserted
by the other Party hereunder, even if the first mentioned Party was
informed or made aware of the possibility of such damages

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2) The maximum liability of each Party arising from any circumstances
including negligence, errors & omissions shall be limited to the total
contract value.
24.0

Bidders are required to quote the Unit rates in R only.

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SPECIFICATIONS

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INTENT OF SPECIFICATIONS
Hindustan Petroleum Corporation Limited (HPCL) intent to automate New 8 Bay
Gantry being constructed at Bhatinda Terminal. The Terminal receives, stores and
dispatch various grades of . MS, SKO & HSD etc. Presently Bhatinda Terminal is
operational & has automated operation for Existing 10 Bay Gantry Tank Truck
Filling, Tank Farm, Product Pump operation, Fire water pump operation interface,
Valve Control logics including module for Management Information System &
Reporting and interface with our ERP. M/s Advanced Systek Pvt Ltd (ASPL) has
done Terminal Automation & provided its software for automated operation of
aforesaid facilities. The New Gantry, VFD & other allied equipment/instrument
proposed to be provided in this tender shall be integrated with the existing
Automation/TAS software. Also existing logics & additional graphics which may
require to be modified/ added due to addition of new Bays, pumps, VFDs etc
shall be suitably modified/ added by the Vendor. All functions defined in this
tender document shall be performed in an integrated cohesive manner. The new
system shall be seamlessly integrated with the existing TAS which in turn will
control and monitor the entire terminal.
Before submitting techno commercial bids, bidders are required to visit and study
the existing scheme of Automation & other aspects of Plant operations for the
terminal. Any job, material, equipment, instrument etc not explicitly mentioned in
the Schedule of quantity but required to be provided to meet the functional &
technical requirement as mentioned in this tender shall be in the scope of
Vendor.
M/s HPCL may appoint Project Management Consultant (PMC) on their behalf for
execution & implementation of the entire TAS including Data Sheets approval,
Site Supervision, Bills Certification, Project monitoring etc. & all related activities
of automation as covered under this tender. However, inspection of Equipments
& materials are excluded from the scope of the PMC. Vendor shall get the
inspection done of the equipments & materials from the approved Third Party
Inspection agency as stipulated in the scope of Inspection of this document.
It may be noted that the quantities given in the BOQ are indicative and
quantities can be revised during execution of the P.O. Change order, if required
will be issued. Completion period is 7 months excluding stabilization period of
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min. 90 days. The following are the major milestones included in the Completion
Period

Datasheet Approval
Functional Design Specification & Hardware Design Manual which shall
include all philosophy for integration with the existing TAS
Batch Accuracy Test
Site Execution
Commissioning & Trial Runs
Site Acceptance Test including compliance

Bidders shall visit the site to understand the process, operation, scope of work
including integration with the existing Automation System. Any further site visits
required by the Vendor after placement of Purchase Order for understanding the
process, study the facilities, detail design engineering etc. shall be part of the
completion period.

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GENERAL
The major operational areas identified for automation are
a) Tank truck loading operation for New 8 Bay Gantry
b) Product pump operation (All T/T Loading pumps) including supply &
integration of the New VFDs
c) Integration with existing software including logic modification, wherever
required and additional graphics
d) Management Information System & Reporting
All these operations shall be logically integrated through existing Servers,
Programmable Logic Controller, other field & control room equipments to ensure
accurate, seamless & secured operation and data exchange.
Successful Bidder hereafter referred as Vendor shall make sure that
commissioning of all the instruments / equipment and Site Acceptance Test (SAT)
shall be completed as per the completion schedule mentioned in Special Terms &
Condition. Stabilization period is not included in the completion period.
Control Room location is inside Administrative building.
As Bhatinda Terminal is an operating Terminal, the Vendor shall carry out day to
day activity after taking necessary hot/ cold work permits. Vendor shall appoint a
Safety supervisor, apart from the Work Supervisor, who shall be available
throughout the working time and shall be responsible for taking permits and
observing safety and security regulation of the terminal. Vendor shall deploy at
least
one
qualified
and
experienced
(1
to
2
yrs)
instrumentation/electrical/mechanical engineer exclusively at the site during the
entire execution period as the work supervisor.
It shall be the endeavor of HPCL to provide work permit beyond normal
operating hour to the extent possible. However all the work shall be preferably
planned for completion by the Vendor within the normal working hour. Vendor
shall be provided suitable area to construct the fabrication yard in the delicensed area within the depot premises to carry out prefabrication job. For works
which may require total/ part shut down of the Gantry operation or which may

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hamper the normal loading operation, the automation vendor is required to work
during night hours/ holidays and during such times when it does not hamper the
operation of the terminal. Prior planning & permission from the Terminal
manager shall be obtained. All hot work shall be planned (min. 21 days in
advance for Gantry/ header job) and discussed with the Terminal manager and
shall be carried out on Sundays / holidays to cause minimum impact on the
regular operation on working days. All Work shall be planned without
interruption to terminal normal working. No extra claim shall be admissible for
night working, holiday working or extra hours working if permission for the same
is given by HPCL.
The mechanical job can be carried out during any day/ Sundays/ holidays,
Vendor shall mobilize its mechanical personnel immediately after placement of
order to carry out modification job in such a manner that all jobs like header
modification for BAE installation, are completed by the time supply of these
equipments & instruments are expected. The modification shall be complete in
all respect after providing spool pieces, valves etc. as required so that equipment,
instruments can be mounted immediately on receipt Only those modification like
metering system which may require actual measurement or instruments
/equipments at site may be taken up after receipt of those equipments,
instruments
The Vendor shall ensure all the safety procedures are followed during the above
activity. The safety procedures to be followed are as listed elsewhere in the
specification & as per the Oil Industry norms. Vendor shall submit the fortnightly
safety report along with the work progress report.
The vendor shall train operating personnel from the location in the following
areas so as to make them fully familiar with the system and its day to day
operation: General design & system Engineering.
All related MMI & logics
Design criterion, specification, testing, functional aspects & installation
of equipment.
Operational & preventive maintenance of individual equipment

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Trouble shooting for all the individual equipment. Operational &
preventive maintenance of individual equipment & overall
system(excluding the existing System)
Trouble shooting for all the supplied equipment/instruments under this
tender.

The above training shall be conducted at the site during handing over of the
system & during the Warranty period. Two such trainings shall be held every year
in the Warranty Period. Each training module shall be of minimum 2 days.
The TT crews are also required to be familiarized with the operation of the TLF
equipments for which HPCL shall organize the program and the vendor shall
demonstrate the T/T operation.

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SCOPE OF WORK
This document serves as detailed specification for the Vendor as minimum
requirement for automating the specified operations at the Terminal. Vendor
shall execute the work on turnkey basis & shall design, supply, install, commission
& stabilize the system as per the deliverables listed in this document.
Notwithstanding the sub divisions of the tender document into several sections
and volumes, every part of each shall be deemed to be supplementary of every
other part and shall be read with and into the contract.
Vendors scope of work is divided into Four Major categories viz .Overall Scope of
Work, scope of work for the New 8 Bay Gantry & Scope of work required for
Integration with the existing System.
A. Overall Scope of Work shall include but not limited to the following:

Complete design and system engineering required for the sub-system &
its interfacing with the existing Terminal Automation System to ensure the
deliverables are achieved in line with technical & functional requirement
laid down in this tender document.

Supply, installation, testing & commissioning of all equipment/

instruments, material etc complete as stipulated in the schedule of
quantities along with its allied hardware. Balance items which are not
explicitly spelt out in the Schedule of quantities but are required for the
completeness of the work like structural steels, foundation work & other
civil works, fittings, gaskets, nut bolts, any other hardware required,
consumables etc. shall also be deemed to be included under the
respective items. No separate payment shall be made for such items.

Third party inspection of the bought out item, Trial run of the system, Site
acceptance test, system stabilization and acceptance of the complete
system.

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

etc.

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Supply, fabrication, welding/ nut bolting, erection, painting of any steel

structural required for installation of equipment, panels, junction boxes,
instruments, etc. including any other free issue items, as required & as per
site engineers instructions.

Supply, fabrication, welding/ nut bolting, erection, painting of any

structural steel required for installation of Cable Trays.

Supply & installation of all Erection materials including consumables &

non consumables as galvanized and perforated cable trays with cover,
cable racks, conduits, junction boxes, pull boxes, clamps, compression
fitting, cable glands, all instrument supports, electrodes and other
materials for completeness of erection. The erection materials shall also be
suitable to the hazardous area classification.

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

Flanges, Gaskets, jumper clip, other pipe fittings etc as required for direct
mounting or for re-routing the existing pipe in order to facilitate mounting
of the instruments & equipments including fabrication, welding, erection,
hydro testing, painting testing and commissioning. All these pipes &
fittings shall be part of the respective instruments, equipment and shall
not be paid separately.

Construction of Cable trench in soft soil, hard soil, rocky strata, RCC etc
including supply & laying of NP 2 Hume pipes below all road crossing, GI
conduit inside tank farm, as required

The spare available in the existing cables, JBs & other hardware can be
used. Any additional cable, JBs & hardware required for the new
equipment shall be supplied by the Vendor

Supply, Fabrication and installation of sunshields 18 gauge GI Sheet/

aluminum canopy for field mounted equipments, instruments such as
pressure transmitters, density meters etc. Dimension of such canopy shall
be such on all sides of the equipment adequately.

Any modification required in the existing pipeline, loading platform,

loading arms for mounting of instruments & equipments like Metering
system, Header line equipments etc. inclusive of supply of pipes, fittings,

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valves etc. In case it is not possible to modify 3/ 1 existing pipeline,
Vendor shall fabricate, erect, lay new 3/1 pipeline including supply of
pipes, fittings, valves etc & painting from existing tapping onwards at the
Gantry. The limit of modification/laying of new 3/ 1 pipeline for
Metering system shall start downstream from the 3 / 1 tapping
provided on the header line inside the Gantry. The vendor scope shall also
include draining & collecting the oil safely from the pipeline, flushing,
degassing, hydro-testing, painting etc. All these modification job,
dismantling, re-installation etc. including supply of pipes, fittings,
consumable, hardware material etc. shall be part of respective instruments
& equipment. No separate payment shall be made for these items.

Submission of all data sheets along with OEMs confirmation on Product

life cycle, his support for Backup engineering & spares

Sealing of cables / tube entries into the control room after laying and
testing of all tubes, cables etc.,

Preparation & submission of all the required Documents including asbuilt drawings, documents as per the execution of work at site and
submission to HPCL

Providing training to HPCL operation team and T/T Crew member as per
the scope defined in the tender,

Execution of Warranty, Comprehensive Annual Maintenance Contract, etc.

Supply of special tools, test equipments, consumables required for

installation, testing, calibration and commissioning of the system. All
commissioning and start-up spares required up to commissioning, system
acceptance and handing over of the system to the HPCL shall be in the
vendors scope.

Certification from the OEM for correct installation & its terminations, if
applicable, at each site for all of the following equipment, instruments
o Metering System
o DCV

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o Loading Arm
o Densitometer
o BAE
o VFD
o Batch Controller

Proper installation and alignment of line / vessels / equipment mounted

instruments like valve, PD meters, etc.

Drilling holes on all panels, power distribution panel, control panels, etc.
for cables / glands.

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

mentioned in this document or in the Schedule of Quantity/ price bid but
deemed necessary for the successful operation of the system complete in
all respects, shall be in vendors scope.

The functional & operational requirements as specified in this tender

might undergo revisions as per the location requirement during detail
design engineering, functional design specification or during execution.
The vendor must ensure that all these changes are incorporated &
demonstrated during Site Acceptance Test.

All Civil works required for execution of TAS including supply of all materials
required like foundation for mounting of instruments and equipment
supplied by Vendor and those given as free issue items, Road cutting , laying
of Hume pipes, re-asphalting the roads, wherever required etc.

All mechanical, electrical jobs required for TAS shall be in Vendors scope.

Calibration & Verification of all equipments & instruments

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

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

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the Vendors scope.

All documentations, drawings & test procedure

Construction of temporary Storage Shed for storing the all the equipment,
material, instruments etc & dismantling the same after completion of work.

Third Party Inspection of the instruments, equipments & materials as per the
approved QAP.

All road permits from Sales Tax authorities for importing/movement of all
these equipment, instruments, material.

The vendor shall be fully responsible for proper selection of equipments,

engineering, performance and successful operation of the complete
system including all bought out equipment, subsystems supplied by them
when integrated with the overall Automation System meeting the
functional requirements.

Vendor shall offer the services of the competent installation team which
would install the equipment / instruments, lay the interconnecting cabling,
check out, testing and commissioning the system.

All technical personnel assigned to the site by the Vendor shall be fully
conversant with the supplied system and software package, and shall have
both hardware and software capability to bring the system on line quickly
and efficiently with a minimum interference with other concurrent
construction and commissioning activities.

Strict adherence to HPCLs Safety, Health & Environment policy

B. Scope of Work in the New 8 Bay Gantry & existing Gantry shall include but
not limited to the following:

Supply, installation, testing & commissioning of the Electronic Metering

System, RIT, Card Reader, earthing relay, RTD, Loading arms, JBs, Cables,
all allied hardware, instruments equipment etc complete required for
Gantry Automation

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Supply, installation, testing & commissioning of Online Densitometer on

the product header line.

The existing header line of the existing gantry (HSD-10, MS & SKO-6) will
be dismantled by HPCL & new line of size HSD-14, MS-10 & SKO-8 will
be laid by HPCL independently for both new & existing Gantry. It is
tentatively planned to use existing 10 HSD BAE for new 10 MS line,
existing 6 SKO BAE for new 8 SKO & existing 6 MS for new Ethanol line
along with other header line equipment like PT, DT, TRV etc. The
dismantling of the header line equipment & re-installation on the new
header line will be in the scope of the vendor along with required fittings
like bends, flanges, expander reducer etc, gaskets, nut-bolts etc complete
required for successful erection of the equipment. Foundation for
equipment as per the requirement shall be in the scope of Vendor. New
Triple offset Butterfly valve (TOBV) with electric actuator shall be supplied
& installed with the existing BAE & the same shall be part of re-installation
item. TRV shall be provided on the BAE & on the downstream of TOBV.
TRVs shall be connected to the U/G Tank through 1 line or shall be
connected to the unloading line, if available, with NRV or shall be
connected at the pump house on the suction line with NRV. All
modification in the pipeline as per the requirement including supply of all
required hardware, fittings like valves, expander, reducer, flanges etc &
pipes.

Rerouting of cables, JBs, providing additional cables, cable tray etc for
reinstallation of header line equipment. This will be part of cable item.

Rerouting & realignment of existing SS additive line over the proposed

trestle up to the existing Gantry along with supply of required SS Pipe,
bends fittings, gasket nut bolts etc. No separate payment will be made for
this item

Supply & installation of new BAE along with TOBV, DT, PT, orifice plate etc
on the header line including modification in the pipeline required for
installation of these equipments. Supply of all required hardware, pipes,
fittings like valves, flanges, bends etc.

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

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

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

As the pipeline is being laid new, the layout shall be made to facilitate
installation of TAS equipment. However any further modification required
in the existing pipeline from the existing tapping onwards available at the
Gantry for both Main product & secondary product to suit mounting of
Automation equipment. Supply if pipes, fittings, gaskets, nut bolts & all
allied hardware etc shall be included in the scope of Vendors job.

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

included in the scope of work.

C. Integration with the existing Terminal Automation System : The existing System
is supplied & maintained by M/s Advanced Systek Pvt Ltd, Vadodara. Vendor
shall get the access authority required for modification/ up-gradation of the
existing TAS (hardware and software) from M/s Advanced Systek Pvt Ltd,
Vadodara. Vendor to submit the same to HPCL in un-priced bid along with
undertaking from TAS integrator regarding non- dilution of warranty of
existing TAS system. Scope of Work for integration with the existing TAS
shall include but not limited to the following:
o Modification, up-gradation, additional graphics as required in the existing
TAS software to seamlessly integrate the new system.
o Modification/ up-gradation of the existing equipment/ instruments,
material or any hardware including all supplies as required for seamlessly
interfacing with the existing Terminal Automation System to meet the
specified technical & functional requirement.
o Integration of header line TOBV to the existing TAS including modification
in the logic & allied graphics
o The MMI/ GUI for all the new items, equipment, instruments shall be same
as the existing one.

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o All the existing reports shall be modified to include the reports required
for the new equipment, instruments & shall be available to the user in a
combined format.
o All alarm, events etc available in the existing system shall be extended for
the new system.
o Any change in the existing TAS logic due to inclusion on new Gantry like
Bay allocation logic, EDU logic etc
o The Spare DI, DO, AI, AO available in the existing PLC may be used. Any
additional I/Os required for integration shall be supplied along with its
allied hardware. Change in ladder logic shall also be incorporated to suit
the requirement of the new equipment/ instruments.
o The spares available in the existing networking component like Terminal
Server etc may be used. In case the same is not sufficient, new networking
components in same configuration along with all its allied hardware shall
be supplied, installed, commissioned integrated by the Vendor
o All the newly supplied equipment/ instruments shall be powered through
the existing parallel redundant UPS. In case the existing UPS capacity is not
sufficient to power up the new equipment/ instruments then same
specification UPS of suitable capacity shall be supplied by the Vendor to
power up the new equipment/ instruments at no extra cost. Any cabling,
hardware etc required powering up the new equipment shall be included
in the cabling item & will not be paid separately.
o Modification/ Up-gradation of the existing Power Distribution panel shall
or alternatively supply of New MCB panel for supply of Power to the new
equipment/instruments. Individual MCB shall be provided for each parent
equipment & instrument so that the same can be powered off as & when
required for maintenance purpose.
o Supply, laying, testing & termination of all additional Power, Control,
Signal cables & all other type of special/ regular, cables required for
modification & integration with the existing TAS.
o The existing Product pumps are either controlled though Motor Control
Center (MCC) or through Variable Frequency Drive (VFD) or combination
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of MCC & VFD. These are currently integrated with the TAS such that the
pumps are started based on the Pump demand & are run based on the
pressure on the header line. Because of new Gantry, the existing pumps
are being upgraded to higher capacity pumps by HPCL along with new
VFDs which are part of this tender. These new Pumps & VFD shall be
integrated with the existing TAS by the Vendor so that the new as well as
existing Gantry comes in the purview of the Pump automation & the
pumps are operated automatically based on the pump demand. HPCL
scope will be limited to providing the Pumps & MCC in working condition.
Any changes required in the ladder logic or TAS software shall be
developed & incorporated to complete the VFD Interface with the existing
TAS. All software, hardware etc. required for VFD interfacing with the
existing TAS including development of graphics, modification in the logic
will be in Vendors scope. Existing cables hardware etc available at site may
be utilized, if suitable.
o Modification in the existing Control Room Cable Trench, if required.
o Any licenses required for due to up-gradation/ modification in the existing
system shall be provided by the Vendor
o All items required for integration, though not specifically mentioned
above, of the new equipment/ instruments are deemed to be included
under integration item only unless otherwise specified.

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HPCLs SCOPE OF WORKS.

HPCL shall provide the following to the successful vendor:

o Gantry Structure for installation of metering system
o Existing Terminal Automation System in proper working condition.
o Cable trenches, Hume pipes if available & having sufficient space
o Cabling from Pumps to the MCC.
o All free issue items in standalone working condition.

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DESIGN CRITERIA
Vendor shall note the following minimum requirement for designing the facilities.
These shall be read in conjunction with the function & technical requirements as
specified elsewhere in this document
The system is required to be designed for following broad parameters:
Maximum temperature

55 Degree centigrade.

Minimum temperature

0 Degree centigrade

Maximum Relative humidity

95 %.

Petroleum products to be :
loaded
Products Characteristics

MS & HSD
As given below

Flow rate

Normal flow rate 150 to 1200 LPM at each

Loading point. Maximum Header Flow Rate
will be when all the pumps for that particular
product are operating & minimum Header
flow rate when the smallest capacity pump
for that particular product is operating.

Working pressure

1 Kg/ Sq cm to 10 Kg/ Sq Cm

Design pressure

15 Kg./Sq.Cm

PRODUCT CHARACTERSTICS
PARAMETERS
MS
Specific Gravity
0.7-0.75

SKO
0.75-0.8

HSD
0.8-0.9

Viscosity @38Deg C

1.2CST

2.54-4.0 CST

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1.1CST

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SYSTEM RESPONSE TIME: Vendor shall design the System so as to have the
following minimum response time.
ACTIVITY
Time for transferring of change of status of equipment
and alarms of the entire terminal
Time for updating of any hardware analogue variable
Remote command from Operator station to action has
taken place via hardware I/O
For BATCH Controller and RIT communication with LRC :
Time taken between card flashing & corresponding :
batch controller message appearance
Other system responses required for driver interaction :
such as card validation, RIT lamp sequences, down
loading of data etc.

28 | 2 3 8

MAX. RESPONSE
TIME
:

5 Sec

:
:

2 sec
2 Sec
2 Sec
4 Sec
4 Sec

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APPLICAPABLE CODES & STANDARDS
The components of instrumentation and control system shall be designed,
manufactured, assembled and tested in accordance with the latest standards of
the Standards Institution, Instrument Society of America, Institute of Electrical
Engineers and Manufacturer's association of the country where they are
manufactured / country of principals. They shall also confirm to the relevant
latest standards of the Bureau of Indian Standards (BIS) wherever available, so
that specific aspects under Indian conditions are taken care of.
The equipment shall also conform to the latest Indian Electricity Rules, OISD,
PESO & petroleum rules as regards safety, earthing and other essential
provisions specified there in for the installation and operation of electrical plants.
The equipment in the hazardous area shall have CMRI, CCOE approvals. OEM
shall have BIS approval.

All painting shall be done in accordance with the General Specification for
Painting.

All equipment shall comply with the statutory requirements of the Government
of India and the State Government of respective states.

The Vendor shall execute the job to comply with the requirements of the
relevant regulations or acts in force in the area together with design
specifications with respect to:

Indian Electricity rule

Indian Factories act

Regulations laid down by chief electrical inspector

Regulations laid down by Factory Inspector of state Indian Standard

Specifications

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Oil Industries safety directorate norms.

International Organization of Legal Metrology.

Regulations relevant to explosion hazardous areas

Petroleum & Explosive Safety Organisation norms & regulations

The equipment supplied shall be designed in accordance with the requirement of

all internationally &locally applicable standards/specifications listed below.

American National Standards Institute (ANSI)

American Society for Testing and Materials (ASTM)

National Electrical Manufacturers Association (NEMA)

American Society of Mechanical Engineers (ASME)

American Petroleum Institute (API)

Institute of Electrical electronic Engineers (IEEE)

National Fire Protection Agency (NFPA)

International Electro-technical Commission (IEC)

International Standard Organisation (ISO)

Open Software Foundation (OSF)

Bureau of Indian Standards (BIS)

The following codes as a minimum shall be applicable in designing the system.

These codes (Latest edition) shall be produced as & when required by HPCL/
PMC for checking the system
Code / Standard
AMSE B1.20.1
AMSE B16.5
AMSE B16.20
ASME SEC VIII
ANSI/ISA 575-01
30 | 2 3 8

Description
Pipe thread
Steel Pipe flanges and flanged fittings
Ring-Joint gaskets and grooves for steel flanges
Boiler & pressure vessel code rules.
Control valve sizing , capacity test procedures, face to face

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dimensions, leakage
RP 520
Fire sizing of safety and control valve
RP 598
Control valve leakage
OIML standard R (Measuring systems for liquids other than water)
117
ISA RP SS-1
Instrument Society of America standard and codes
S 62-01, S82-02
S8-03, S18.1
IEC
801/EN Electromagnetic compatibility
50081/82
IEC 79.10/BS 4683/ Hazardous area classification
IS 2148
IEC-529/IS 2147/
For execution of Inst. Enclosures
NEMA
OISD
For storage, handling and safety systems and
recommendations transportation
API MP MS Ch 21
Flow measurement using Electronic Metering System
ISO/TC28/Section
Terms relating to calculation of oil quantity
3
ISO 4266
Petroleum and liquid petroleum products Measurement
of level and temperature in storage tanks by automatic
methods.
OIML R85
Automatic level gauges for measuring the level of liquid in
fixed storage tanks.
IS 2801
PD meter Accuracy
BASEEFA/PTB/KEM Statutory standards
A/FM/ATEX/ TUV/
PESO/CMRS/ IBR/
RDSO/W&M
BS 5308 Part-I
Instrumentation Cable
ISA S5.1
Instrument Symbol & Identification
ISA- S 5.2
Graphical symbol for Process Operators
IS 2148
Flame proof , enclosure for electrical apparatus
IS 3043
Cod of Practice for Earthing

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DESIGN CRITERIA FOR TANK TRUCK LOADING FACILITIES

Tank Trucks are loaded on a volumetric basis in the filling Gantry. New 8 Bay
Gantry is constructed to load MS & HSD at each bay which shall be filled
simultaneously, if required, through two different loading arms. Each loading
Point shall be capable of filling multiple variant of the same product
depending on the infrastructure available.

Each loading point shall be provided with a 3 Positive displacement meter,

dedicated strainer cum air eliminator and digital control valve. In case of MS,
additional 1 Positive displacement meter, dedicated strainer cum air
eliminator and digital control valve shall be provided for Ethanol blending. All
variants of particular product shall be handled by same loading arm. Same
Tank truck may have different variant of the same product loaded into
different compartment. The variants of the particular products could be any of
the following:
o Base product
o Base product with blending.
o Base product with one additive.
o Base product with Two additives
o Base product with blending and one additive
o Base product with blending and two additives.

Vendor is required to specify the total pressure drop across complete

metering assembly. Maximum allowable pressure drop shall be limited to 1.3
kg/cm2 across metering; strainer, air separator cum eliminator, PD Meter &

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DCV. The pressure drop will be required to be demonstrated during SAT.
Necessary arrangement on the metering assembly/ piping to be provided by
the vendor. After successful demonstration of the pressure drop, the same to
be plugged.

Each loading points shall be provided the Batch Controller as per the technical
specification. This Batch Controller shall control the digital control valves of
the base products, secondary product being used for blending and the
additives. These loading points shall be operated through batch controller as
per the batch downloaded from LRCS. The Batch Controller shall send the
Pump demand to the existing PLC to start/ stop the pumps ( Main Product,
Secondary Product, Additive as the case may be) as per the requirement

RTD shall be provided at each loading point .

Each loading point shall be provided with a Remote interaction terminal (RIT).
Each RIT will have emergency stop push button to shut down filling operation
in case of emergency.

Intrinsically safe proximity card reader shall be provided at each bay

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

Each product pipeline entering into TLF shall be provided with a densitometer
with Orifice plate arrangement for measuring ambient & standard density of
product. Density for the blended product shall be calculated by the
application software based on the density input of individual product as the
blending is done at point. The existing software shall be modified to monitor
& record density for each truck compartment and communicate it to ERP for
printing on the invoice. Orifice plate shall be designed to ensure that the
product flow through the densitometer all the time during loading of that
particular product. In case the product is not flowing through densitometers
during loading of that particular product then Error message shall be
displayed instead of last healthy reading

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

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

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transmitted to PLC / LRC. If pressure in the delivery pipeline header exceeds
specified value or reduced below specified value, alarm should be transmitted
to PLC panel from pressure transmitter for stopping the Batch Controller or
starting/ stopping the pump.

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

Description

1.0 GENERAL
1.1 Vendor engineering and service
personnel organization chart including
set up for this project.
1.2 Training facilities at work
1.3 Descriptive catalogue / literature
1.4 Functional Design Specification
1.5 Procedure for dismantling existing
instruments, equipments, cabling,
structure etc. wherever applicable
1.6 Operational Philosophy
1.7 Progress report (Fortnightly)
1.8 Safety Report ( Fortnightly)
1.9 Document Control Sheet (Fortnightly)
1.10 Payment Control Sheet (Monthly)
2.0 ENGINEERING DOCUMENTS
2.1 System Architecture
2.2 Detailed list of component
2.3 Individual data sheet
2.4 Power Requirement KVA
2.5 Heat dissipation Kcal /H
2.6 Individual G.A.Drawing
a)
Flow metering system
b)
Densitometer, PT
2.7
a.
b.
2.8

SYSTEM CABINETS
Arrangement of modules
Structure, dimension, construction, etc.
AUXILIARY CABINETS

35 | 2 3 8

For
Information
Approval

Final Docu mentation

I
I
A
A

A
I
I
I
A
A
A
A
I
A

F
F
F
F
F
F

I
I

F
F

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a.
b.
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
2.17
2.18
2.19
2.20
3.0
3.1

3.2
3.3
3.4

4.0
4.1
4.2
4.4
4.5
4.6
4.7

Arrangement of modules
Structure, dimension, construction etc.
Power supply distribution diagram
Cable layout
System drawing (loop
diagrams,reports)
Wiring diagram
Terminal strip diagram
Hardware Design Module
Software Design Manual
Interfacing scheme
MIS Formats
Interconnection diagram
Earthing System
As built drawing
CERTIFICATES
Authority approval for
Ex-Proof, IS, Weather Proof ( shall also
be submitted along with Data sheets
for approval)
Vendors guarantee /warranty
Original Software Licenses
Certification of Installation for
Metering system, Densitometer,
Loading Arms, by the respective OEM
INSPECTION AND TEST
Inspection and test report from
Vendors quality control department
Imported shipping documents along
with test certificate
Factory acceptance tests procedure for
Batch accuracy tests
Site Acceptance Test procedure
Pre-Power Up Report
Pre-commissioning Test & procedure

36 | 2 3 8

A
I
A
A
A

F
F
F
F
F

A
A
A
A
A
A
I
A

F
F

F
F
F
F

F
F
F

F
F
A
A
A
A

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5.0 MANUALS (BOTH FOR VENDORS &
SUB VENDORS SUPPLY)
5.1 Vendors & Sub-vendors test
F
Procedure
5.2 Installation manual
F
5.3 Operating manual
F
5.4 Maintenance manual
F
5.5 HOTO Report covering all the details
A
F
of the Project( to be submitted in both
hard form & CD)
7.0 QULAITY ASSURANCE PLAN
A
F
NOTE :
a. The above documents cover the minimum requirements and shall be
supplemented with other requirements listed in the specification, if any. Any
other documents required to understand and maintain the system, as felt
necessary till handing over of the project, shall be supplied by the vendor.
b. All documents shall be supplied in English language as per following.
- Approval/ Information - 4 sets
- Final -4 sets
c. DVD 2 sets (soft copy)
d. As built drawings shall be laminated and properly bound with index sheet for
preservation and future reference.
(1) All drawing which are submitted for approval, shall be submitted on DVD as
a final document (after approval) along with HOTO Report

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TECHNICAL SPECIFICATION
TECHNICAL SPECIFICATIONS SUPPLY OF NEW INSTRUMENTS/EQUIPMENT

Technical Specifications/ information given in this section serve as the minimum

guidelines to the Bidder. The bidders are requested to visit the location, study its
requirement, design the most suitable system and shall quote accordingly.
The equipment shall be reliable and field proven, High-grade components of
proven quality having high MTBF (at least 10 years minimum ) shall be selected to
achieve the desired functions.

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TECHNICAL REQUIREMENT & SPECIFICATION FOR TANK TRUCK GANTRY
AUTOMATION:
Tank Truck Gantry Automation shall include but not limited to the following
o The Vendor shall design the flow metering system to suit different set of
process flow condition (Flow, temperature, pressure etc) such that the
combined accuracy of the flow metering system, after site calibration of
the equipments, shall be +/-0.05% of the Batch. The metering system shall
be checked with reference to the existing Calibrated Mobile Prover Tank of
capacity 2 KL
o Electronic Metering System for primary product (MS, HSD etc) shall
comprise of Batch Controller, Positive Displacement meter, Digital Control
Valve, Strainer cum Air Eliminator shall be provided. The Batch Controller
will control one Loading point & its Blending and dosing operation.
o Blending System comprising of Positive Displacement meter, Digital
Control Valve, Strainer cum Air Eliminator for blending the Secondary
Product like ethanol in the Primary Product. Rate of blending shall be User
configurable. The current rate of blending is 5% which may go up to 20%.
The System design shall cater to blending of maximum 20%
o RTD shall be provided at each loading point & its input shall be taken in
the Batch Controller.
o Remote Interaction Terminal for operation by Tank Truck Crew member.
o Earthing Relay for each Bay.
o Calibration & Weights & Measure (W&M) Stamping : The existing Mobile
Prover Tank is already calibrated & stamped by Weights & Measure
(W&M) Department. The Calibrated & W&M stamped Mobile prover tank
shall be used for calibrating the Flow metering system as per the
Calibration procedure given in this document. W&M stamping shall be
done by the Vendor for the Flow metering system used for the Main
product, Secondary product if the tapping is downstream of the flow
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metering system of the main product i.e. Ethanol Product is blended in
the main product without flowing through the main metering system. Thus
W&M Stamping may not be required for Secondary product if the tapping
is upstream of the Main metering system and if such an arrangement is
permitted/approved by statutory rules/Local W&M Department. Batch
Controllers shall also be stamped by W&M & the meter factor/K Factor
for all the Products ( Main, Secondary) shall come under W&M
configuration parameter such that these cannot be altered after providing
the W&M sealing. Stamping of these newly supplied equipments, by state
W&M Department & the entire coordination shall be in the scope of the
Vendor during execution as well as in Two year Warranty period & 5 year
Comprehensive AMC period. All liaison & incidental charges shall be borne
by the Vendor. HPCL will reimburse the statutory charges for stamping
during warranty & AMC period against submission of Original receipt in
the name of HPCL. Statutory Charges paid during project execution &
system stabilization shall not be paid separately & shall be in the scope of
Vendor In case the W&M stamping is required before the due date for
reasons not attributable to HPCL, all charges including the statutory fees
shall be paid by the Vendor. If the reasons are attributable to HPCL,
Statutory fees paid shall be reimbursed by HPCL against submission of
Original receipt in the name of HPCL.
o FRLS Cables, Double compression Cable Gland, Flameproof Junction box,
etc. from main JB to respective instrument shall be part of that equipment.
o All these Automation equipments can be mounted on the Gantry Platform
with suitable foundation/ Structural Steel support. Supply, installation &
re-routing of the 3 pipeline/ 1.5 pipeline and or laying of new 3/1.5
pipeline including all associated hardware, fittings, gaskets, jumpers
required for mounting these equipments from the header line tapping
onwards at the Gantry shall be in the scope of the Vendor. The new/
modified pipeline shall be painted as per the color coding of HPCL. All
these hardware shall be supplied as per the specification given in the
tender document.

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o All Structural Steel like angles, flats channels beams, brackets etc required
for mounting/ supporting these equipments or any existing equipments
shall be in the scope of the Vendor.

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SPECIFICATION FOR BATCH CONTROLLER FOR WHITE OIL

Make

Model No
Qty
Type

:
:
:

Service
Area Classification
Inputs (from each loading
point)

:
:
:

Outputs (to each Loading

point)

42 | 2 3 8

Vendor to Specify (from the approved

vendor list)
Vendor to Specify
Refer BOQ
Microprocessor based field mounted,
configurable, indicating, Single Channel
(One BC for each Loading Point)
For White Oil Application
Zone I, Gr II A/II B , T3
Pulse input from pulse transmitter of
main product line meter
Pulse Input from pulse transmitter of
2nd product for blending
Pulse Input from pulse transmitter of
Additive Injection 1st meter
Pulse Input from pulse transmitter of
Additive Injection 2nd meter
Start, Stop, Acknowledgement digital
input from RIT
Safety permissive/Interlock inputs like
earthing
inputs
(bonding
&
static),Loading Arm Position, overspill
Temperature input (RTD Pt-100)
Serial input
Manual Call Point
Emergency shut down
Digital control signals to solenoid
valves of set stop valve in Main
Product
Digital control signals to solenoid
valves of set stop valve in Secondary
Product
Digital control signals to 2 nos. of

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Alarms

Communication port

Power requirements
Data entry

:
:

43 | 2 3 8

additive injection system.

Pump Demand contacts for Main
Product pump, , Blending product
pump & Additive Injection pump
Digital Output to various lamps on
RIT
Trip the Pump in case of DCV
malfunction/ DCV non closure at the
configurable value above the preset
quantity. The Output to be
hardwired to the PLC.
Interlock failure
Pulse Transmitter failure
RTD Failure
Flow Rate out of limits
Unable to close valve meter
Communication failure
Mode Change from Auto to Manual
Under dosage of Additives
Over dosage of Additives
Under
blending of Secondary
Product
Over Blending of Secondary Product
Auto deletion of memory
Dual redundant RS 485 Serial link to
Terminal server
Maximum of 4 Batch controllers
shall be multi-dropped on the same
transmit & receive data lines (i.e
Single loop) and taken to the control
room.
Interface for proximity Card Reader
The baud rate for communication of
batch controller shall be capable for
transmission of min. 19200 bps
230 V AC +10% to -15%, 50Hz +/- 5%
Alpha numeric entry pad

HINDUSTAN PETROLEUM CORPORATION

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Online Self diagnostics
Memory capacity & backup

:
:

Battery

Battery Life
Meter Linearization

:
:

Scan Time
Display Type

:
:

Display Parameter (Dynamic)

Enclosure

Protection

44 | 2 3 8

Required
Non Volatile RAM capable of retaining
data. Minimum 200 transactions. All data
pertaining to One Truck load of 20 KL shall
be treated as one transaction
Internal Lithium battery / flash memory
shall be provided for data retention.
Min 8 years
Min 5 point over 10 100% flow rating of
meter by entering "K" factor of meter in
memory
Max 300 m sec
Alpha Numeric, Backlit Two Liquid Crystal
Display Non Glare / Vacuum florescent, 8
Character Numeric & 16 Character Alpha
Numeric. Visibility from at least 2 mtr.
distance
Pre Set Quantity
Loaded
Quantity
of
each
component(Main
product,
Secondary Product & Additive)
Balance Quantity
Flow Rate
Temperature
Diagnostic Alarm
Totaliser reading for Main Product,
Ethanol & Additive
Engineering Unit, Control Mode
3 LEDs for Alarm, Auto Mode and
permissive power
User selectable data display
Explosion proof to IS-2148, Gr. II A
&
II B Weather proof to IS-2147, IP-65
Radio
Frequency
Interference
Protection
Electromagnetic
Interference

HINDUSTAN PETROLEUM CORPORATION

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Approvals /Certification

Batch
Accuracy of the
Electronic Metering system
Functions

45 | 2 3 8

Protection
Electrical Transient Suppression on
all power, communication and data
input & output to provide
protection from transient over
Voltage.
PESO(CCOE) approved
Ex Proof to Zone-1, Gr II A & II B
Weather Proof to IP 65
W&M Model Approval : OIML approval as
per R 117 for Custody Transfer
Shall be 0.05% of batch over the full flow
range
Indication & Totalization
Batch Control
Display & Totalizer of Each Product
(Main Product, Secondary Product
being blended & Additives) Locally
as well as on Remote on the TAS
System
Blending of Two products ( Blending
% configurable from TAS System) at
each loading point
Additive Injection (Dosing PPM
configurable from TAS System) with
2 additives per loading point.
Meter factor linearization (min. 5
points over 10-100 % flow rate)
Dynamic flow display
Programmable ramp up/down for
multistage opening/ closure of set
stop valve
Batch summary
Executing local loading (min.200
Batch to be stored for auto retrieval
by
TAS
System
when
communication is established)

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
Automatic Flow optimization
Temperature Compensation
Trip the Pump (only particular
product)
in
case
of
DCV
malfunctions/ DCV not closing at
the preset quantity.
Stop the Loading in case of Under
dosing/over dosing of Additive and
or Ethanol Product
Stop the loading in case of Power
failure of the product pump.
Shut the DCV/Trip the Pump when
ESD is activated.
Slow opening/closing of shut off
valve
Cut Off flow through meter at Power
Failure
Local Start/Stop Operation
Manual deletion of memory shall
not be permitted. Memory shall be
auto delete.
Totalizer shall be non-resettable.
Audit Trail
The quantity to be loaded is entered in the
TDM is uploaded to LRC which in turn
upload this information to Batch controller
via RS485 link as preset quantity
Only Authorized Person shall have
the access to calibrate or alter
function of the metering system.
System shall be designed to limit
access for the purpose of altering
any input variables that may affect
the measurement.
Minimum three Layer Password
protections/hardware
protection
shall
be
available.
Separate

Security & Data Integrity

46 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
password shall be available for any
basic
database
configuration
affecting volume measurement like
setting of K factor, Separate
password shall be available for
operator for various activities like
alarm acknowledgement & other
system operation & separate
password shall be available the
other for system operation like
changing the System Mode ( Auto
to Manual or vice versa).

47 | 2 3 8

A Security code shall be used

anytime changes/edit are performed
that will alter the quantity measured
or deletion of memory
Changes to any Flow parameter shall
be captured in the Audit trail as a
part of event log in the TAS System.
Change in Pulse Security shall be
logged in the system with time,
date, unique ID & the Original and
revised pulse error defined. TAS
shall display Pulse security enabled
/disabled in the Control Room
Each time a flow parameter
constant, that affects the calculated
volume, is changed in the system
the old & new values along with the
date, time & unique ID shall be
logged
Any time memory/ data is erased it
shall be recorded along with the
date, time & unique ID shall be
logged
Non-resettable totalizer reading

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT

Keyboard Type
Keyboard Function

:
:

Key Lock
Audit Trail

:
:

Salient Features

48 | 2 3 8

shall also be captured

All such changes in Shall be
generated as exception reports.
Touch Sensitive
Configuration entry
Operator Data entry
Display Selection
Alarm Acknowledgement
Start/Stop
When in Auto mode Key Pad shall
be disabled other than Start/Stop
Button
Required ( Through Password)
Any changes affecting the Volume
reported shall be logged with Date,
time & unique ID. The Audit Trail
may consist of Single or multiple
records.
Any
Change
in
the
Meter
Factor/Kfactor shall be logged in
the TAS System
Mode Change from Auto to Manual
(either Remote or local) shall be
logged in the System.
Totalizer for each Batch Controller
shall be logged when End of Day is
run & shall be available in the report
form for reconciliation & it shall be
send to JDE.
Each batch controller should be in a
position to operate in standalone
mode.
Each batch controller should be able
to store at least 200 batches in local
mode which can be retrieved later
by the automatically by TAS System

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
along with Truck Number. Provision
shall be available in the Batch
Controller for input of Truck No &
Load No
Sequential Blending as well as inline
Blending & dosing
Meter
Factor/Kfactor shall be
available in the MMI of TAS System
Mode Change from Auto to Manual
shall be available from remote
through TAS System. Facility shall be
provided in the system for the user
to incorporate the reasons of
change in the mode. Mode Change
at local level shall be available only
when TAS is not operational/
communication failure

49 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
SPECIFICATION FOR FLOW METER (POSITIVE DISPLACEMENT METER) FOR
MAIN PRODUCT
Make
Qty
Type
Casing
Size
Service
Power Supply
Materials
Body

:
:
:
:
:
:

As per approved vendor list

Refer BOQ
Oval gears / tri-rotor design / rotary vanes
Double case
3
MS, HSD, SKO etc.
230V AC +10 % to -15%, 50 Hz +/- 5%

Rotor Elements

Wet parts
Seals
Outer Housing
End connection
Flange

:
:
:
:
:
:

Carbon Steel ASTM A 216 Gr. WCB/ IS

6240 Gr. B
Anodized aluminum/ Carbon Steel ASTM A
216 Gr. WCB
Aluminum / SS 304
Viton/Buna N
Carbon steel
3", class 150#, RF serrated ANSI B 16.5
RF Serrated ANSI B 16.5

MOC for Rotary Vane / Oval

Gear / Bi-Rotor/Tri-Rotor

Anodized Aluminum / Carbon Steel

Bearings

SS 316 / Tungsten Carbide / Ni-Resist and

Carbon (for Naptha)

Other Parameters
Minimum Design Pressure
Normal Working Pressure
Operating Temperature
Body Hydro test Pressure
Flow Range
Linearity
Repeatability
Rangebility
Mounting & Coupling

:
:
:
:
:
:
:
:
:

15 Kg/sq cm
1-10 Kg/Sq Cm
As defined in the design parameter
15Kg/ Sq cm minimum.
150 1500 LPM
0.1`% of the reading
0.02% over 10:1 flow range
100% to 10% of max. flow range
Horizontal / Vertical, Magnetic

50 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
Calibration

Direction

Meter shall be factory Calibrated & also at

the Location. Weights & Measure stamping
is a must at all Locations irrespective of the
place of manufacturing
Bidirectional. Direction of Flow shall be
clearly stamped or cast on the body

NOTE: Total pressure drop across meter assembly The strainer, Air eliminator,
PD meter, Shut off valve shall be limited to 1.3 Kg/ Sq cm under all process
conditions.

51 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT

SPECIFICATION FOR DUAL PULSE TRANSMITTER FOR MAIN PRODUCT

Make

As per approved vendor list.

Qty

Refer BOQ

Application

To convert volumetric flow to pulse

Operating Range

Upto 1500 LPM

Type

Opto- Electric, serrated disc type/ Inductive

type / Magnetic Inductor type/ Approved
OEM standard

Max Pulse frequency

Up to 2 Khz

Pulse Resolution

Min.

100

pulse

per

revolution

of

the

Calibrator output shaft for pulse security

conforming to Level A as per IP 252 / 76.
Output

Dual pulse stream to Batch Controller, each

pulse shifted by 90 deg. with each other.
Confirms to pulse security level A as per IP252/76, ISO 6551 and API chapter 5

Materials

Body

Aluminum Alloy LM 25 TF

Operating torque

To suit the P.D meter

Mounting

On the O/P shaft of the PD meter

Power Supply

From the Batch Controller

Shaft Rotation

Bi-directional

Pulse security

52 | 2 3 8

To be provided through verification pulse

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
:

generated through additional grid element.

Supply current

MFR STD

Allowable vibration

1 Gs at 10-150 Hz,

Supply Voltage

8-24V DC

Power Supply

From Batch Controller

Enclosure

Intrinsic Safe or Ex-proof to Zone 1 , T3 Gas

Group IIA / IIB as per IS 2148
Weather proof to IP 65 as per IS 2147

Signal Transmission

20M From counting instrument

Housing

Explosion Proof

Approval

PESO(CCOE), CMRI, CENELEC

Cable Entry

1/2" NPT (F) or as per design

53 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT

SPECIFICATION FOR AIR ELIMINATOR CUM STRAINER (FOR POSITIVE

DISPLACEMENT METER OF MAIN PRODUCT)
Make

As per approved vendor list

Qty

Refer BOQ

Type

Wire Mesh Basket type

Size

Mounting

Pipeline

Service

White Oil

Design

As per ASME Section VIII

Design Pressure

15 Kg/cm2

Working Pressure

1.5 to 10 Kg /cm2

Materials

Mesh

60 mesh of SS 304 for White Oil

Body

Carbon steel as per ASTM A 216 Gr. WCB

Seal

Viton/Buna N

Flange

Carbon Steel

Float

Float actuated pilot operated

Float & Reed Material

Stainless Steel 304

Basket

CS Reinforcement sheet / SS 304

Differential Pressure Gauge

Required with Tapping

Air Release Body

Carbon steel to ASTM A 216 Gr. WCB

Drain Connection

NPT, 150# Flange end with CS Drain

Valve

54 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
Vent

End Connection

Inlet

3" ANSI 150 Flanged :RF serrated

Outlet

3" ANSI 150# Flanged, RF serrated`

Reed switch

55 | 2 3 8

NPT (F)

Required. It shall be capable of giving

output signal so that the batch can be
suspended. In case of differential
pressure across the suction side and
discharge side of SAE is greater than 1
kg/cm2 then the loading for that point
shall be suspended with an alarm in TAS
software as well as at batch controller.
Alarm description shall be termed as
Strainer choked.

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
SPECIFICATION FOR DIFFERNTIAL PRESSURE GAUGE ACROSS STRATINER
FOR MAIN PRODUCT
Type

Direct

Make Model No

:
:

Model No

Vendor to specify

Mounting

Local across strainer

Dial Size

6(150mm)
graduation

Material

Cast aluminum

Bezel ring

Press fit

Window Material

Toughened glass

Enclosure

Element material & Type

Weatherproof to IP 65
SS 316, diaphragm /Piston

Socket material

SS 316

Zero Adjustment

Micrometer pointers

Connection

/ NPT (M), 2 nos.

Connection location

Bottom

Accuracy

2% of FSD

Over range protection

As per IS 3624

Blow out protection

As per IS 3624

Range

0-2 Kg / Sq.Cm

Maximum Static Pressure

15 Kg / Sq.Cm

Accessories

3 way manifold- SS 304

56 | 2 3 8

As per approved Vendor list

White

Color

with

black

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT

SPECIFICATION FOR DIGITAL CONTROL VALVE FOR MAIN PRODUCT

Make
Model
Type

:
:
:

Size
Type of Body
Qty
Service
Flow Range

:
:
:
:
:

Max. working pressure

Test Pressure

:
:

Operating Pressure
Mounting
End connection

:
:
:

Leakage Class
Failure Position
Materials
Valve body
Valve cover
Spring
Internal parts
Needle Valve/ Ball Valve

:
:

57 | 2 3 8

:
:
:
:
:

As per approved vendor list

Vendor to Specify
Diaphragm type digital control with
linear characteristics , Electrically
actuated hydraulically operated.
Alternatively piston type DCV is also
acceptable.
3 (80 mm)
Globe
Refer BOQ
White Oil
1500 LPM (Maximum) ,200-1200 LPM
(Normal Flow Range )
15 Kg/sq. cm
1.5 times the Design pressure i.e. 22.5
Kg/Sq cm
1.0Kg/Sq cm -4 Kg Sq cm
Horizontal, Downstream of PD meter
3" ANSI 150# Flanged, RF serrated for
Main Product & 1.5 ANSI 150#
Flanged, RF serrated for secondary
product
Class VI
Close
Carbon steel A 216 WCB / SS 304
Cast steel A 216 WCB
Stainless steel AISI 304
Stainless steel AISI 304 / CS
SS 316 body & needle/ball, tubed
through compression type fittings, 2
Nos ( One at upstream & one at
downstream)

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
Tubing & Pipe
Diaphragm material
Trim
Seals
Body type
Solenoid Valve
Type

:
:
:
:
:

SS 316
Viton/ NBR-LS
SS 316
Viton
Inline

SOV Make
Body
Trim
Mounting
Max. working pressure
Test Pressure

:
:
:
:
:
:

Elec. Connection
Limit switches

:
:

Enclosure

Power Supply
Coil Insulation
Approval/Certification for
Digital Control Valve
Features Required

:
:
:

1 No. Normally Open (NO) &

1 No. Normally Close (NC)
ASCO
Stainless Steel
SS 304
On Digital Control valve
15 Kg/sq. cm
1.5 times the Design pressure i.e. 22.5
Kg/Sq cm
Min 1/4" NPT (F)
Single for closed position indication,
explosion proof, class I, Gr IIA & IIB
Explosion proof class 1, Group II A &II B,
T3 & Weather proof to IP 65
230V +10% to -15% AC , 50 Hz +/-5%
F Type
CCOE

58 | 2 3 8

Fail Safe
Bubble Tight Shut off
No reverse flow
Valve close on Power Failure
Adjustable rate of opening &
closing of Valve.
Low Pressure Drop

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT

SPECIFICATION

FOR

POSITIVE

DISPLACEMENT

FLOW

METER

FOR

SECONDARY PRODUCT ( Max Blending 20% V/V) :

One Set of Flow metering System (PD Meter, Strainer Cum Air Eliminator, Set
Stop Valve, Pulsar) is required for each MS Point for Blending of Ethanol. The Size
of metering system shall be min. 1 1/2 inch. The actual size may vary based on the
design & detailed Engineering by the Vendor. The Current Blending of Ethanol in
MS is 5% v/v. However, it may go up to maximum 20% v/v in future stage wise.
Facility shall be provided in the TAS Software (password protected) with the User
for changing the blending proportion. Change in the blending proportion shall
be logged with time, Date, Unique ID, previous blend ratio & the new blend ratio.
The specification for Flow Metering System (PD Meter, Strainer Cum Air
Eliminator, Set Stop Valve, Pulsar) required for Ethanol will be same, except the
size which shall be min 1 1/2 inch, as for the main product unless otherwise
specified
Flow meter type
:
PD meter, Double case, SS 316 wetted
parts
Size

Suitable for tapping of 1 , expander/

reducer suitable for site Installation shall be
in the Vendors scope.

End Connection

ANSI class 150#, RF serrated ANSI B 16.5

Service

Ethanol

Flow rate

40 LPM to 400 LPM

Body Material

Carbon steel A 216 WCB

Rotor Material

Stainless Steel 316

Accuracy

+/-0.5%

Linearity

0.15%

Repeatability

0.05%

59 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
Seals

Viton/Buna N

Integral type

Pulse transmitter

Dual pulse

NRV

Lift Check Valve

Strainer

cum

Air

Eliminator

NOTE: Batch Controller shall control the Blending proportion based on recipe &
product code

60 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
Specification for Digital Control Valve for Ethanol
Make
Model
Type

:
:
:

Size
Type of Body
Qty
Service
Flow Range
Minimum Design pressure
Test Pressure

:
:
:
:
:
:
:

Operating Pressure
Mounting
End connection
Leakage Class
Failure Position
Materials
Valve body
Valve cover
Spring
Tubing & pipe
Interconnecting Tube
Fitting
Trim
All Internal Parts
Needle Valve/ Ball Valve

:
:
:
:
:

As per approved vendor list

Vendor to Specify
Diaphragm type digital control with linear
characteristics , Electrically actuated
hydraulically operated.
Min 1.5 and to suit the design
Globe
Refer BOQ
Ethanol
40-400 LPM (Normal Flow Range )
15 Kg/sq. cm
1.5 times the Design pressure i.e. 22.5 Kg/Sq
cm
2 Kg/Sq cm -10 Kg Sq cm
Horizontal, Downstream of PD meter
1.5 ANSI B 16.5, 150# ASTM A 150
Class VI
Close

:
:
:
:
:

Carbon steel A 216 WCB

Carbon steel A 216 WCB
Stainless steel AISI 304
Stainless steel AISI 304
Stainless steel AISI 304

:
:
:

Diaphragm material
Seals
Solenoid Valve
Type

:
:

Stainless steel AISI 304

Stainless steel AISI 304
1 No. Stainless steel AISI 304 , tubed through
compression type fittings,
Viton/ Buna N
Viton/ Buna N

61 | 2 3 8

1 No. Normally Open (NO) &

1 No. Normally Close (NC)

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
SOV Make
Body
Trim
Mounting
Max. working pressure
Test Pressure

:
:
:
:
:
:

Elec. Connection
Limit switches

:
:

Viscosity
Enclosure

:
:

Power Supply
Coil Insulation
Approval/Certification
Features Required

:
:
:
:

62 | 2 3 8

As per approved make

Stainless Steel
SS 304
On Digital Control valve
15 Kg/sq. cm
1.5 times the Design pressure i.e. 22.5 Kg/Sq
cm
Min 1/4" NPT (F)
Single for closed position indication,
explosion proof, class I, Gr IIA & IIB
Explosion proof class 1, Group II A &II B, T3 &
Weather proof to IP 65
230V +10% to -15% AC , 50 Hz +/-5%
F Type
PESO (CCOE)
Fail Safe
Bubble Tight Shut off
No reverse flow
Valve close on Power Failure
Adjustable rate of opening & closing of
Valve.
Low Pressure Drop

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT

SPECIFICATION FOR DIFFERENTIAL PRESSURE GAUGE (Secondary Product)

Make

As per approved vendor list

Qty

Refer BOQ

Mounting

Across Strainer

Dial size

100 mm

Dial

Aluminum

Colour

White dial with black engraving

Bezel ring

Press fit

Unit of measurement

kg/cm2

Pressure element

Diaphragm, SS, Piston

Accuracy

2 % of FSD

Zero adjustment

Through micrometer pointer

Over range protection

125 % of FSD

Process connection

Through 1/2" NPT (M)

Service

For Ethanol Strainer in TLF Gantry

Range

5000mm water column adjustable throughout

the range

Materials
Case

Die cast Aluminum

Window

Toughened glass

Movement

SS 316

Element

SS 316

Socket

SS 316

63 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
Standard

64 | 2 3 8

IS 3624

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT

SPECIFICATION FOR BASKET TYPE STRAINER CUM AIR ELIMINATOR

(Ethanol Service)
Make

As per approved vendor list

Model No

Vendor to specify

Qty

Refer BOQ

Mounting

In line upstream of 1 PD meter

Design Code

ASME Sec VIII

End Connection

Flanged, ANSI 150# RF

Mesh Size

60

Mesh Material

SS 316

Seals/ O-Ring

Viton

Flange Material

ASTM A 105

Flow Rate

40 LPM to 400 LPM

Pressure

1.5 Kg/ Sq cm 10 Kg/ Sq cm

Vent

Required

65 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
SPECIFICATION FOR CHECK VALVE FOR ETHANOL SERVICE BEFORE
TAPPING
Make

As per approved vendor list

Quantity

Ref BOQ

Type

Lift Check Valve

Rating

ANSI Class 800

Service

ETHANOL

Size

1/2 to 1

Cover

Bolted

End Connection

Socket Weld ended

Applicable Codes

BS : 5352, ANSI B 16.34,

Testing Code

BS : 6755 Part I

Hydrostatic Test Pr. : Shell /

3000 / 2200 psi

General

Seat
Material

Body / cover

ASTM A 105

Disc

13% Cr. SS, Stellited

Seat ring

13% Cr. SS, Stellited

Fasteners

ASTM A193 Gr. B7/A194 Gr. 2H

66 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT

RESISTANCE TEMPERATURE SENSOR

Type

Inserts
Insulation Resistance
Nipple Union
Head and Cover
Cable Entry
Enclosure class
Area Classification
Terminal block

PT 100, 3 wire Simplex element as per DIN

43760 standards. Input shall be taken to the
Batch Controller

Mineral insulated, sheath 316 SS, OD 6 mm

More than 500 at 500 VDC

316 SS

Die Cast Aluminum with SS chain

NPT

IP 65

Zone II, Gr. IIA / IIB T3

ceramic with spring loaded screw

Bar stock drilled 316 SS, Tapered

16mm

STS (Design shall be in such a way that 2/3rd of

product pipe I.D. to be immersed)

21mm

At 45 degree w.r.t. Product pipe of horizontal

THERMO WELL
Type
Hot End O,D
Immersion length
Cold End O.D
Tapping

67 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
(X)-Axis
:

1 ANSI 150# RF 125 AARH Flanged

NPT (F)

To suit element

1.5 max operating pressure

STS

RTD Pt 100 to DIN 43760

Alphanumeric LCD Display

+/- 0.15% of Input

Threaded connection on main pipeline header

going to TLF.

4-20 mA signal proportional to temperature.

RTD linearisation, upscale or downscale for open

circuit / short circuit sensor-Smart transmitter

Circuit protected against surges, lightning,

reverse polarity, reverse insertion

Enclosure

IP-65,

Execution

Intrinsic safe with active barrier in control room

Process Connection
Instr. Connection
Bore Diameter
Hydro test
Make/Model No.
Signal Source
Local Display
Accuracy
Mounting
Output
Functions
Protection

68 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT

SPECIFICATION FOR REMOTE INTERACTION TERMINAL(RIT)

Make

As per approved vendor list

Model

To be specified by the Vendor

Qty

Refer BOQ

Enclosure

Explosion proof suitable for T3,Gas Group

II A & II B as per IS 2148 and Weather
Proof as per IP 65

Push Buttons

3 nos. for start, stop & acknowledge

Indicators

LED Cluster -3 nos ( Red, Amber & Green)

LED shall be cluster design & each LED
shall be bright so as to be clearly visible in
the Day light.
LED Cluster shall be soldered on glass,
epoxy PCB and varnished to corrosion
inhibition.
Lamp Housing & clear lens shall protrude
out of Exd housing for 270 degree viewing
angle.
NOTE: Indicator lamp combined with
Push Button is also acceptable.

Power supply

69 | 2 3 8

230 V AC + 10% to -15%, 50 Hz +/- 5%

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT

SPECIFICATION FOR EARTHING DEVICE

Make
Model
Function

:
:
:

Connection

Signal Input

Protection

Intrinsically
mounting

70 | 2 3 8

safe

Isolator :

As per approved vendor list

Vendor to Specify
Detect & Earth the tank truck.
Detect that the Crocodile Clip is
clamped on Tank truck and not on any
other Earth Structure.
Detect Resistance of the Earthpit/Grid
To detect & provide the Bonding of
Tank Truck with the loading arm
Interlock with the existing Manual
copper braided Earthing strip.
Allows loading only when both the
Device & manual copper braided Earth
strip is connected to the Tank Truck
and the Earth pit resistance is less than
2 Ohm
Earthing connection through SS/ Brass
Crocodile clamp. Length of the Flexible coil
shall be minimum 16 Ft
From earth pit/grid at loading area for
detecting the correct potential.
From Body/Brass Strip of the Tank
Truck at the bottom for detecting &
providing the Earthing
From the Body of Tank Truck at the
top/ Loading Arm for providing &
detecting the bonding
From the Manual Earth Strip to detect
the loop.
Intrinsically safe/ Explosion proof class 1,
Group II A & B, T3 & Weather proof to IP 65
In explosion proof junction box suitable for
mounting in class I div. II, Gr llA and
llB

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
Input
Control output

:
:

Power supply

Input
Indicators

:
:

Enclosure

Area Classification
Approval/ Certification

:
:

To Batch Controller
2 Nos of Potential free contact (SPDT) rated
for 110 V DC 0.5 amp/ 230 V AC 1.0 Amp
24 - 35 VDC, supplied from batch controller
or 230VAC +/- 10%, 50Hz, 5%
To Batch Controller
Red vehicle not earthed
Green - vehicle earthed
Explosion Proof & weather proof to IP 65,
NEMA 4/IS 2147 & NEMA 7/IS 2148
IEC Zone 1 , Gr II A, II B T3
PESO (CCOE)

Functional requirement for Earthing and bonding interlock

Tank truck loading shall be interlocked with earthing and bonding . The earthing
relay shall have two probes in minimum. One probe shall be used for earthing of
TT and the other probe shall be used for bonding of TT. The earthing relay shall
be combined unit for earthing and bonding. Apart from the earthing and
bonding clamps of new earthing relay, the existing earthing wire needs to be
integrated. The system shall also detect that the clamps are attached to tank
truck earth only and shall not give green indication if they are attached to
existing MS structures like catwalk, gratings, gantry structure etc. The system shall
also monitor at each loading point level the value of resistance of each earth
pit/earthing grid to which the earthing relay is connected. The system shall be
designed such that when all the three clamps ( one clamp for earthing of new
earthing relay, one clamp for bonding of new earthing relay, one clamp of
existing earthing) are put and all are found to be healthy and resistance of
earthing grid is less than 1 ohm ( incase the existing earth pits are not in grid
then individual earth pit reading to be checked and shall not exceed 2 ohm ),
then loading of particular compartment shall start.
In case of failure of any of the contacts or the earthing resistance going beyond
the cut off value ,then loading shall stop immediately
NOTE : A 16 sq mm cross-section braided copper strip of 3 m length shall be
provided with each earthing relay.

71 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

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SPECIFICATION FOR PROXIMITY CARD READER

Make

As per approved vendor list

Model No

Vendor to specify

Qty

Refer BOQ

Type

Proximity type

Operation

Access control

Sensing Distance

25 mm

Enclosure

Intrinsically safe/ Explosion proof class 1,

Group II A & B, T3 & Weather proof to IP
65/NEMA 4

Power

230 V AC + 10% to -15%, 50 Hz +/-5%

Connections

With Terminal Server in the Control Room

Card media

Laminated cards

Card Dimension

As per manufacturers standard

Card Thickness

Min 1.8mm

Communication

2 no RS485 serial port

Battery

V Lithium, with 8 years min life

Baud rate

9600

Protocol

To be indicated in the offer

Additional feature

HPCL logo and location name to be printed

on the cards.

72 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

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TERMINAL AUTOMATION PROJECT
SPECFICATION FOR TOP LOADING ARM SELF SUPPORTED TYPE
Make

As per approved vendor list

Qty

Refer BOQ

Description

Swivel, Top loading

Inboard Arm

3" NB Seamless pipes, quality

conforming to ASTM-A106 Gr. B Sch.40

Outboard Arm

Elbows and Reducers

Swivel joint

3 Aluminium conforming to AA 6063 T6/AISI

63400
3" NB 90 Deg SR Elbows , quality conforming
to ASTM-A234 Gr. WPB, Sch.40
Material conforming to ASTM A 106 Gr.B/ A105 having High Carbon Steel balls, ball races
are to be hardened to min. 250 BHN, sealing
rings

of

Aluminum

material

shall

swivel

joints

be

Viton/PTFE.

should

have

replaceable ball races for longer life.

Material of Aluminum Swivel joint shall be
aluminum alloy. Aluminum swivel joint should
have steel ball races to achieve longer lift
Type of Swivel joints

Swivel joints have to be split type design so

that seals can be replaced without removing
the steel balls.

Aluminum drop pipe

(73 mm OD x 63 mm ID) Aluminum pipe of

1000 mm long with tapered end on one side
& other side screwed.

Spring Balancing System

73 | 2 3 8

Quality conforming to IS: 1239. Helical Spring

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
box with spring of material conforming to EN
47/45.
Inlet Flanges

Raised face serrated finish, ASA class 150, with

holes drilled according to ANSI B 16.5 face to
face as per ANSI B 16.1 made of ASTM A 105
material

Intermediate Flanges

Flanges other than inlet flanges in the loading

arm shall have dimensions as per TTMA & will
be made of IS 2062 & aluminum alloy.

Balancing

Spring Type (Torsion / Compression)

Design Pressure

15 Kg/ sq.cm

Working Pressure

2-8 Kg/Sq cm

Hydrostatic Test Pressure

15 Kg/ Sq Cm

Operating Temp

0 - 50 deg.C

End connections

3" ANSl 150# WNRF FLANGED

Seals

Viton

Working envelope

Reach 3 - 4 mtr.(Typical). 4 mtr. X 6 mtr. X 1

mtr.(Vertical)

Vacuum Breaker

integral viton Diaphragm type with SS

nipple. It shall be at the apex of the system
where vacuum is generated

Filling

Position

Arrangement

locking :

A suitable locking arrangement for the

outboard arm shall be provided to prevent
jerking action of Loading Arm as well as lock

74 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

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TERMINAL AUTOMATION PROJECT
the outboard arm at the operation desired
position while filling tankers.
Locking chain shall be provided
Parking Lock

A suitable locking arrangement for the

inboard arm shall be provided to lock the
loading arm in parking position so that it
remains in parking place. Lock should be
spring loaded so that locking in parking place
is automatic & should be easy to operate.

Loading Arm type

Self supported Top Loading. Quantity for Left

hand type & Right hand type shall be as per
the location requirement.

Inlet Pipe entry

75 | 2 3 8

To suit the site condition

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
DESIGN REQUIREMENT
1. Loading Arm shall be self supported type. Extra bearing support which
creates obstruction to the movement of manpower & other equipment
should not to be required by the Loading Arm i.e. Design of Loading arm
should be such that it do not require any extra Bearing support.
2. Base swivel joint should be capable of taking bending load of the loading
arm. Loading shall be checked of bending load by applying 40 Kg weight
at the end of inboard arm and will be checked for smooth rotation.
3. Swivel Joint should be offered for Cycle testing of 20000 Oscillations of
Min. 270 degree and should be checked for pressure testing at 10 Kg
under rotation after the same.
4. The swivel joints shall be designed to make the loading arm maneuverable
with minimum effort. All swivel joint should be of split type design and
have minimum type rows of chrome steel hardened balls fixed in suitably
hardened carbon steel guide ways. Material conforming to ASTM A 106
Gr. B/A-105 having HCS Balls, ball races are to be hardened to 500 BHN,
seal of VITON / PTFE. Sealing surfaces of Swivel Joint should have overlay
with SS material.

Aluminum swivel Joint shall be Aluminum Alloy.

Aluminum swivel joint should be hardened Ball races to achieve longer lift.
All Swivel joints of steel or Aluminum should be of Split type design.
Swivel joint made of Aluminum should have replaceable snap type ball
races in which balls moves.
The quantum of force required at the end of outboard arm to move the
outboard arm in horizontal place and in vertical plane and the complete
loading arm from the base swivel joint in horizontal plane without fluid &
checked on shop floor will be as below:
-

In Horizontal plane

76 | 2 3 8

1 Kgf

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
-

In Vertical plane (downward pull)

4 Kgf

From base swivel in horizontal plane :

2 Kgf

5. Seals of swivel shall be of Metal inserted Viton material. Swivel joints shall
be completely leak proof under operating pressure and vacuum.

The

tightness of seal shall not hinder the easy operation of swivel joint.
6. Spring Balance Assembly:
The Outboard arm and drop pipe shall counter balanced by spring
balancing Mechanism will be of Helical Compression spring type
with totally enclosed cover design. Spring box should be such that,
setting of the spring tension can be done by any one [person at site
without any special tools, Helical spring assembly.
The spring shall have in-build provision to limit downward travel
and upward travel of outboard arm.
The expected life of spring is 2 Lakh cycles. The spring shall be
designed with excellent fatigue resistance properties and adequate
strength to perform operation throughout the lift of the spring.

77 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

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TESTING AND INSPECTION BY TPI

Visual and Dimensional inspection and witnessing hydrostatic testing of 100%

Loading Arms.

After assembly, the arms shall be subject to the following tests:

a) Balancing Test:
This is conducted in Loading arm to demonstrate that the arms are
mechanically counterbalanced. Test under no hydrostatic pressure.
Quantum of Check : 100%
b) Performance Test (Maneuverability test of Swivels):Rotate the swivel joints for three cycles in forward & three cycles in reverse
Direction to demonstrate that swivel joints can be easily operated and
operating torque required are in following range.
In horizontal plane
In vertical plane (downward pull)
From base swivel in horizontal plane
Quantum of check 100%

:
:
:

1 Kgf
4 Kgf
2 Kgf

c) Hydrostatic Shell Test:

The loading Arm is pressurized to 15 Kg/cm2 using water as test fluid &
pressure Held for 15 minutes. Requirement : No leakage is allowed.
Quantum of check: 100%
d) Radiography:
10% of all the carbon steel butt weld joints in a loading arm shall be
radiographed.
Quantum of check : 10% quantity
e) Manufacturer of the Laoding arms Test Certificate, indicating details of
materials for Inboard arm, outboard arm and drop

78 | 2 3 8

pipe & scope of

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
Inspection indicated above, shall be provided along with supplies. Also
verification of material of construction (thru mill Test report).
Quantum of check 100%
f) Life cycle testing of swivel joint of each type shall be done & the
certificates shall be offered for verification during inspection.
Additionally Aluminum swivel joint shall also be tested for endurance test
for 20,000 cycles, which will be witnessed by TPIA.
Quantum of check : 1 No of each type of swivel joint.
g) Bending moment test for springs & base swivel joint shall be done & the
certificates shall be offered for verification during Inspection. Additionally
Bending moment test shall be done for split flange type of Swivel joint &
witnessed by TPIA.
Quantum of check : 1 No of each type of swivel joint.
h) Forces required for movement of loading arms to be checked for
conformity with purchase order requirements.
Witnessed by

TPIA

20%

i) Certificate for chemical analysis of seat ring material

Quantum of check : 1 No. sample per batch.
j) Vacuum test: Closing inside and inlet side. The loading arm assembly to
be tested at (-) 0.15 BAR vacuum condition inside and hold for 15 minutes
(no drop at vacuum gauge permitted).
PAINTING
Loading arm and the accessories shall be painted one coat anticorrosive
paint and two coats of enamel paint of colour code shade as given below :

79 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

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TERMINAL AUTOMATION PROJECT

HSD - OXFORD BLUE

SKO - GOLDEN YELLOW
MS - DEEP ORANGE

The colour code shall be given with a spray gun to get a shining finish.
Aluminium nozzle shall not be painted.

NOTE:

One extra O ring shall be supplied with each loading arm.

Locking facility to be provided :

i) When loading arm in parking position
ii) When loading arm is inserted in T/T

80 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

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TERMINAL AUTOMATION PROJECT

Calibration Guideline for the Flow metering System

Vendor shall submit the elaborate calibration procedure based on the following
general guidelines:

Existing 2KL Mobile prover tank stamped by W&M shall be used by the
Vendor for calibration of the new electronic metering System.

Temperature of the Prover tank shall be recorded

Meter linearization shall be done at multiple flow or single flow as per the
process requirement at an individual location & as directed by the
Engineer-In- Charge.

Compensation for Temperature shall be incorporated so that meter

performance is consistent & repeatable at all the process condition

Accuracy & Repeatability shall be established as per the specification

before W&M stamping

All Calibrated metering system shall be W&M stamped

81 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

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TERMINAL AUTOMATION PROJECT

OTHER FIELD EQUIPMENTS

SPECIFICATION FOR DENSITY METER
Make

As per approved vendor list

Model No

Vendor to specify

Qty

Refer BOQ

Service

As given in the design criteria

Working Principle

Direct / Coriolis type

Range

0.6 to 1.0 gm/cc

Size

Min 10 mm

Accuracy

0.0003 gm/cc over the entire range

Repeatability

0.00005 gm/cc

Location

Power Supply

Open to sky, On the by-pass to the header

line near Gantry
24 V DC

Temperature Range

As defined in the design parameter

RTD

Transmitter

Built in or separately as per the

specification. Incase provided separately
the same shall be integrated with
densitometer for providing the Standard
Density & temperature locally as well as on
the remote.
Integral

Transmitter Accuracy

Vendor to specify

Pressure

0 to 10 Kg/ cm2

Protection

IP 65

82 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

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TERMINAL AUTOMATION PROJECT
Flanges

SS 316 / SS 316L

Wetted parts

SS 316 / SS 316L/Ni-Span-C

End Connection

Min: 1

Housing

SS 316 fully welded

Pressure Drop across the main

Less than 0.15 Kg/ Cm2

Vibration effect

Negligible

Communication Interface

Local Display

ASTM Table

Configuration

HART, Modbus (RS 485), 4-20 mA,

linearised & temperature compensated.
Serial output communication to TAS
System on RS 485. The density details shall
be displayed at the TAS system & shall be
relayed to ERP for printing on the invoice
as per the details given in the functional
requirement
Microprocessor based ex proof or IS local
Display of Ambient Density, temperature
and Standard Density.
The readings
observed at the local mode & the remote
mode shall be same at uncorrected
temperature
The densitometer shall have inbuilt latest
ASTM Table 54 B for density correction
suitable for the products used.
Via RS 485 communication

Area classification

Class 1, Zone I, Group II A & II B, T3

Certification

Ingress Protection

CCOE (PESO) Approval is mandatory for

use in hazardous area & any one of the
following FM/UL/ATEX/CENLEC approval.
Weather Proof to IP 65

header

83 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

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TERMINAL AUTOMATION PROJECT
Other Protection

Other Requirement
Calibration

Diagnostic Features

Alarm

Flow

Switch

(For

Direct

Direct

Densitometers only)
Side

Glass

(For

Densitometers only)
On Site Verification

Material conformity certificate

Circuit shall have protection for surge,

reverse polarity, lightening protection.
Mass Flow meter, if used, shall have
Custody Transfer approval.
All densitometer shall be calibrated at FCRI,
Palaghat or any other NABL approved Lab.
Required, Health check up, Calibration
Factors.
Alarm shall be generated if the standard
density is beyond tolerance limit as
specified in the functional requirement.
Required at the bypass line. The feedback
shall be available in the TAS to know that
the product is flowing through the bypass
line.
Required after the densitometer with
toughened Glass
Required. By Pycnometer as per API MPMS
Chapter 14 Section 6 or by Digital
hydrometer or any other method as
defined in API Chapter 21 Clause 11.6.3. All
Equipments required for Onsite Verification
& commissioning like pycnometer/ digital
hydrometer , HART Calibrator shall be
brought by the Vendor at no extra cost
during SAT or as & when requested by
HPCL
during
the
commissioning,
Stabilization, warranty, comprehensive
AMC
Required

NOTE: Restriction Orifice to be sized based on the corresponding pressure drop

and flow. Vendor shall calculate the net flow through the main header and shall

84 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

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TERMINAL AUTOMATION PROJECT
size restriction orifice plate as per the net flow and pressure drop (Minimum)
across the density meter. Restriction orifice material shall be SS316.

85 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

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TERMINAL AUTOMATION PROJECT

SPECIFICATION FOR TEMPERATURE SENSOR (RTD) TRANSMITTER (FOR

DENSITOMETER)
Make

As per approved vendor list

Type

Pt-100, Simplex, 3 wire as per DIN standards

Qty

Refer BOQ

Thermowell

SS 316, barstock

Instr. Connection

1/2" NPT(F)

Immersion length

As required

Range

0-100deg C

Total length

As required

Mounting

On the Header TLF shed, Incoming lines to

tank

Service

As given in the design criteria

Enclosure

Explosion proof, Class I, Division I, Zone 1,

Gr II A, IIB and weather proof to IP 65

Process connection

Screwed connection 3/4" NPT(F)

Output

4 to 20 mA signal, HART/ Modbus

Insulation

Mineral Insulated

Accuracy

Accuracy As per DIN 43760

Sheath

Made of SS 316 having 5 mm diameter

Lead wires

Copper

Note: This is required only if the densitometer does not have inbuilt Temperature
sensor

86 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
SPECIFICATION FOR PRESSURE TRANSMITTER FOR WHITE OIL HEADER LINE
Type

Make

Output

Accuracy

4-20mA, HART/ Modbus. Pressure readings

shall be communicated to TAS & alarms
shall be generated
0.07% of Calibrated Span

Principle of operation

Variable capacitance

Range

0 7 bar

Material of construction

SS 316 for wetted parts

Service

Header Pressure Measurement

Process connection

Over range protection

150%

Power

24 VDC

Element Type

Diaphragm with fill fluid silicon Oil

Area classification

Zone 1, Group II A/II B, T3

Enclosure

Weather Proof to IP 65, Explosion Proof

Protection

Zener barrier

Protection
required
against
lightening, reverse polarity
Required

Isolation Ball valve

2 Firesafe, antistatic, Full bore

Zero & Span Adjustment

Required & shall be carried out at Site as per

the requirement

87 | 2 3 8

Electronic microprocessor
transmitter
As per approved vendor list

based,

smart

surges,

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
DATA SHEET TRIPLE OFFSET BUTTERFLY VALVE ON HEADER LINE
1

Valve Size

Valve Type

3
4
5
6

Mfg. Standard
Face to Face
Inspection and
Testing
Fire Safe

7
8
9
10
11

ANSI Class
Rated Travel
Flow direction
Fire Safe
Anti Static Device

As per BOQ
DESIGN PARTICULARS
Triple Offset high performance , metal to metal
seated, non-rubbing, torque seated, double flange
end, quarter turn, anti-static, anti-blow out stem
arrangement butterfly valve. Complete actuated
valve shall be SIL2 capable certified by third party
agencies like TUV/Exida
API 609
As per API 609, Long Pattern
API 598
API 6FA/API-607-Vth Edition, Zero leakage before,
during after fire.
150#
90 Degrees
Bi-directional, tight shut-off in either direction
Required
Required
CONSTRUCTION

12
13
14
15
16
17
18
19
20
21
22
23

88 | 2 3 8

Body
Disc
Stem
End Connection
Flange & finish
MATERIAL
Body
Disc
Seal Ring
Stem
Bushing
Disc Retainer
Flange
Disc and Bottom

Cast
Cast
Bar-forged (No casting)
Double flanged as per ANSI B 16.5RF
150#, RF, 63-125 AARH, smooth finish
ASTM A216 Gr. WCB
ASTM A216 Gr. WCB/ASTM A351 CF8M
UNS S 31801 Douplex SS+ Graphite
A479 UNS 41000/17-4 PH Hard Chrome
UNS S31600
ASTM A 516
UNS 31600+ Graphite

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT

24
25
26
27
28
29
30

31
32
33

Flange
Seat
Pin/Nut/Washers
Thrust Bearing
Body Hydro test
Seat Hydro test
Pneumatic Seat
Test
Leakage Class
required
Safety Integrity
Level
SIL Certification
Std.
Third Party
Certification

Stellited Gr. 21 Weld Overlay

SS 316
SS 316/ Hardfaced /Cobalt based alloy
TESTING
1.5 times the flange rating (30 bar #150)
22 bar #150, test duration as per standard
NA (6 bar # 150)
Zero Leakage/ bubble tight shutoff
SPECIAL REQUIREMENTS
SIL 2 capable for actuated valve when it is Type A
Device
IEC 61508
TUV/Exida
ACCESSORIES

34
35
36
37
38
39
40
41
42
43
44
45

89 | 2 3 8

Dust Excluder
Quick Exhaust
Valve
Fire Safe Box
Volume/ Buffer
Tanks
Port Protector
Pilot Valve
Make & Model
Weight in kgs
Design Pressure
Design
temperature
Fail Action
Valve Torque+25%
safety margin

N.A.
N.A.
N.A.
N.A.
N.A.
Vendor to specify
Vendor to specify
Vendor to specify
PROCESS DATA
As per #150
65 deg. Centigrade
Fail to Close
Vendor to specify

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT

DATA SHEET ACTUATOR

1

Sizing basis

Actuator Type

3
4
5
6

11

Electric Supply
Make & Model,
Weight in kgs
Power
Consumption
Open/Closing
Time
Open/Closing
Torque
Hazardous Area
Protection
Ingress
Protection
Control

12

ESD Command

13
14

Motor Type
Fault Level
Supply system
Rating kW
Speed (RPM)
Direction of

7
8
9
10

15
16
17

90 | 2 3 8

1.25 times the valve torque for shut-off

pressure and less than valve stem shear
torque
Electric Actuator with Integral Starter suitable for
quarter turn valves, 2 wire remote control using
communication through Field control unit /
Master control station SIL2 capable when
classified as Type A device
415 V AC, 50 Hz 3 Phase
Vendor to specify
Vendor to specify
Vendor to specify
Vendor to specify
Vendor to specify

Zone 1 Gr. IIA / II B, T3

IP 65 as per IEC 529
Two wire communication - MODBUS RTU
network through Field Control Unit / Master
Control Unit
Hardwired command for Emergency
Operation
Squirrel Cage, induction type
Fuse protected
Vendor to specify
Vendor to specify
Clockwise, Anti Clocwise (Facing Drive End)

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT

18
19
20
21
22
23

24
25
26

27
28
29
30
31
32
33

34
35
36
37
91 | 2 3 8

Rotation
Cooling Method
Starter
Reduction
Gearing
Local /Remote
Switch
Local On/Off
Controls
Hand wheel for
Manual
Operation
Open/Close
Limit Switches
Local position
indicators/LEDs
Cable Entries

Air
Integral with motor
Integral with actuator
Required
Required
Required

Required
Required
M12/M25- for control, min. 2nos, M25/M40
for power

Control Status & Alarms

Opening & Closing
Required
Open & Closed
Required
Stopped
Required
Torque switch stopped
Required
Local/Remote & Local Push
Required
Button Pressed
Main Power Loss/ Phase
Required
Loss, Control Power Loss
Actuator Fault, Field Unit
Required
Fault, Contactor Energising
Fault
Thermostat Tripped
Required
Valve Jammed
Required
COMMANDs
Open
Required
Close
Required

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
SPECIFICATION FOR BULK AIR ELIMINATOR
GENERAL
Air eliminator shall be of horizontal / vertical cylindrical mild steel dished end
tank construction with internal baffles and float operated air release valve along
with supporting steel frame work and anchor bolts. The tank shall have large
cross-sectional area to slow the flow of liquid. The volume of the tank shall be at
least 10% of the flow rate in LPM. The units shall conform to the following
specifications.
Makes
Model No
Quantity
Service
Mounting

:
:
:
:
:

Rated flow in LPM

Operating Pressure in KG/cm2
Test Pressure
Inlet & outlet Flange size in mm
Allowable Pressure drop in the air
separator at rated flow
Weight of BAE
Painting

:
:
:
:
:

Design

Material of Construction
Fabricated Body and baffles

Flanges
Pipes
Supporting frame

:
:
:

92 | 2 3 8

:
:

As per approved vendor list

Vendor to specify
Ref BOQ
As given in the design criteria
On each Product Header Line near
Gantry
1200 LPM/Per Point
1.5 Kg-4Kg
15 Kg
As per header line sizes
0.1 Kg/cm2
Vendor to specify
2 coats of Zinc Phosphate primer(25
microns each) and 2 coasts of
aluminum paint (20 micron each) with
Color bands as per product code of
HPCL Standard
Vendor to submit

Carbon Steel SA 516 Gr 70/ IS 2002

Gr. 2
ANSI B16.5, class 150, A 105, RF
ASTM A 106, Gr. B, SCH-40
MS IS 2062, Gr. B 99

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
Drain Plug/socket NPT
Drain

:
:

Vent
Float & accessories
Seals
Code of construction

:
:
:
:

93 | 2 3 8

ASTM-A-105
1 NB 150# with Carbon Steel Ball
Valve.
NPT with Carbon Steel Ball Valve
SS 304
Nitrile/Viton/ Buna N
ASME Section V III Div I

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT

SPECIFICATION FOR THERMAL RELIEF VALVE

Make

As per approved vendor list

Model

Vendor to specify

Quantity

Ref BOQ

Service

As given in the design criteria

Valve Type

Thermal Relief Valve

Bonnet Type

Closed

Conventional/Bellows / Pilot

Conventional

Inlet Connection

1 Flanged / 3/4" NPT(M)

Outlet Connection

1 flanged / 1" NPT(F).

Cap over adjustment Bolt

Shall be Provided

Applicable Code

API 520, API 526

Body & Bonnet

ASTM A 216 WCB

Nozzle & Disc

SS 316

Spring

Cd Plated CS

Basis of Selection

Liquid Thermal Relief

Required Flow Capacity

Nominal

Operating Temperature : 0C

Amb upto 500C

Back Pressure

Atm (constant)

Set Pressure

7.5 Kg/cm2g

Orifice Area

As per design

Operated

Material

94 | 2 3 8

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
SPECIFICATION FOR CABLES

GENERAL
Design, engineering, supply, laying of Cables suitable for trays, trenches, ducts
and conduits and for underground buried installation with uncontrollable backfill
and possibility of flooding by water & chemicals. Spare core in the existing cable
& JBs may be used to the extent possible if suiting the requirement. Additional
Cables that are required for the newly installed equipment shall be supplied
under the cabling item.
Power Cable shall be heavy duty 1100 V grade & Control cables shall be heavy
duty be 660 V grade, Multi stranded copper conductor. PVC insulated, PVC inner
extruded sheathed, GI wire / Strip armored and FRLS PVC outer sheathed
confirming to IS 1554. The Oxygen Index shall be 29 at 27 +/-2 Deg C. In addition
suitable chemicals shall be added into the PVC compound of the outer sheath to
protect the Cable against rodent & termite attack.
All cables covered in this specification shall be Flame Retardant Low Smoke
(FRLS) unless specified otherwise.. The outer sheath of PVC shall possess flame
propagation properties meeting requirement as per IS 10810 (Part -62) category
AF
The overall diameter of the cables shall be strictly as per the values declared by
the manufacturer in the technical information subject to a maximum tolerance of
+/- 2 mm upto overall diameter of 60 mm & +/- 3 mm for beyond 60 mm.
PVC/ Rubber end caps shall be supplied free of cost for each drum. In addition,
ends of cables shall be properly sealed with caps to avoid ingress of water during
transportation & storage.
Sequential marking on outer sheath shall be provided at an interval of 1 M.
The scope of Cabling shall include supply, laying ferruling, end termination, loop
checking & commissioning for all the equipments included in this Terminal

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Automation System including existing equipments which are proposed to be
integrated with Terminal Automation System.
The following Cables shall be considered as a minimum:
All analog, digital & other signal cables from field to control room.
All data communication cables including special computer cables, if
required
Communication cable between MCC room and Control room for data
exchange regarding VFDs, if required.
All power supply cables from UPS to all Instrumentation and
Automation equipment.
The Cable shall be laid underground as per the specification & approved drawing
wherever possible & shall be laid on the perforated Cable tray with cover
whenever laid above ground.
Power Cable shall be laid in separate trench and
Signal & communication
Cabling shall be laid in different trench. The same may be laid in common trench
provided physical barrier in the form of bricks are provided in such a way that
both are laid min 300 mm apart.
Location of the Control Room is marked in the layout & is attached
Cable Route marker shall be provided at each 20 m c/c distance & at the turning
whichever is less
Vendor shall submit Cable layout along with the schedule for approval to
HPCL/Project Management Consultant. The Vendor shall also submit crosssectional drawing of Cable Trench for approval before proceeding with Cable
trench

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SIGNAL & COMMUNICATION CABLE

Make

As per approved Make

Quantity

Refer BOQ

Type of cable

Single pair/ Multi-pair shielded copper cable

Construction

Primary insulation

Pair twist

Shield (Individual Pair)

Shield (Multi-pair)

Shield thickness

Min. 1.5 Sq. mm, 7/0.53 strand annealed

electrolytic copper
PVC compound type ST2 as per IS 5831 type A.
Thickness - 0.7 mm (Nominal)
Two cores of the pair shall be twisted. Ten
number of twist per meter shall be minimum
Each pair shall be shielded with aluminum
backed mylar tape with 100 % coverage and
minimum 25 % overlap.
Same as above for individual pair shielding. Also
the overall shield shall be of aluminum backed
mylar tape with 100 % coverage and minimum
25 % overlap.
Min. 0.05 mm for individual and overall shielding

Inner Jacket

Outer Jacket

Pair identification

Rip cord

Drain wire

Armour

Electrical characteristics

97 | 2 3 8

Extruded PVC, type ST2 ,

Thickness As per IS 1554, Part -1
Extruded PVC, type ST2, FRLS, Blue colour
Thickness As per IS 1554, Part -1
As per BS:5308 ( Table 11). The number shall be
provided at a distance of not more than 1 mtr
Shall be provided
0.5 sq. mm multi-strand tinned copper
conductor in a continuous contact with
aluminum side of the shield shall be provided,
Armour over inner jacket shall be of Galvanized
steel wire as per IS 1554. (Part 1)

Maximum resistance (DC) of the

conductor of the complete cable shall not

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LAN Cabling

98 | 2 3 8

exceed 12.3 ohm/Km at 20-deg. C

Mutual capacitance of the adj. cores or
pair shall not exceed a max. Of 250 pF/M
at a frequency of 1 kHz.
Capacitance between any core and screen
shall not exceed 400 pF/m at a frequency
of 1 kHz.
L/R ratio shall not exceed 40 micro
henries per ohm.

Enhanced CAT 6 Cables. The Cabling shall be

structured & factory crimped to the extent
possible.

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SPECIFICATION FOR POWER CABLE

Make

As per approved Make

Quantity

Refer BOQ

Type of cable

Copper Cable

Voltage Rating

Up to and including 1100 volts

Construction

2.5 sq. mm multi stranded annealed bare

electrolytic grade copper conductor
(7/0.67 mm)

Primary insulation

Extruded PVC compound as per IS 5831

type C

Inner Sheath

Extruded PVC compound type ST2, min

thickness as per table 4 of IS 1554 Part (I)

Outer Sheath

Extruded PVC compound, type ST2, min

thickness 1.24mm up to 6 Core & 1.4 mm
above 6 core , FRLS, Black Colour.

Armour over inner sheath

Galvanized steel wire for UAD less than 13

mm, Galvanised steel strip for UAD
greater than 13 mm Dimensions as per
table 5 of IS 1554 Part

Core Identification

2 Cores:

Red & Black

3 Cores:

Red, Black & Green

4 Cores

Red , Yellow, Black & Green

Note:

Extra core to be considered for purpose

of internal earthing of FLP equipment

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SPECIFICATION FOR CONTROL CABLE

Make

As per approved Make

Quantity

Refer BOQ

Type of cable

Copper Cable

Construction

Primary insulation

Inner Sheath

Outer Sheath

Armour

Electrical Characteristics

Voltage Class

1.5 sq. mm , insulated and sheathed as per

IS-8130.. 5 sq. mm multi stranded annealed
bare electrolytic grade copper conductor
Extruded PVC compound as per IS 5381
type C. Min thickness as per IS 1554 Part 1
Extruded PVC compound, type ST2, min
thickness 0.7mm as per IS 5831
Extruded PVC compound, type ST2, min
thickness as per IS 1554 Part -1, FRLS, Black
Colour
Shall be provided of galvanized steel
wire/flat strip (Thickness as per IS 1554 Part
-1)
Max. Resistance (DC) of the conductor of
the cable shall not exceed 12.3 ohm/km at
20 deg. C
660 V

Core Identification

Rip cord

100 | 2 3 8

Core identification number shall be

provided at a distance of not more than 1
meter
Shall be provided.

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SPECIFICATION FOR RTD CABLE

Makes
: As per approved vendor list
Quantity

Ref BOQ

Type of cable

Triad cable

Construction

1 sq. mm cross section, individually shielded

and overall shielded with drain wire

Core

7 X 0.52 mm nominal stranded ATC wires.

Polyethylene insulated with a nominal min.
insulation thickness of 0.5 mm

Twisting

3 insulated cores shall form a triad

No of Twists/metre

Min 12 to 20

Drain wire size

10 strands 0f 0.25 mm ATC

Triad shielding

100% coverage with Al Mylar tape 0.062 mm

with a Min of 25% overlap along with drain
wire.

Overall taping

0.015mm thick Polyester taping

Overall outer sheathing

1.6mm(+/-0.2mm) thick for triad

Drain ire

AWG 20

Voltage class

600 V

Conductor Resistance

14 Ohms/Km @ 20 Deg C

Insulation Resistance

As per IS 5831

Mutual capacitance

Between cores with shield grounded shall be

not more than 150pF/Mtr

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Capacitance

Between one conductor and

other

Conductors connected to the shield shall be

not more than

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250pF/Mtr

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SPECIFICATION FOR CABLE LAYING
Cables shall be laid both aboveground as well as underground. The Cable shall be
laid aboveground in the Gantry & tanks. Apart from the Gantry & Tanks, Cabling
shall be laid underground as per the specification until unless there is a constrain
of laying underground. In such cases, Vendor shall take permission in writing
from HPCL/ Consultant for laying the Cable aboveground. All aboveground
cables shall be laid on the Cable tray with cover as per the specification.
Laying of the cables underground shall be in trenches of min. 1 mtr. depth in all
types of soil both hard & soft soil including dewatering, if required. Big boulders,
sharp edges of the steel sections, vegetarian, growth roots etc. if encountered
shall be removed completely. Only soft earth excavated shall be kept for refilling.
Such earth shall be approved by the Engineering-in-charge. Excavated trench
shall be in true straight line as far as possible and bends if necessary shall be
provided. Such bends shall be gradual and not sharp in nature, the excavated
trench shall be approved by the Engineer-in-charge before laying cables In case,
during excavation hard rock is encountered which in the opinion of HPCL EIC/
Consultant cannot be excavated further, then additional sand bedding of 150
mm shall be provided over & above the 150 mm specified for the bedding. The
decision of HPCL/ Consultant is final & binding in this regard. Rate of cable
laying shall include excavation, supply and laying of two layers ( 150 mm thick
each, below and above) of river sand conforming to IS 383 and a layer of good
quality bricks of compressive strength min. 35 Kg/Sq cm. on top of the second
layer of sand & backfilling with good quality excavated earth. Rate shall also
include cutting/excavation of RCC wherever encountered & construction of RCC
culvert/ cable alley in RCC 1:1.5:3 with reinforcement as per design requirement.
All care shall be taken to ensure that no underground utilities like cables,
pipelines etc. gets damaged. However, in case any underground utility like
cables/pipes are damaged, the same shall be repaired/ replaced by the Vendor
immediately at no extra cost. Rate to include backfilling of the excavated earth &
carting away surplus earth within the depot premise as directed by HPCL EIC/
Depot Manager.
Before cutting the cables exact length as per the site conditions shall be
measured and recorded. Cut ends of the cable shall be wound by insulating tape
to protect them from rain water etc. Cable ends shall not be kept open for long.
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Power Cable shall be laid in separate trench and

Signal & communication
Cabling shall be laid in different trench. The same may be laid in common trench
provided physical barrier in the form of bricks are provided in such a way that
both are laid min 300 mm apart.
All the cables inside tank farm area shall be laid through class B GI pipes buried
underground not less than 1000mm deep. 25mm dia. pipe to be used for one
cable & 50mm dia. pipe to be used for two cables. Power & Signal/
communication/Control cables shall be laid thru separate GI pipes.
Wherever the cables have to cross the asphalt roads, the rate quoted shall
include cutting of the asphalt and WBM roads including soling and necessary
excavation to the required depth and back filling the trench with river sand and
restoring the asphalt / WBM roads to its original condition including compacting
and rolling the surface.
Road crossing shall be done through the Hume pipe. The existing Hume pipes
may be used in case sufficient space is available for laying the cables. Supply &
laying of the NP2 Hume pipes, if required, shall be in the scope of the Vendor.
Wherever the cables comes aboveground, a suitable size GI sleeve with bend
shall be used. Such pipe shall be laid 150mm below ground level and the
projecting bend shall raise to 500mm above ground level along the
steel/concrete/brick columns. The sleeve shall be neatly clamped by MS clamps
of adequate size and wooden bushes. Necessary precautions shall be taken to
make the opening water tight by wooden bushes.
Whenever, the Cable is laid above ground, it shall be laid on the perforated cable
tray with cover. The cable shall be tied on the GI Cable tray with GI Clamps. No
PVC ties or MS wire shall be used for tying the Cable on the GI Cable tray. The
Cable shall be laid on the tray with min. D spacing (D being the diameter of the
thicker Cable). Bunching of Cables or laying Cable on top of each other is not
permitted.
Separate Cable tray shall be used for laying Power & Signal/ communication/
Control Cables
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The perforated GI Cable tray shall be supported at regular interval. The existing
structural support at Gantry, Tanks may be used for supporting the Cable tray. In
case additional supports are required the same shall be supplied & erected by
the Vendor & shall be included in the cost for cable laying.
Cables shall be brought inside the control room through the trench. All the cables
shall be brought inside the control room through various sizes of GI pipes . These
GI pipes shall be encased in brick structure which shall be provided by vendor on
the entry side of the trench. GI pipes supply and fixing is in vendor scope. The
mixing of power , signal or communication cables inside GI pipes shall not be
allowed. The cables which can cause interference of any type shall be separated
apart by min 300 mm and shall enter cable trench inside control room by
separate GI pipes. Once all the cables are laid through GI pipes, both ends of GI
pipe shall be sealed by cable sealant compound so as to prevent entry of any
creeping creatures, water inside control room. Selection of pipes and bunching
of cables shall be done in such a way that it shall be possible to replace the cable
, if required in future date. The cable trench shall be sealed perfectly once all the
cables are laid so that the ingress of water, dampness or any creature is totally
restricted.
HPCL shall provide cable trench in the control room. The cable trench (length,
width height), flooring modification to suit the erection of panels and consoles
will be in TAS vendor scope. TAS vendor needs to supply and install cable trays
inside the control room Cable trench for taking power and signal cables.
Necessary loops of min 5 mtr. shall be provided at both ends of the main cables.
Cable shall be laid without any joints.
Cable route markers at 20 m/c and at all the bends/ turnings shall be provided.
Bending radius of cables shall not be less than 12 times O.D. of cable.
All cores of cable shall be identified at both ends by means of PVC ferrule.
Line drivers & all other accessories required in this regard are included in the
scope of work of the vendor.
Cable laying shall also include termination of Cables at both the ends. Cable leads
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shall be terminated at both ends by crimped type soldering.
Rate shall also include megger test by 1000V megger for establishing the
healthiness of cable in the drum before removing the same, unwinding and
straightening the cable & after laying of cables.
INSPECTION, TESTING AND ACCEPTANCE
The cables shall be tested and inspected at the manufacturers works. All the
materials employed in the manufacture of the cable shall be subjected, both
before and after manufacture, to examination, testing and approval by Third
Party Inspection. Manufacturer shall furnish all necessary information concerning
the supply to HPCL/ Consultant. The Third Party inspector shall have free access
to the manufacturers works for the purpose of inspecting the process of
manufacture in all its stages and he will have the power to reject any material,
which appears to him to be of unsuitable description or of unsatisfactory quality.

After completion of manufacture of cables and prior to dispatch, the cables shall
be subjected to type, routine, acceptance and special tests as detailed below.
HPCL/Consultant reserves the right to witness all tests with sufficient advance
notice from vendor. The test reports for all cables shall be got approved from the
Third Party Inspection agency before dispatch of the cables.
All routine tests, acceptance tests, type tests and additional type tests for
improved fire performance shall be carried out as listed in IS:1554 (Part I).
The test requirements for PVC insulation and sheath of cables shall be as per
latest revision of IS:5831.

Test for Resistance to Ultra Violet Radiation:- This test shall be carried out as
per DIN 53387 or ASTM-G-53 on outer sheath. The retention value of tensile
strength and ultimate elongation after the test shall be minimum 60% of
tensile strength and ultimate elongation before the test. Test certificates with
respect to this test (not older than one year) from recognized testing
laboratory to be furnished for review by Third Party Inspection agency before
dispatch clearance of cables. In case test certificates are not available, test is

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to be conducted by vendor at his own cost in any recognized test laboratory
or in house testing laboratory, before dispatch clearance of cables. Sampling
for this test is to be done randomly once for each order, provided outer
sheath remains same.

Acceptance tests as per IS-1554 (Part 1) and the following special tests to be
performed on the cables as per sampling plan. These tests are required to be
witnessed by Third Party Inspection Agency before dispatch of cables.
a. Accelerated water absorption test for insulation as per NEMA-WC-5 (For
PVC insulated cables). Test certificate with respect to this test (not older
than one year) from recognized testing laboratory to be furnished for
review by Third Party Inspection Agency before dispatch clearance of
cables. In case test certificates are not available, test is to be conducted by
vendor at his own cost in any recognized test laboratory or in house
testing laboratory, before dispatch clearance of cables. Sampling for this
test is to be done randomly once for each order, provided type of
insulation remains same.
b. Dielectric Retention Test:- The dielectric strength of the cable insulation
tested in accordance with NEMA WC -5 at 75 =/- 1 deg C shall not be less
than 50% of the original dielectric strength (For PVC insulated cables).
Test certificates with respect to this test (not older than one year) from
recognized testing laboratory to be furnished for review by Third Party
Inspection Agency before dispatch clearance of cables. In case test
certificates are not available, test is to be conducted by vendor at his own
cost in any recognized test laboratory or in house testing laboratory,
before dispatch clearance of cables. Sampling for this test is to be done
randomly and once for each order.
c. Oxygen Index Test:- The test shall be carried out as per ASTM D2863 or
applicable Indian Standard Specifications. Sampling to be done for every
offered lot/size as per sampling plan.
d. Flammability Test:- The test shall be carried out on finished cable as per
IS-10810 (Part 61 & 62). Sampling for these tests is to be done randomly

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once for each order provided outer sheath remains same. The acceptance
criteria for tests conducted shall be as under:Part-61:- The cable meets the requirement if there is no visible damage on
the test specimen within 300mm from its upper end.
Part-62:- The maximum extent of the charred portion measu8red on the
test sample should not have reached a height exceeding 2.5 m above the
bottom edge of the burner at the front of the ladder.
e. Test for rodent and termite repulsion property. The vendors shall furnish
the test details to analyze the property by chemical method. Sampling to
be done for every offered lot / size as per sampling plan.

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SPECIFICATION FOR EXPLOSION PROOF JUNCTION BOX

Make

As per approved vendor list

Model No

Vendor to specify

Quantity

Ref BOQ

Materials
Body & Cover

Cast Aluminum Alloy (LM-6); minimum 5

mm thick.

Gasket

Neoprene rubber

Terminals

Clip on type block locked at both ends

suitable for up to 2.5 mm 2 conductor

Tag name plate

Required

Paint

Anti corrosive epoxy paint, shade light Grey

JB type

Explosion Proof Suitable for hazardous area

Zone I, Gr. II A, IIB T6

Protection class

Weather Proof to IP 65 as per IS 2147

Earthing

All junction boxes shall be provided with

external earthing lugs.

Cable Gland

Double compression Gland, Nickel plated

brass material, NPT threads, Minimum
engagement of threads shall be as per IS
2148

Other Requirement

Explosion proof junction boxes shall have

detachable cover, which is fixed, to the box

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by means of cadmium plated hexagonal
head screws.
Terminal shall be spring loaded, vibration
proof, clip-on type, mounted on nickel
plated steel rails complete with end cover
and clamps for each row.
Sizing shall be done with due consideration
for

accessibility

and

maintenance

in

accordance with the following guidelines:

50 to 60 mm between terminals and sides
of box parallel to terminals strip for up to
50 terminals and additional 25 mm for
each additional 25 terminals.
100 to 120 mm between terminals for up
to 50 terminals and additional 25 mm for
each additional 25 terminals.
All junction boxes shall be provided with
20% spare cable entries and terminals.

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SPECIFICATION FOR CABLE GLANDS
Type of protection

Compression

Bushes

Threading type

Thread Engagement

NPT Threads shall be provided. ET threads

will be permitted only if any equipment does
not have provision for NPT threads.
As per IS

Material of Construction

Brass-Nickel plated

Tag plate

Shall be provided

Mounting

Protection class
Gland Size

:
:

Suitable for area classified as zone- I, group

IIA and IIB
IP-65
As per detailed engineering

111 | 2 3 8

Explosion proof suitable for zone 1,group IIA

& II B as per IS 2148
Double
compression
type.
Single
compression type
Neoprene

HINDUSTAN PETROLEUM CORPORATION

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SPECIFICATION FOR CABLE TRAY GI
Material

GI

Size

As per design

Perforated

Slotted holes

Length

3M

Thickness

2 mm

Height without cover

50 mm for 150 mm wide trays, 75 mm for

300 wide trays

Cover height

10 mm cover to be provided for trays

Hot Dip galvanized

According to BS-729-1971 or equivalent

standard, suitable for indoor/outdoor use
having moderate humidity and air pollution.

NOTE : Payment of Junction Box, Cable Tray Cable Glands shall not be done
separately & will be part of Cabling

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SPECIFICATION FOR INSTRUMENT FITTINGS (Carbon steel Fittings)

Fittings shall be socket-weld type forged pipe fittings of material cadmium

plated ASTM A 105. The minimum rating shall be class 3000.

SS tube Compression Fittings

Nomenclature of all tube fittings shall be as per ISA 42.1

Fittings shall be flare less compression type and of three-piece

construction with ferrule, nut and body suitable for use on SS tube
conforming to ASTM A 269 TP316, hardness not exceeding RB 80.

Hardness of ferrules shall be in the range of RB 85-90 so as to ensure

minimum hardness difference of 5 to 10 between tube & fittings for better
sealing.

Threaded ends of fittings shall be NPT as per ANSI B1.20.1.

Instrument Valves

The impulse line isolation and drain valves shall be forged gate valves with
inside screwed bonnets.

For SS valves body and trim material shall be ASTM A182 Gr. F316.

For CS valves body material shall be ASTM A 105-gr. and trim material
shall be ASTM A182 Gr.F316.

Valve hand-wheel material shall be cadmium or nickel-plated steel.

Impulse pipes
Impulse pipe shall be either Sch. 80 seamless carbon steel pipes as per ASTM A
106 gr. with socket weld fittings or shall be fully annealed, seamless and cold
drawn 316SS tube as per ASTM A 269 with compression fittings. Tube wall
thickness shall be 0.065 unless otherwise specified.

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The process tapping shall be min. 1/2 in dia unless otherwise specified. Root
valves shall be min. 1/2 stainless steel ball or gate valves, suitable to maximum
pressure and temperature. Pressure testing of piping shall be done after
provision of Instrumentation tapping points and closing root valves.

For installation of temperature elements/gauges, suitable tapping on pipeline,

welding of boss with threads or flange shall be arranged by vendor. Pressure
testing of pipelines shall be done by vendor after installation of thermowells.

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SPECIFICATION FOR VARIABLE FREQUENCY DRIVE

GENERAL
The product pumps for which the VFD/ Soft Starters/DOL feeders etc are
covered in the specifications are under various stages of tendering and
placement of order. As such the ratings indicated are tentative and may be
subject to changes depending upon the mechanical equipments supplier.
Besides HPCL reserves the right to vary the ratings, quantities while placing the
order on the successful bidder or during execution of the work. For all such
changes the prices quoted for the components by the bidder and agreed by the
HPCL shall be applicable. However the changes will be limited to +/- 10% of the
rating given.

Detail specification
Details of VFD & Soft Starters are as given below:
1. VFD/Soft Starters for Tank Truck loadings pumps.( VFD: 1No, Soft Starter: 4 Nos)
a)
No. of Centrifugal Pumps:
4 (Four)
b)
Power
:55 kW (Motor Rating)
c)
Discharge Rate
:
3600 LPM
d)
Product to be pumped :
MS
2.

VFD/Soft Starters for Tank Truck loadings pumps (VFD: 1 No, Soft Starter: 7 Nos)
a)
No. of Centrifugal Pumps:
7 (Seven)
b)
Power
:
75 kW (Motor Rating)
c)
Discharge Rate
:
4800 lpm
d)
Product to be pumped :
HSD

3.

VFD/Soft Starters for Tank Truck loadings pumps (VFD: 1 No, Soft Starter: 3 Nos)
a)
No. of Centrifugal Pumps:
3 (Three)
b)
Power
:
37 kW (Motor Rating)
c)
Discharge Rate
:
2400 LPM
d)
Product to be pumped :
SKO

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Erection, testing and commissioning of the equipment supplied includes

commissioning activity with require coordination with existing Terminal
Automation System (TAS) integrator M/s ASPL. Vendor shall be
responsible for successful execution of testing and commissioning
through coordination as required.
Supply of connected items like nickel plated brass cable glands, Glands,
tinned copper lugs for all power and control cable shall also be included
in scope of VFD/Soft Starter supply.
Submission of Test Certificate and technical catalogues for all equipment
and accessories for use in Hazardous and Non - hazardous areas. Supply
of all operations and maintenance manuals and all as built / approved
and reference drawings and documents after commission of all
equipments. The scope of supply shall be considered as completed only
after submission of as built final documentation.
The scope of work also includes supply commissioning spares required
for successfully commission the equipment at the site and the same shall
be supplied free of cost and without delay at site.
Each set of product loading pumps consisting of one VFD with associated
control gear, Motor starter consisting of soft starter and associated
control gears for each pump of a product group of pump, PLC for each
product pumps control, suitable instrumentation for feedback control and
energy measuring /data acquisition / monitoring / transmission of data to
existing TAS (Terminal Automation System), recording and reporting
system for individual motors. The system envisaged for tank truck loading
at Bhatinda terminal will be as follows:

For each product group of drives, there shall be preferable two sets of
panels adjacent to each other as follow:

VFD panel consisting of a common VFD (with control and programming

unit on panel door) with associated control gear/ protections for a group
of product pumps, PLC with power supply unit and pressure signal
converter/isolator unit (two for two analog pressure input signal for each

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product group of pumps), energy meter and energy data acquisition and
transmission system, programming interface, displays, lamps, MCCBs/
switches, auxiliary contractors, MCBs etc. I/Os from following interlocking
panels shall also be wired to the above PLC. Central Interface Unit (CIU)
and RS-485 to Ethernet converter with built-in power supply unit as may
be required for energy meter data acquisition and transmission shall be
located in this panel. This panel door shall have provision to connect PLC
programming terminal for programming and monitoring as only one
programming terminal shall be supplied.
Interlocking control panel (may have number of vertical panels as per
requirement) shall consist of Soft Starters (With control and programming
unit on panel door with associated switch gear (MCCB,CTs, Contactors
(VK-1,2 etc and SK-1,2 etc) for VFD connection and Soft Starter
connection to each motor of the groups of pumps, thermistor relay units
for motor (30 KW and above) for over temperature monitor and
protection, one Digital Speed indicator for VFD driven pump, energy
meter and energy data acquisition and transmission system for each soft
starter, displays, lamps, switches, auxiliary contactors, MCBs etc.

The Bidder should note the following:

o Modification of schemes / changes in components, if any suggested
during scrutiny/approval of drawings and execution of work, shall be
carried out successful contractor at no extra cost.
o The scope of contractor includes all associated items/ sensors/ interlocks
required for smooth and efficient working of system and required during
installation, testing & commissioning. All such items are deemed to have
included in the contractors scope.
o Safety interlocks, necessary to ensure maintenance operation shall be
provided.
o The system shall work in conjunction with the HPCL existing TAS PLC/
complete system and connected to TAS Ethernet bus (10/100 MBPS) for
exchange of information/data/ commands. Contractor shall program his
system for control, monitoring the operation of the pumps on receipt of

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command from TAS PLC in desired format and also transmit the energy
consumption data and other information about the status/ operation of
the drives and starters to TAS PLC. The communication format for the
required exchange of information / data for desired controls, reporting
and monitoring system of the bidder shall be submitted by him during
detailing.
POWER AND CONTROL SUPPLY

415 10% V, 3ph 50 5% Hz, 3 phase will be made available by the

HPCL. Different voltages required for various other purposes shall be
obtained by providing suitable MCB/MPCB, transformer, rectifiers etc in
each panel separately. The electronics shall be suitable for voltage and
frequency variations of 15% and 6% respectively.
230V AC supply for illumination lamp operated by door switches and
power socket.
110V AC control, indication lamps.
Input/ Output interrogation voltages.
a)

Digital Input to PLC

b) Analog input to PLC

c)

Digital output from

PLC

d) Analog output to

Potential free from the field instruments/

MCC & interrogated at 24 V DC.
4 20mA DC, 2 wire, loop power 24V DC

Potential free to the field instruments /VFD /

Soft Starter / panel & interrogated at
24V DC but contacts used in 110 V
Control circuit.
: 4 20mA DC, loop power 24V DC

Alternatively the soft starters/VFD shall communicate directly to the controller

on modbus/ Ethernet protocol. Vender shall include the necessary
communication module along with cable and other accessories.

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CONTROL MODES AND PHILOSOPHY OF CONTROL
4.1 The main objective of the control system is to provide facility to start any
pump of the group with one VFD and run the same on VFD to control the
required set pressure in the line by switching in other pumps (one by one) on
their respective soft starters. At any time during control if two or more
pumps of a group are to be operating then it shall be assured that soft
starter driven pumps must run at rated load and VFD driven pump can be
lightly loaded. Both VFD and soft starters work for energy saving while
controlling/ maintaining the set header pressure.

Two modes of control are envisaged for operation and maintenance of the
pumps. The mode of operation LOCAL OR REMOTE is selected at local
control station of the respective pumps.

Local mode of operation is envisaged mainly for maintenance and testing of

the pumps. Each pump can be started and stopped from their respective
LCS but with permission contact from PLC for the particular group pumps.
Stop/Emergency stop PBs on LCS shall also stop the pump in remote mode
of operation. Emergency operation of filing products will also be possible
only in case of failure of the group PLC and one of the pump will be
operated with VFD in this case.

Remote mode of the operation is the normal mode of the operation and
control for group of the pumps. All the pumps are selected in REMOTE
mode from their LCS. The operation shall be carried out from existing TAS
PLC.
For group the set point, start command and stop command will be provided
by TAS PLC to Group PLC on ETHERNET and TAS PLC will monitor drives
and their energy consumption and further generate necessary reports
including energy consumption reports pump wise and product group wise.
The group PLC will provide the set point to the group VFD drive and
provide start command when the system is ready and healthy.

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A PID loop is envisaged in each PLC to control the pumps to maintain the
header pressure for proper loading. First one of the selected pumps of the
group is started and allowed to run. The group PLC shall monitor the VFD
run pump speed and as soon as the speed rises above the set speed a
command is generated by PLC to start the next pump with its soft starter
and at the same time control speed of the VFD run pump speed. Even after
the start of the second pump the VFD run pump increases then the
command is given to third pump. Under all the condition the VFD run pump
is controlled and monitored continuously. All the pump control work
independently to conserve/ save on energy consumption. From VFD there
shall be continuous feedback of VFD driven pump speed for the above
purpose. 4 20mA feedback shall also be envisaged to indicate the speed
of the VFD controlled pump on the digital indicator with motor ID and
speed in RPM. However there shall be provision to alternatively execute the
PID in VFD drive in case of emergency and bidder shall include all hardware/
software also.

There shall be provision to record the date, time and the number of times
the system is run on soft starter.

All the addressable digital energy meters and group PLCs shall be
connected on 10/100 MBPS Ethernet bus with existing TAS PLC for
integrated operation.

All meters shall have digital indications but the energy meter (as per IEC1248) shall have RS-485 port to communicate energy consumption and
other data to central interface unit (CIU). The CIU shall have digital display
and built-in soft keys for parameter setting/ selection and monitor the data
from CIU shall be taken to TAS PLC through convertor (RS-485 to Ethernet
10/100 MBPS ). Energy transducer shall have accuracy as per IEC 687/1036.
The CIU at a location shall have connections to energy indicator cum
transducer installed in motor soft starter circuit and VFD circuits so that

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motor data collected by transducer are read by CIU periodically and displays
the same on its indicator and transmit data (real time
KVA/KW/PF/AMP/VOLT and KWh for selected time interval) to TAS PLC with
motor ID.

VARIABLE FREQUENCY DRIVE (VFD) UNIT

VFD unit shall mainly consist of a three phase twelve pulse rectifier
bridge with necessary three winding transformer, D.C link with
reactor and capacitors, inverter bridge, control system
(microprocessor based). The VFD unit shall have cooling fan and
this shall be controlled based on heat sink temperature.

The VFD shall be pulse width modulation (PWM) type with flux
vector control for closed loop speed control with pump header
pressure feedback for high accuracy and good dynamic
performance. Pressure shall be maintained at set value by speed
control of the motor operating on VFD and switching motors
operated on soft starters.

VFD shall control operation and speed of product group pumps

through a PLC (to be located in each VFD panel) by hardwired
contact and signals as depicted in the enclosed typical control
scheme.

The unit shall comprise of an incoming microprocessor based

MCCB with suitable over current, short circuit & earth fault
releases, three winding transformer, three phase twelve pulse
diode bridge rectifier acting as the line converter and three phase
inverter as the load converter interconnected through DC link
reactor and capacitor unit and output reactor. The MCCB incomer
shall be fully rated having short circuit withstand 50 KA for 1 sec

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minimum. For the inverter unit IGBTs shall be used. The outgoing
of the unit shall include reactor, contactor and thermal over load
relay with (1NO + 1NC) contacts. The unit shall also be equipped
with thermister relay also for motor ratings 30 KW and above. But
these contactors, thermistor relay & over load relay shall be
located in interlocking panel.

Line side filter shall be provided to contain line side current/

voltage harmonics within the limits of IEEE/ IEC standards.

Contactors shall be 3pole air break, electro-magnetically operated.

The contacts shall be made of special silver alloy suitable for
higher switching frequency. The contacts shall have minimum
bounce. The contactor shall have mechanical ON/OFF indication.
The coil shall be rated at 110V AC and operate satisfactorily from
50 to 110% of rated voltage. Minimum size of contactor shall be
16A.

All the buster works of VFD system shall be of copper only.

The unit shall have fully digital microprocessor based regulation

and control system with suitable interfaces for communication with
the PLC (mark in configuration also) as well as the required
instruments and signals. The microprocessor shall carry out all the
functions required from the unit including triggering protection,
self-diagnostics, operator & various parameterization interfaces.

Suitable operator panel unit for programming/ debugging and

control shall be provided. Display of faults, alarms as well as
diagnostics messages shall also be available in plain text on this
operator panel on the cubicle door. It shall be sealed type with
membrane switches & LCD display unit. It shall be connected to
the VFD control board thru communication cable and installed on

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the panel door. This shall also be user configurable for
simultaneous display of two process parameters customized to
user scaled units for simultaneous display. Besides the above, the
following PBs and lamps shall also be provided on the door and
connected to the VFD
1.
2.
3.
4.

START PB
STOP PB
Fault reset PB
LED indication lamp for power on (R,Y,B), Drive ready
drive on, drive fault, off, overload trip etc.

All required high speed electronic protections shall also available

with unit apart from self diagnostic features. A few are listed
below.

Over current instantaneous trip

Short circuit protection for converter/ inverter

Adjustable current limit.

Earth fault protection

Over temperature at heat sink.

DC bus under voltage & over voltage

Control & regulated power supply failure

Phase reversal protection.

Abnormal conditions shall initiate alarm and shut down drive based on the

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nature of the fault.

Instruments
o
Digital speed indicator.
o
Digital Energy meter (accuracy class 0.5 0r better)
o
All meters shall have digital indications but the energy
meter (as per IEC-1248) shall have RS-485 port to
communicate energy consumption and other data to
central interface unit (CIU).

VFD unit shall have the following operational features :

Auto tuning.
Parameter lock
Power loss ride through.
Adjustable acceleration/ deceleration.
Adjustable starting torque
Suitable for constant torque/ squared torque application as per
requirement.
Torque boost at start (adjustable)
Adjustable switching frequency.
Analog inputs/ outputs of the converter shall be galvanically
isolated type. Digital outputs shall be potential free type.
Minimum I/Os shall be as per enclosed drawings with spares.
Components for the same function and rating shall be of
identical design, make and of modular construction to reduce
the inventory.

DESIGN CRITERIA
Input voltage
Input frequency
Ambient temperature
Output Voltage

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:
:
:
:

415V (+10%, - 10%), TPN

50 5% Hz,
50 Deg C
0 415 input voltage, 3

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phase
Output frequency
Resolution
Inputs and outputs
(Minimum)

:
:
:

Communication for which :

Hardware provided in
Equipment

0-60 Hz, 3 phase as required.

0.01 Hz
Analog I/Os: 3 on board inputs
& 2 programmable outputs.
Digital I/Os: 9 inputs & 4
programmable outputs.
RS-485, Ethernet (10 or100
MBPS )

TESTS
Following tests shall be performed as part of testing requirements
for VFD units:
Factory test:
Insulation resistance
Light load test
Checking of auxiliary devices
Control system test.
Efficiency test.
Site Test:
Insulation resistance
Light load test
Rated current test
Checking of auxiliary devices
Control system test.
Efficiency test.

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Programmable Logic Controller
The programmable Logic controller (PLC) system shall be programmable,
modular microprocessor based System. PLC shall be mounted in VFD
panel as a separate module.
The PLC shall have a very high noise immunity in order to ensure safe and
reliable operation when subjected to electrical radio frequency
interference and electromagnetic disturbances expected in a plant. The
design of system electronics shall be in compliance with the
electromagnetic compatibility requirements as per IEC.
One programming terminal shall be supplied with the equipment. This
shall be suitable for panel door mounted with suitable plug/port. The
programming unit shall be panel mounted type unit with PC/Monitor
(17) / membrane type key board fixed on the panel. Necessary
arrangement will be made in the panels for placing these equipments and
shown in the drawing during detailed engineering.
Operation of the PLC shall be completely unaffected by a momentary
power loss of the order of 20 milli seconds.
The offered processor shall have floating point operation and a minimum
reference capacity to handle at least 100 real time I/O.
The size of memory shall be sufficient for the storage of the program
instructions required by the logic schemes. Loading of memory shall be
60% and shall have 40% free space for future also.
Memory shall be non volatile. In case volatile memory shall be provided,
battery back up shall be provided for minimum of three months to keep
the storage intact. A battery drain indication shall be provided at least
one week before the battery gets drained.
Function requirement of Processor
-PID and feedback control
- Time on delay, off delay
-Self tuning capacity of closed loop
-Algorithm, arithmetic function, comparison, limiter, selector and logic
function etc
-Emergency and safety shutdown

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-Diagnostics of the entire system as well as the connected equipment

-Capable of interfacing with TAS PLC (Owner Supply) on ETHERNET
INPUT/OUTPUT SYSTEM
The maximum number of Input/output per module shall be limited as
follows
DI 16, DO- 16, AI -8, AO -8
Each I/O shall be electrically isolated from external control circuit by
suitable means. The minimum insulation level between I/O and logic
circuit shall be 1000VDC.
Each I/O shall be protected against reversal of polarity of power supply
voltage to I/O.
Each module shall have LED for each I/O channel to indicate the status of
each input/output.
Each input shall be provided with filters to filter out any noise in the input
line or noise because of input contact bouncing.
PLC inputs shall be provided with potential free /dry contact unless
otherwise specified. Each input shall also be protected by fuses. Each
output shall be short circuit proof and protected by fuse. Visual indication
of fuse blown must be provided for each output.
The interrogation voltage to the input /output shall be powered from
separate redundant power supply units sand shall not be a part of PLC.
Output contacts from the PLC shall be potential free/ dry contacts and
contact ratings as per table below. Wet contacts /powered contacts/TTL
output etc shall not be acceptable. Suppression device for each output
contact is to be provided.
S.N

Applicable for

Volt

Contact Rating

All output card for driving

alarm annunciator

110V DC
24 V DC

0.5A
2.0A

All Output cards for driving

LT
motors/
pumps
/solenoids

230V AC

5.0 A

Input type shall be intrinsically safe with barriers for analog input
modules and explosion proof type for digital input modules. Only Active

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barriers shall be employed for achieving galvanic isolation.

Scan Time shall be
I/O

Critical
Loop

Analog
Digital

Closed

Closed Loop

Open Loop

>200 msec

>500msec

>1 sec

>200 msec

>500 msec

ANALOG INPUT MODULES

All Analog Input modules shall be Galvanic isolated.
All the Analog input channels shall be Floating-point type
Transmitter power supply shall be generally be from the analog input
module of PLC (24VDC) and measurement DC signals shall be in the
range 4-20mA. However range shall be selectable 0-20mA, 1-5V DC and
0-10VDC.
Module shall have provision of filtering the measuring signals and input
open circuit detection.
ANALOG OUTPUT MODULE
Analog output module shall be galvanic isolated.
All the Analog input signals shall in general in the range 4-20mA.
However the range shall be selectable 0-20mA, 1-5VDC and 0-10VDC.
The load capacity of the current signals shall be 750 ohms.
Output signals shall have a current limitation of 50mA.
POWER SUPPLY MODULE
Power supply module shall operate on power supply with Voltage
203VAC+/- 10% and frequency of 50HZ +/- 5%
Power supply module shall have LED for healthiness check.
Each input output rack shall be provided with separate power supply
module.
COMMUNICATION MODULE
Operating speed shall be min. 10/100M bits per seconds (Ethernet) and
shall be real time data transmission between PLCs and TAS PLC. OLM
modules for bus connections shall be considered with bus inside the
panels and with provision for connection of owners bus from TAS PLC.
System shall be designed as the fault tolerance providing transient error

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detection, data protection, secured independence for dual redundancy of

its unit enhance fail safe function.
Internal bus/ communication module shall be redundant. Switching over
shall be automatically.
For connection of CIU ( for energy monitoring system) to TAs PLC bus RS485 to Ethernet controller module shall be provided.
All communications interfaces shall be galvanically or optically isolated.
SPARES
One module of each type (viz. CPU card, Ethernet card, memory card,
Ethernet switch, Power supply unit/card, FO connectors, Digital Input and
output card, Analog Input and output card, Signal isolator etc) shall be
supplied to enhance the system functional requirement for future.
20% spare slot for installing I/O modules of each type in future.
The processor and memory shall have spare capacity to execute logic, PID
function for additional 20% I/Os spares and I/Os installed in spare slots.
Whenever relays are used to interface process inputs/outputs with PLC
10% additional relays shall be provided.
SELF DIAGNOSTICS
The system shall have an extensive set of self diagnostic routines which
shall be able to identify the system failures at least upto module level
including redundant components and power supplies.
Al the local level, failure of a module in any sub system shall be identified
by a individual LED.

SOFT STARTERS
Selection Criteria
Soft starter shall be provided for the pumps. Design and selection of soft
starters shall be done taking into consideration the fact that the soft
starters are to operate continuously (without bypass contactor) and with
all reasonable precautions and provisions for the safety of operating and
maintenance personnel. The soft starter rating shall be at least equal to

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motor KW rating at 50C for continuous operation and other specified site
conditions.
For the motor, the incoming AC voltage to soft starter shall be 415V, 3
phase, and 50 Hz neutral earthed system.
All the busbar works of soft starter system shall be of copper only.
The soft starters have digital control using microprocessor based digital
regulation & control. This shall be provided with six thyristors in power
circuit and shall have all controls suitable for energy saving also.
Individual soft starter module for each motor shall be with MCCB with
built-in releases, 3 core CTs for connection to energy meter, Energy Meter,
surge suppressor, soft starter, Contactors and Overload relay. The digital
regulation and control system shall be compatible for operation from PLC
provided in VFD panel.
5Salient Features

Soft Starter for AC drives shall comprise of following features:

1) The other protective features for the Soft starter shall include
following:

Electronic type AC surge suppresser with fuse monitoring device

Harmonic filters

AC incomer under voltage & over load

Negative Phase sequence protection & monitoring

2) Suitable for soft start I current limit I full voltage mode of operation.

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3)

Built in energy saver feature when motor is lightly loaded or is

running on no load. Soft starters are expected to run at or near rated
loads. If loads less than rated loads are encountered then VFD shall
alone control the motor.

4) Regulation & control equipment

The digital drive regulation shall be considered and speed and

torque accuracy of drives shall be as required for the process.

The regulation equipment shall be able to carry out all the control
functions including following important features.

Current feedback & controller

Adjustable acceleration I deceleration time.

Adjustable starting torque.
5) Pulse transformers & trigger models
6) Protection, indication & annunciation devices.
7) Load side filter

Protection Features Protection, Indication and Annunciation

The protection of the soft starter is to be provided as per the

clauses stipulated in IEEE-444 as suitable and required for each case
and shall generally include the following.

Control power supply failure

Ventilation failure

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Wrong phase sequence

Motor stalling monitor

Any other protection as required for particular application.

The indications shall be provided as listed but not limited to the

following:

Speed indicator of motor as required.

As marked SLD Digital Energy meter (accuracy class 0.5 or better)

shall also be provided in soft starter circuit.

All meters shall have digital indications but the energy meter (as per
IEC-1 248) shall have RS-485 port to communicate energy
consumption and other data to Central Interface Unit (CIU).

The annunciation shall be provided as listed but not limited to the

following:
Main power ON
Control supply ON
Incoming breaker trip
Phase loss
Microprocessor healthy
System faulty

Following shall also be annunciated

Motor Faults
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Over load relay or Thermister relay
Over current
Over voltage
Earth fault

Soft Starter status

Readiness
Fault
Run

SPECIFICATIONS OF PANEL COMPONENTS AND LCS

Control Transformers
Control transformers of adequate rating (3 kVA each) shall be provided for
110 V AC control supply for each PANEL. Higher rating shall be selected
based on actual requirement with 50% margin and voltage drop in control
transformer shall be less than 3% at peak KVA requirement during coil
pickup.
MCB shall be provided for primary side of control transformers. MCB of
suitable rating shall be provided on the secondary side.
Voltmeter class 1.5 and scale 0-250 V.
Control transformer shall be horizontally mounted in one of the bottom
compartments with adequate ventilation.

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The transformer shall be double wound, dry type with class E insulating
materials.
The control supply for the motor feeders shall be fed through suitable
rated MCBs in the modules.
Control transformers shall be provided with +/- 5% and +/-10% voltage
taps on 415 V side.
The control bus of the PANEL shall be electrolytic grade copper only and
will be designed to carry the transformer rated secondary current as well
as withstand the available short circuit level.

Molded Case Circuit Breaker ( MCCB)

The MCCB rating shall be as per SLD. Adjustable inverse time overload
and I or instantaneous magnetic releases shall be provided suitably.
Operating handle, door interlock and padlocking at ON/OFF position shall
be provided. Symmetrical breaking capacity shall not be less than the
system short circuit level. At least 1 NO and 1 NC auxiliary contacts shall
be provided. These MCCBs shall be provided only for power supply
feeders in PANEL. MCCBs to be provided for VFD and soft starter circuits
shall be as per details given under Technical Specification.
Switches

The switches shall have quick make, quick break, fault make, load break
mechanism operated by an external insulated and earthed handle
complete with ON/OFF position indicator plates.
The switches shall be
a) AC 23 rated (motor duty) conforming to IS 4064-1978 capable of
interrupting minimum six times the rated current at 0.3 p.f of the switch
for switch ratings upto and including 250 amps.

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b) Heavy duty conforming to IS 4064-1978 capable of interrupting three
times the rated current at 0.3 p.f at rated voltage for switches rated
above 250 amps.
c) In case heavy duty switches are offered for (a), then AC-23 rating for the
switch shall be indicated along with test certificate.

All switch contacts shall be silver plated.

In combination with series current limiting fuses, the switches shall be

capable of making all currents up to the system short circuit level
specified.

The load break switch shall be provided with a through door operating
mechanism with visible blades or a visible means of determining the
disconnected position (when the door is opened) and mechanically
interlocked with the door so that switch must be in off-position before the
door can be opened. Provision shall also be there to defeat the door
interlock.

It shall be possible to padlock the load-break switch handle in the OFF

position. Integral padlocking discs shall be provided.

The load break switch shall be TPN.

Bolted type removable copper links of adequate size shall be provided for
neutral in all incomer feeders and outgoing feeders with TPN fuse switch I
switch fuse units.

Solid links shall be used for connections between switches and fuses.

Fuses

All fuses shall be HRC link type (knife edge but not bolted type)
conforming to IS: 9224-1979. The HRC fuses shall be current limiting, nondeteriorating type having breaking capacity of not less than 50 kA.

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Fuse holders shall be selected based on the highest fuse rating for the
given load break switch and specified lower size fuses shall be fitted by
means of suitable links if required.

All fuses shall be provided with distinct type operating indicators, to show
whether they have operated or not.

Fuse holders and fuse bases shall be made of unbreakable noninflammable and non-hygroscopic material like phenolic mouldings.

3 sets of fuse pullers required for inserting and removing HRC fuses shall
be supplied for each panel.

Current Vs. time and 12t characteristics of all fuses shall be furnished along
with the tender.

Contactors
Contactors provided for control of motors shall be 3 pole air
breaks,electro-magnetically operated Contactors meant for capacitor
switching shall have duty corresponding to 150% of rated capacity of bank
at 440V. The contacts shall be made of special silver alloy suitable for
higher switching frequency. The contacts shall have minimum bounce, the
contactor shall have mechanical ON/OFF indication, 2 NO + 2 NC auxiliary
contacts rated at 5A at 440 V. The coil shall be rated at 110 V AC, and
operate satisfactorily from 75 to 110% of rated voltage. Incoming and '
outgoing terminals shall be segregated and terminal capacity shall be
suitable for the type of termination adopted.

Current transformer
Protection and measuring current transformer shall be of cast resin, bar
type primary, with 5A or 1A secondary conforming to IS-2705 -1992 Part

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11, Ill and IV. The minimum burden shall be 15 A CT shall be suitable for
415 V +/- 10 %.
Measuring current transformers shall conform to accuracy class 1 of IS2705 -1992 and burden of CTs shall be as required by the associated
measuring instruments and connecting leads, The CTs shall have saturation
factor of 5.
Protection current transformers shall have their accuracy and burden as
required by the protection circuit in which they are used and shall have
minimum saturation factor not less than 10.
CTs for restricted earth fault protection shall conform to Class 'PS',

Part IV of IS-2705. All CTS shall withstand without injury dynamic stability
and thermal stability currents specified for PANEL.
The current transformer' ratios specified are provisional and are subject to
alteration and confirmation later at the time of approval of manufacturer's
drawings.
Indicating lamps
In addition to the mechanical indicators on the circuit breaker, each
breaker cubicle shall have cluster LED type indication lamps as Specified.
All indication lamps shall have series resistance for long life maintaining
visibility. Lamps shall be replaceable from front of the cubicle without
opening the door.
Control switches
Circuit breaker control switches, when provided, shall be of pistol grip,
spring return to neutral type. They shall be arranged to close the breaker
by being turned clock-wise and to trip it being turned antilock wise. The
trip, neutral and close positions shall be clearly located and the switch
cannot be operated inadvertently. It shall be mechanically inter locked to
trim before close. Lost motion contacts shall be provided in these switches.
Cable termination accessories

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Undrilled G.l gland plates and compression type brass cable glands shall
be provided for termination of cables. The gland plates shall have gaskets
so that the enclosure conforms to IP-54. . Provision for terminating 1/2
core on to earth bus and neutral bus shall be made. All lugs shall be tined
copper lugs only. All lugs and glands for all power and control cables shall
be supplied with the equipment.
Provision shall be made in the PANEL to terminate aluminum cables
matching the feeder rating. The cables are selected based on a derating
factor of 0.6. Necessary glands and lugs have to be supplied along with
the PANEL. The sizes of power cables are given in single line diagrams and
the control cables will be as follows.
Local Control Stations
All motors for Pumps shall have local control station (LCS) mounted near
driven mechanism, which shall be flameproof located at hazardous area.
These shall be supplied by the Owner and shall be interlocked / connected
to the bidder's equipment for operation of the system.
PANELS / PLC SYSTEM CABINETS

CONSTRUCTIONAL DETAILS
Single/Double front design, Non-draw out, free standing,
compartmentalized floor mounting type suitable for both front
and rear access. The panel shall be extendable on both sides at
site.

Shall have an integral base channel.

A transport section shall not exceed 3 vertical

Lifting facility shall be provided for each section.

Feeder module doors and cable alley doors shall open in opposite
direction for providing more working area for maintenance
purpose.

Cable alley shall be adequately designed for use of aluminum

conductor power cables. Cable entry shall be from bottom with
undrilled gland plate.

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Neoprene gaskets shall be used for cable alley doors, bus bar
chamber covers to ensure tightness and making it dust proof.
Cutouts in the module door shall have neoprene gaskets ensuring
dust tightness.

All switches, push buttons etc. shall be capable of operating from

the front. Each feeder module shall have door interlock, defeat
interlock and padlocking facility.

The panels shall be sheet steel enclosed of minimum thickness 2

mm dust and vermin proof, free-standing, floor mounted type
having Panel illumination lamps, space heaters and sockets for
soldering etc. Base channel of height 75 mm shall be provided.

Max. height of operating knobs of any device or indicating meters

shall not exceed 1800 mm from floor of room. Minimum height
shall not be less than 450 mm.

Anti-condensation heaters-of suitable rating with thermostat

cutoff shall be provided in each PANEL.
The control blocks shall be plug-in type with required/necessary
test sockets. The layout of components shall be such. Designed
that the testing operation & maintenance is convenient. The
panels shall have enclosure with class of protection conforming to
IP-54.

All cabinets shall be completely wired with all modules /

components in place. Inside cabinet wiring shall be done using
ribbon type pre-fabricated cables for PLCs.
Busbars & Supports

139 | 2 3 8

Main busbars shall be made of high conductivity aluminum of

grade E91E (IS-5082/1981), Control bus electrolytic copper as per
IS-1897-1983.
Three phase and Neutral bus shall have facility for connection with
earth bus.
Shall be heat shrinkable PVC shrouded except at the points of
tap-off. The bus bars shall be color coded for phase identification.

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140 | 2 3 8

Busbars shall be housed in totally enclosed compartments having

removable type covers for easy maintenance.
Horizontal power bus bars and control bus bar shall be located at
the top of PANEL.
Power and control bus bars shall be segregated.
Main bus bars shall run throughout the length of transport section
and vertical bus bars throughout the height of PANEL. A
continuous earth bus shall be provided for the PANEL at the
bottom with an earthing bolt at each end.
Busbar joints shall be of bolted type with suitable spring washers
to ensure tight fittings. Bolts and washer shall be galvanized or
cadmium plated.
Horizontal bus bars shall be extensible on either side of PANEL.
The earth bus shall be of aluminum having the same size as that
of neutral bus bar at the top. Neutral and earth busbars shall be
connected through a link.
Provision shall also be made for terminating on earth bus the 4th
core of incoming & outgoing cables. Bolted joints with tooth
spring washers shall be provided for good earth continuity.
Bus bars shall be sized for the current rating specified (with
temperature derating) to withstand a short circuit of 35kA rms for
1 sec. The current density shall not be more than 0.78
Amps/sq.mm.
Temperature rise of bus bars shall be limited to 40 Deg. C.
Bus bar supports shall have adequate mechanical strength, high
dielectric strength, and low moisture absorption characteristics.
Hylam shall not be used.
Bus bar supports shall be rigidly held to the frame work of PANEL
and shall be so spaced as to ensure rigid support for bus bars.
Bus bar supports shall be designed to withstand thermal and
dynamic stresses resulting from specified short circuit current.
Min. clearance between live parts shall be 25 mm and live to earth
19mm.
All core type CTs mounted on bus bars shall be supported
separately and not supported on bus bars. CT secondaryconnecting cables shall be properly dressed and clamped such
that these do not hang loose I pass directly over bus bars.

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Wiring & Terminal Blocks

Suitable provision shall be made to terminate control / power
connections near the respective module. The terminals selected
shall be suitable for the termination of armored cables, as per the
details of cable required. Adequate space shall be kept for
cabling.

Panels shall be completely factory wired, ready for connecting to

equipment.

Power circuit wiring shall be with 1100 V grade single core

stranded, PVC insulated copper cable of minimum 4 sq. mm.

Control circuit wiring shall be with 1100 V grade multi strand, PVC
insulated copper cable of 1.5 sq. mm.

Internal control wiring shall be laid in PVC ducts with detachable

snap - on covers and there shall be enough length to avoid the
necessity to stretch the cables for door movement connection,
disconnection or changing.

All terminals, as well as terminations, at various control devices

inside the compartment shall be provided with interlocking type
ferrules having engraved numbers. Terminals having connections
from other modules shall be marked with red ferrules.

There shall be no joints or tappings between two terminations. No

more than two connections shall be made to any terminal.

20% spare terminals shall be provided in each control terminal

block.

The wiring shall be terminated in the respective terminal with

suitable crimp type sockets.

Interlocking type ferrules for identification shall be provided.

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All spare contacts to be wired to terminal block.

Inter-panel wiring shall be through horizontal bus bar chamber.

All holes or tubes for wiring runs shall be bushed and shall have
room for reasonable additions.

All power cable terminal blocks / boards shall be stud and nut
type with phase barriers.

For higher rated feeders, suitable staggered extension links

shall be provided to permit direct termination of cables.

Cable supports / clamps shall be provided in cable alley.

Double compression type GI / brass glands, accessories including

tinned copper lugs to outgoing cable sizes to be supplied loose.

The color-codes for the wires shall be as follows:

415V, 3phases
Neutral
Earth
Single phase - line
110 V AC line
24V DC +ve
24V DC ve

Red, yellow & blue

Black
Green
Red
Brown
Orange
Black

Doors & side panels shall be fabricated from cold rolled steel
sheet of minimum 1.6mm thickness. Load bearing parts shall be
minimum 2 mm thick cold rolled sheet steel. The cable gland plate
shall be 3.0 mm thick.

Each Panel shall be maximum 2300 mm high (including 75-mm

channel base), minimum 800 mm wide and 800 mm deep, in
general. An anti vibration pad of 20 mm thickness shall be
provided. Construction shall be modular preferably to

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accommodate all components. All cabinets shall be of same
height. Maximum swing out for pivoted card racks, doors and
drawers shall be limited to 600 mm.

Panels shall be equipped with the front and rear access doors.
Doors shall be equipped with lockable handles and concealed
hinges with pull pins for easy door removal.

In order to remove dissipated heat effectively from cabinets, vent

louvers backed by wire fly screen shall be provided in cabinet
doors. Further ventilation fans as required shall be provided.

Each cubicle shall be provided with panel illumination lamp

operated by door switch and 15A, 3 pin socket with switch. 230V
AC supply for this shall be tapped from horizontal bus bars.

Equipment within the panel / module shall be laid out in an

accessible and logically segregated manner. Cable glands shall be
provided for incoming and outgoing cables to prevent excessive
stress on the individual terminals. All metal parts of the cabinet
shall be electrically continuous and shall be provided with a
common grounding lug.
CABLE TERMINATIONS

Cable terminating facilities and terminals shall be suitable for the

specified cable type and conductor size. Contractor shall take
consideration and provision on the equipment design for the use
of cable with aluminum conductors.

Terminal blocks shall be arranged and positioned for easy access

for carrying out external cable termination, testing, inspection and
maintenance. There shall be clear space allowed between the
terminal block and the cable entry for the spreading and
termination of external conductors.

Terminal blocks shall be mounted in a single tier arrangement.

The panel wiring shall be on one side of the terminal block only.

All terminal blocks shall be shrouded or provided with transparent

covers.

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Terminals for different voltages shall be separated by partition.

An undrilled gland-plate or entry panel of sufficient dimensions to

terminate the specified cables shall be provided. Cable entry shall
be from bottom unless specified.

Positioning of cable terminations shall avoid obstruction of other

cable terminations, removable covers, etc. and sufficient space
shall be available for maintenance work and cable termination.

Cable clamping arrangement shall be provided to avoid undue

strain on the cable termination.

ANTI-CONDENSATION SPACE HEATERS

Thermostatically controlled heaters suitably rated to

prevent condensation shall be provided within the
distribution board.

The heater shall be supplied with a double pole isolator

The heater terminals shall be clearly marked as to their

use.

LABELS

A main nameplate shall be affixed in a prominent position on the

front of each distribution board giving the following information:

Manufacturers name.
Distribution board Tag Number and name.
System voltage, phase, wires and frequency.
Year of manufacture.

Characters shall be of 12 mm height.

Labels shall have black characters on a white background and be

made of non-corrodible material. Warning/Danger labels shall
have black lettering on a yellow background.

Label shall be affixed by screws or rivets.

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Each panel board shall have fitted a circuit directory within-a clear
protective cover located on the inside of the outgoing circuit
compartment door.

DRAWINGS

The manufacturer shall develop his own general arrangement

drawings and schematics adding necessary auxiliary devices,
accessories, components particulars of the supplied equipment
etc., which are required for a safe and convenient operation of the
distribution board.

The manufacturer shall submit the general arrangement drawings,

flooring and mounting detail, schematic drawings and bill of
material with all component details for owner's review/approval.
Owner's concurrence of all drawings is required before the
manufacturer proceeds with the manufacturing.

Owner's review of the manufacturer's drawings shall not relieve

the manufacturer of his responsibility for supplying equipment
conforming with the relevant specifications and standards, or for
any mistakes, errors or omissions in manufacturer's drawings.

Owner's review of the manufacturer's drawings shall not relieve

the manufacturer of * his responsibility for supplying equipment
conforming with the relevant specifications and standards, or for
any mistakes, errors or omissions in manufacturer's drawings.

EARTHING

A continuous earth bus shall be provided for the

VFD/PLC/SOFTSTARTER PANEL at the bottom with an earthing
bolt at each end.

Provision shall be made for connecting 4th core of incoming and

outgoing cables.

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The earth bus shall be of electrolytic grade copper (E 91E) having

the same size as that of neutral busbar at the top.

Neutral and earth busbars shall be connected through a link.

Electrical equipment shall be interconnected with earth grid using minimum size 50 x 6 copper.

Earthing shall conform IS 3043 - 1987, IE rules and statutory

regulation.

Each cabinet, console and other equipment supplied as a part of

panels shall be provide with an earthing lug. All these lugs shall be
properly secured to the AC mains earthing bus.

All circuit grounds, shields and drain wires of control cables shall
be connected to the system ground bus which shall be electrically
isolated from AC mains earthing bus. This bus shall be typically of
50 mm wide and 6 mm thick of copper.

All barriers, if used, shall be securely grounded. Safety barrier

ground wire shall be capable of carrying a maximum fault level
current of 0.5 A at 250 V r.m.s per barrier.

PAINTING

146 | 2 3 8

Cabinets shall be thoroughly de burred and all sharp edges

grounded smooth. Cabinet finish shall include sand blasting,
grinding, Degreasing, Pickling in acid, Cold rinsing & Phosphating,
chemical cleaning, surface finishing by suitable filler and two coats
of high grade lacquer with wet sanding between two coats. Three
coats of paint in light grey or approved color shall be given for
non-glossy high satin finish. The interior of panel shall have
eggshell white paint.

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APPLICABLE CODES AND STANDARDS
All applicable Indian and IEC codes, regulations and standards shall
govern the work. In the event of the requirements of the specification
exceed the requirements of the corresponding codes, regulations or
standards, the specification shall govern. The applicable standards shall
include standards listed below:
1. IS 2705 Part I 1992 to Part IV: Current transformers,
general requirements.
2. IS 12021 1937: Control Transformers
3. IS 13947 Part 4 1993: Contactors
4. IS 13947 Part 3 1993: Specific requirements for the direct
switching of the individual motors,
5. IEC 171: Molded Case Ckt. Breakers
6. IS 2419 1979 Reaffirmed 1991: Dimensions for panel
mounted indicating and recording electrical instruments.
7. IS 8197-1976:Terminal markings Electrical measuring
instruments.
8. IS 8623 Part 2 1993: Factory built assemblies of switchgear for
voltage up to and including 1000V AC and 1200V DC. Particular
requirement busbar trunking system.
9. IS 13947 Part 1 1993: General requirements for switchgear and
control gear for voltages not exceeding 1 000V AC.
10. IS 10118 - 1982: Code of practice for design installation and
maintenance of switchgear and control gear.
11. IS 13947 Part I - 1993: Degree of protection provided by
enclosure for low voltage switchgear and controlgear.
12. IS 13703-1993: HRC cartridge fuse links.

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13. IS 1554 Part 1 1988 & Part 2 1990: PVC insulated (heavy-duty)
electric cables.
14. IS 3043 - 1987: Earthing
15. IS 5578 - 1984: Guide for marking of insulated conductors.
16. IS 13234-1992: Guide for short circuit calculation.
17. IS 2551-1982: Danger boards.
18. IS 3722-1983 : Letters and Symbols used in electrical technology.
19. IS 9676 1980: Reference ambient temperature for electrical
equipment.
20. IS 8923 -1978 : Warning symbols for dangerous voltages.
21. IS 5 1994: Colour for ready mixed paints and enamels.
22. IS 722: Specification for AC Electricity meters.
23. IS 1248 : Specifications for direct acting indicating analogue
electrical measuring instruments and their accessories.
24. IS 3618: Phosphate treatment of iron and steel for protection
against corrosion.
25. IS 4047: Heavy-duty air break switches and composite units of air
break switches and fuses for voltages not exceeding 1000 V.
26. IS 4064: Air break switches, Air break disconnection, Air break
switch disconnectors and fuse units for voltages not exceeding
1000 V AC or 1200 V DC.
27. IS 5082: Specification for wrought aluminium and aluminium alloy
bars, rods, tubes and sections for electrical purposes.
28. IS 5578: Guide for marking of insulated conductors.

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29. IS 6005: Code of practice for Phosphating of iron and steel.
30. IS 11353: Guide for uniform system marking and identification of
conductors and apparatus terminals.
31. IS 13925: Specification for Shunt capacitors for power Systems

TESTING

TPI shall carry out testing of VFDs at Factory

Tests at works shall include the following:

a. One minute PF withstand voltage between phases, phase to earth

and between open poles as well as for the auxiliary / control circuit.
b. Insulation resistance test for power, auxiliary and control circuits.
c. Physical inspection
d.Operational tests and other routine Tests as per standards/TS.
e. Tests to prove inter changeability of equipment/ components with
same current rating.
f. Calibration of meters.
g. Check of control circuits
h. Test to prove operational requirements, programming, monitoring
etc.
i. Heat run test on the panels.
j. Others as will be specified in approved QAP.

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SPECIFICATION FOR MANUAL CALL POINT & EMERGENCY SHUTDOWN
Manual call points are manually operated devices to initiate an alarm signal and
operate the fire pump. The manual call point & Emergency Shut Down shall be
located at the Gantry. The manual call point shall be painted with fire red as per
IS-5-1994, sheath 536. & ESD hall be grey in color. The manual call point & the
Emergency Shut Down shall be wired to PLC.

Manual call point & ESD shall consist of MS enclosure with a safety glass front.
The front glass keeps the switch in pressed condition. One spare front glass shall
be supplied spare with the MCP & ESD

Manual call point & ESD shall have CMRI certified flame proof enclosure.

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SPECIFICATION OF RADAR GAUGE FOR WATER TANKS

Make
: As per approved vendor list
Model No

Vendor to specify

Qty

Refer BOQ

Tank Dimensions

As per Annexure. Vendor to cross check the

details during Site visit

Type

Microwave Type

Technology

Frequency Modulated Continuous Wave/ Pulse

Type

Service

Water Tank

Intrinsic Accuracy

+/- 10 mm

Installed Accuracy

+/- 20 mm

Resolution

+/- 1 mm

Supply voltage

230 VAC +/- 10%, 50 Hz +/- 5%

Distance (Range)

0.8 mtr to 20 Mtr

Output

To the Tank Side Indicator

RS-485 through CIU to the TAS System

Wireless output

Tank Side Indicator

Either integrated or Standalone

Mounting

On

Open

Rood

Tank.

Entire

Mounting

arrangement shall be in the Vendors Scope.

Ingress Protection

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SPECIFICATION FOR PORTABLE TANK GAUGING INSTRUMENTS
Make

As per approved vendor list

Model No

Vendor to Specify

Service

To measure Ullage (Level), Avg. temp, Avg.

density & Water/Oil Interface for White Oil
application

Accuracy

Density (+/-) 0.3 Kg/Cum

Temp (+/-) 0.1 Deg C
Ullage (+/-2mm)
Interface Detector ( +/-2mm)

Repeatability

Density (+/-) 0.15 Kg/Cum

Temp (+/-) 0.1 Deg C
Ullage (+/-1mm)
Interface Detector ( +/-1mm)

Temperature Compensation

Required

Hazardous Area Classification

Zone I & II, Gr II A,II B T3 as per IS 2148

Approval

CCOE

Controller

Intrinsically safe

Battery Operated

Required; Min 8 hrs Operating time without

charging

Data Handling

Backlight LCD is required

Min 200 transaction memory with date &
time stamp
Shall have provision (USB/Bluetooth) for

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download data in the PC
Note: The Probe shall be preferably combi-probe (single probe for all
measurement) for ease of operation. Alternatively, multi-probes (separate for each
measurement) are also acceptable. However for payment purpose multi-probe
shall be considered as one item only. It shall be delivered in compact hand carrying
case

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EARTHING SYSTEM
Vendor shall furnish recommendations for the grounding (Earthing) of the system
supplied by him. All the equipments installed in gantry & in the field need to be
earth by flexible 4 sqmm (min) copper wire of green colour of approved make.
The wire from instruments shall be taken inside the existing channel section of
gantry or thru cable tray and hooked up to earthing bus bar on each point. Two
GI Strip shall be taken out from each earthing bus bar which shall be connected
to the existing gantry structure earth pits.
Bus bar MOC shall be of copper with zinc coating and provided with two
insulators . Each bus bar back shall have minimum two insulators. The bus bar of
each point shall be fixed so that the cables are secured and are not prone to
snapping. Mixing of electrical and electronic earthing shall not be acceptable.
No bolting is allowed on the GI Strip. The joints shall be welded and protected
from rusting by treating with Barium chromate. Such welded surfaces shall be
treated with Bitumen paint. TFMS earthing shall be as per OEM recommendations
Vendor shall submit detail earthing scheme to HPCL for approval.

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TECHNICAL REQUIREMENT OF OTHER HARDWARE MATERIAL

TECHNICAL SPECIFICATIONS FOR SLEEVED PLUG VALVES
3 / 1 Sleeved Plug valves shall be non lubricated, PTFE sleeved with high pressure
sealing areas circumferentially around internal body bore tap & bottom and 360 degree
port defining lips and adjacent relief areas for sleeve expansion with 2 degree taper
plug & three point adjustment
Plug valve should be of short pattern , teflon sleeved type, wrench operated plug
valves. Valves should be of ANSI 150 lbs rating and should confirm to BS 5353.
Sleeved Plug Valves should provide Bubble Tight Shut Off. These valves should be
maintenance free and quick shut off (quarter turn) type. There should not have any
metal to metal contact in a Sleeved Plug Valve to avoid sticking problems. Sleeved plug
valves should have downward tapered plug to avoid any adjustment to maintain sealing
integrity.
DESIGN FEATURE
TYPE
BODY
COVER
PLUG
SLEEVE
TOP SEAL KIT
END
OPERATION
TESTING

Non lubricating sleeve

ASTM A216 WCB
ASTM A216 WCB
ASTM A351 CF8M
PTFE
Fire safe As per API 607
Flanges 150 Class serrated raised face
Wrench operated
ANSI B 16.34
BODY Hydrotest : 32 Bar
Seat Hydrotest : 21 Bar

BOLT/NUTS

ASTM A 193 Gr B7/ASTM A 194 Gr 2H

ENDS SHOULD HAVE RAISED FLANGES CONFORMING TO ASA 150 CLASS WITH HOLES
DRILLED AS PER ANSI-B-16.5
WORKING PRESSURE

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CS WRENCHES: Operating wrenches suitable for operating this type of valves.

THIRD PARTY INSPECTION by approved agency

All Valves (100 %) shall be tested by manufacturer's quality control officials, before
offering the valves for inspection.
All test certificates for material conformance and pressure test shall be verified and
endorsed by the third party inspection agency.
Testing procedure shall confirm to API-598. / BS 6755 -PART-I
The following tests will be witnessed by the third party inspection agency
a) Hydraulic shell test.-100 % Valves.
b) High pressure closure test -10 % Valves selected at random in one batch. (Minimum
of TWO Valves to be tested)
c) Low pressure closure test on 10% valves selected at random in one batch. (Minimum
of TWO Valves to be tested)
In addition they shall also do the following:a) Overall dimensional check on assembled valves for conformance with
drawings/specifications.
b) Identification against Manufacturer's test certificates.

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TECHNICAL SPECIFICATIONS FOR SLIP ON / BLIND FLANGES

-------------------------------------------------DIMENSIONAL DETAILS :
------------------------------------------------------------------------------------ITEM
SIZE (MM)
THICKNESS
NO.
(DIA)
(MM)
---------------------------------------------------------------------------------------A. SLIP ON FLANGE
----------------------------------------------------------------------------------------1.
600
48.0
2.
500
43.0
3.
450
39.7
4.
400
36.6
5.
350
35.1
6.
300
31.8
7.
250
30.2
8.
200
28.6
9.
150
25.4
10.
100
23.9
11.
80
23.9
12.
50
19.1
B. BLIND FLANGE
----------------------------------------------------------------------1.
600
48.0
2.
500
43.0
3.
450
39.7
4.
400
36.6
5.
350
35.1
6.
300
31.8
7.
250
30.2
8.
200
28.6
9.
150
25.4
10.
100
23.9
11.
80
23.9
12.
50
19.1

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TECHNICAL SPECIFICATION FOR FLANGES

1.Specification

: Conforming to ASA Class

150 raised face without neck.

2.Material

: MS plates conforming to
IS:226/IS:2062 Gr A

3.Dimensions &
Holes drilled

: As per ANSI B.16.5

4.Rating

: 150 psi

5.Face

: Raised with serrations.

Both faces shall be turned
smooth before fabrication.

6.Bolt holes

: All bolt holes shall saddle

the centre line.

The third party inspection shall be carried out by the approved agency:

The following inspection shall be carried out by the 3rd party :

a) Visual Inspection
b) Dimension check
All (100%) Flanges shall be inspected by the 3rd party.

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SPECIFICATION FOR "MS ERW PIPES FOR PRODUCT PIPELINES

MS ERW black line pipes of various sizes conforming to following specification/details.
Item

Mild steel Pipes - ERW

Code

IS 1978 - Latest Edition

Dimensional standard :

IS 1978 - Latest Edition

Length of each pipe

Single random 4-7 M

Ends

Bevelled with end protection caps

Marking

As per Clause no.13.3.1

of IS 1978/1982

DIMENSIONAL DETAILS :
Nominal size
( NB In mm )
500 mm
400 mm

Thickness / Class

Grade

7.1 mm
7.1 mm

Yst 210
Yst 210

350 mm

7.1 mm

Yst 210

300 mm

7.1 mm

Yst 210

250 mm

7.1 mm

Yst 210

200 mm

6.4 mm

Yst 210

150 mm

5.2 mm

Yst 210

100 mm

4.8 mm

Yst 210

80 mm

4.0 mm

Yst 210

Third party inspection shall be carried out by one of the following agencies only :

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SCOPE OF INSPECTION FOR MS ERW PIPES :

Inspection shall be done strictly in accordance with the relevant IS Code .
1. CHEMICAL REQUIREMENT :
(i) Laddle Analysis
(ii) Product Analyses
The supplier shall conduct the above tests in an approved Chemical Laboratory, and
shall get the test results endorsed on the respective test reports by the third party
inspection agency.
The third party inspection agency shall ensure correlation between the
manufacturer's report of heat analysis with the material and the finished pipes.
2. PHYSICAL TESTS :
(i) Longitudinal Tensile Tests
(ii) Transverse Tensile tests
(iii) Weld Tensile Test
(iv) Flattening Test
(v) Hydrostatic Test
(vi) Inspection of Bevel ends, diameter, wall thickness
etc.

All Physical Tests, mentioned above, shall be done with samples from each lot. Lot sizes
for Chemical analyses as well as other Physical tests shall be as specified in relevant
IS code.

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STEEL STRUCTURAL & PIPELINE WORKS

Supply, fabrication, erection, painting of all structural steel works required for the
automation job shall be in the scope of the Vendor. Separate payment shall be
made only for the structural steel used for extension of Gantry platform as per
the relevant line item of the Schedule of quantity.
All pipeline job required for mounting the Automation equipments & instruments
like Electronic Metering, Strainer cum Air Eliminator, DVC, Bulk Air Eliminator,
Orifice plates, Pressure Transmitters, RTD etc shall be in the scope of the Vendor.
In case it is not possible to modify the existing pipeline or the existing pipeline
length becomes inadequate to mount the Automation equipments &
instruments, new pipeline may be laid by the Vendor. Inside the Gantry, laying of
new pipeline is limited to downstream of existing 3 & 1 tapping till loading
arm. The existing pipeline & isolation valves may be re-used to the extent
possible & any additional pipeline, valves, flanges, nut bolts, gaskets etc. required
shall be in the scope of vendor.
For payment of structural steel used for Gantry extension, the weight shall be
calculated based on section given in the standard steel tables and physical
verification whichever is less. The net fabricated dimensions edge to edge shall
be taken into account. The measurement shall exclude any allowance for wastage,
weld metal, etc. All other structural steel required shall be included in the
respective items & will not be paid separately.
No separate payment shall be made for pipeline work & it shall be included in
the cost of respective items.
Vendor shall arrange temporary power connection from the local Electric Supply
Authority by his own effort and cost. Alternatively, Vendor shall have to carry out
the work with his own DG sets at no extra cost. Vendor shall arrange 3 phase
rectifier & welding machine, approved brand of electrodes and skilled welders. All
welders need to be approved by HPCL/PMC before starting of the job.
Steel structural works shall include:
Preparation and supply of arrangement drawings, detailed fabrication drawings,
erection drawings, modification of existing steel structures / platforms, material
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indents, material lists, site bolt lists and dispatch documents for the steel
structures etc.
Supply, fabrication, erection, painting, transportation, delivery, storage, testing
and handling of all steel structures including bolts, nuts, washers, & consumables
like electrodes etc. complete in all respects.
Erection (including tools, tackles and any staging, or false work, required for
erection) handling, transport and rectification of damaged structures, fixing,
aligning, leveling, bolting and welding etc. of all steel structures complete in all
respects. Vendor shall take necessary safety precautions for carrying out HOT
WORK in the premises after obtaining HOT WORK permit.
Painting of steel structures as per specifications
List of Steel structures
The steel structures shall include essentially (but not necessarily limited to) the
following:
Column sections either Box channels or ISMB sections.
Platform sections like ISMC, ISMB or ISA sections.
Gratings for floorings Rounds for Hand Railings and Plates etc.

Drawings and Documents

Modification drawings shall be prepared comprising of general arrangement /
marking drawings, fabrication drawings, erection drawings, bill of materials and
schedule of bolts and nuts. These drawings shall be prepared in conformity with
the best modern practice with due regard to speed and economy in fabrication
and erection. All fabrication drawings shall be approved before commencement
of fabrication.
Drawings accompanying the tender document are indicative of scope of work
and issued for tendering purpose only.

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The contractor is required to prepare the drawings for the complete piping work
with its isometric view, etc., to calculate the actual requirement of various items /
fittings like bends, flanges, etc. The piping layout must show the expansion loops
as per the requirement. The complete set of drawings shall be submitted for
approval, before commencement of the work. No fabrication will start without
the approval of HPCL. The construction drawings shall include:
General arrangement drawings.
Locations of all weld seams, weld sizes, details of weld, etc.
Material to be used.
Edge preparation and method employed.
Tolerances
Quality, brand and gauge of electrodes to be used.
Details of welding reinforcement
Details of brackets for supporting pipes, platforms, etc.
Complete bill of materials to be supplied
Revised drawing shall be submitting incorporating any correction
modifications suggested by HPCL/PMC while approving the drawings.

or

The drawings shall be prepared on computer and the as built drawings shall be
submitted in a floppy after completion of work. All drawings are to be prepared
on Auto-CAD (on PC).
Codes / Standards to be followed:
API - 1104

: Standard for welding of pipelines.

ANSI B 31.3 : Code for petroleum Refinery Piping.

IS 823

: Code of procedure of manual Arc welding of mild steel

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IS 814

: Metal arc welding for mild steel

IS 817

: Welder qualification tests.

Method of construction

The mode of construction shall be either welded and / or bolted to suit the
following but limiting the site work to minimum possible

Process requirements

Transportation

Effective erection considerations

The most effective modern mode of fabrication.

Method of splicing shall be similar to the mode of construction adopted for

structures .

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Materials for Construction
All structural steel plates will conform to IS 2062 1992, Fe 410W, Grade A, for
thickness up to and including 20 mm. All structural steel rolled sections will
conform to IS 2062 Fe 410W Grade A
Electrodes for mild steel will conform to IS 814 1991. The electrodes will be
chosen according to the welding procedure to be adopted, and the quality of
metal to be welded. The strength of the weld metal will not be less than that of
the parent metal.
Hexagonal head bolts will generally conform to the property class 4.6 as specified
in IS 1367 (Part 3) 1991 unless otherwise noted.
Bolts and nuts of property class 4.6 will conform to IS 1363 Part 3, 1984.
permanent bolts will not be less than 16 mm

Size of

Minimum size of fillet weld will be as per recommendation of clause A 2.1.8 of

IS 9595 1980 except that leg size will not be lower than 6 mm.
Fabrication
All welding shall be done by the Qualified Welder. The welder shall have
Welder Qualification Certificate or shall be qualified at Site as per IS 817.
Fabrication of all steel structures shall conform to the best practices and
relevant standards.
Welding shall be in accordance with the standard codes fulfilling the
requirements of electrodes and flux combination, current characteristics,
preheat and post weld heat treatments. Established practices shall be followed
to ensure that the weldment and the heat affected zone metal properties are
not inferior to the parent metal properties.

Elements shall be machined / finished as the case may be as per line and
levels in the shop and assembled suitable for transport / shipment.

Fabrication tolerances shall be within permissible limits as per applicable

standards / codes of practices.

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Structures shall be fabricated to meet transport requirements.

Subject to fulfillment of transport requirements structures shall be fabricated

in sizes so as to minimize site work.

Important structures to be connected together shall be control assembled in

shop so as to avoid mismatch of components during erection at site.

Bends, reducers, expanders, tees and end blinds provided shall be factory
made and forged irrespective of diameter of pipeline. Such fittings shall have
approximately the similar material composition as that of pipeline under
fabrication.

Inspection tests

Engineer-in-Charge or his authorized representative or third party appointed

by HPCL shall have free access at all reasonable time to inspect those parts at
the manufacturers works which are connected with the fabrication of the
steel work and shall be provided with all reasonable facilities for satisfying
himself that the fabrication is being undertaken in accordance with the
provision of this contract.

Inspection shall be made at site / at the place of manufacture prior to

dispatch of the fittings. The inspection shall be conducted so as not to
interfere unnecessarily with the operation of work.

Should any structure or part of a structure be found not to comply with any of
the drawings and specifications, it shall be rejected. No structure or part of
the structure once rejected shall be re-submitted for test except in case where
the corporation considers the defects as rectifiable.

Defects, which may appear during fabrication, shall be made good by the
contractor.

The suitability and capacity of all plants and equipments used for erection
shall be to the satisfaction of the engineer.

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Inspection of structures shall generally be in accordance with relevant

standards and codes

Painting
General

All surfaces need to be manually cleaned with sandpaper /emery paper etc
before painting. Surfaces in direct bonded contact with concrete, stainless
steel or other corrosion resistant alloys, metals are not required to be painted,
unless specified, except for identification marks wherever relevant.

Unless otherwise specified areas, which become inaccessible after assembly,

shall be painted before assembly after cleaning the surface.

The surface shall be perfectly dry before painting.

Painting shall not be done in frosty or foggy weather or when humidity is

such as to cause condensation on the surface to be painted (relative humidity
80% or above) or ambient temperature less than 40 degF.

General compatibility between primer and finishing paints shall be certified by

the paint manufacturers supplying these paints.

Color scheme of painting of structures shall take into account national and
international safety standards on accident prevention and shall also be subject
to HPCL/PMCs approval.

Application of primer and finishing paints

The primer painting shall consist of 2 coats of Zinc Phosphate red oxide
primer & the finish coat shall consist of 2 coats of black synthetic enamel
paint for structural steel/ 2 coats of Aluminum paint for product pipes & HPCL
approved colour banding
All paints shall be of approved quality.

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Whenever the primer paint is damaged, the surface shall be thoroughly

cleaned and touched up with the corresponding primer paint before applying
the second coat of primer.

All paints shall

recommendations.

Parts of steel structures embedded in concrete, shall be given a protective

coat of portland cement slurry immediately after fabrication after surface of
this part is thoroughly cleaned from grease, rust, mill scales, etc. No paint shall
be applied on this part at site.

The approved makes for paints are Berger, Asian Paints, Jenson Nicholson,
Shalimar, ICI

be

applied

in

accordance

with

manufacturers

Erection
The erection of structural steelwork shall be done in accordance with the
relevant standards and in the proper sequence.

The Vendor shall manufacture, erect and dismantle any false work, staging,
temporary supports, bracings etc. required for safe and accurate erection of
steel structures.

The Vendor shall maintain a full-fledged workshop at site so as to enable him

to take up necessary site modification.

Bolts used for site erection shall be long enough so that the end of the bolt
protrudes or is at least flush with the edge of the outer face of the nut, when
the nut is fully tightened. Nuts shall be tightened to maximum limit to prevent
loosening. All Bolts shall be supplied with the correct length of shank and
thread considering the grip length of the elements in the joint to be fastened
together.

The number of washers on permanent bolts shall not be less than two, one for
the bolt and one for the nut.

All site welds shall be uniform and shall be free from any slags, cracks and

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blow holes.

Undercutting of the parent metal shall be avoided.

During site assembly by welding, suitable jigs and fixtures must be used to
avoid distortion of members after welding.

All welding shall be carried out by qualified welders.

Erection tolerances shall be as per the relevant Indian standards or as per

special technological requirements, whichever is more stringent.

Before erection of all pre-fabricated spool pieces, pipe fittings etc., shall be
cleaned inside and outside by suitable means. The cleaning process shall
include removal of foreign matter such as scale, sand, weld spatter, cutting
chips etc., by wire brushes, cleaning tools, etc., and blowing out with
compressed air and / or flushing out with water.

Flange Connections - While fitting up matching flanges, care shall be

exercised to properly align the pipes and to check the flanges for trueness so
that faces of the flanges can be pulled together without inducing any stresses
in the pipes and equipments nozzles.

Valves shall be installed with spindle / actuators orientation / position as

shown in the layout drawings.

Pipe supports are designed to effectively sustain the weight and thermal
effects of the piping system and to prevent its vibrations. Location and design
of pipe supports will be as per the following table or as given by site engineer:
Nominal pipe size in MM.
20/25mm
50mm
80mm
100mm
150mm
200 mm
250mm
300mm
350mm & above

Maximum span in M.
2.10 m
3.05 m
3.60 m
4.25 m
5.15m
5.75 m
6.70 m
7.00 m
7.60 m

The above spacings are indicative and will be kept as per site requirements
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(mm. above). The minimum clearance of 300 mm has to be maintained
between the ground and the bottom surface of pipeline. All pipeline supports
will be numbered serially for identification.
Testing of piping system:

Testing of piping after erection shall be done as per API -1104 and as
specified in price bid.

With the exclusion of instrumentation, piping systems fabricated or

assembled in the shop / factories shall be tested at the site, irrespective of
whether or not they have been pressure tested prior to site welding or
fabrication.

A test pressure of 10.5 kg/Sq.cm shall be maintained for minimum 4 hours.

All tests shall be completed to the satisfaction of site engineer including

retesting if any leakage is noticed during testing.

The site engineer shall be notified in advance by the contractor of testing

sequence / program, to enable him to be present for witnessing the test.

All equipment, materials, consumables and services required for carrying out
the pressure testing of piping system shall be provided by the contractor at
his own cost.

Water for testing shall be given by HPCL.

Test records in triplicate shall be prepared and submitted by the contractor

for each piping system line wise for the pressure test done in the Proforma as
approved by site engineer.

DOCUMENTS TO BE SUBMITTED BY CONTRACTOR:

Welders qualification certificate

Complete record of the Hydrostatic testing carried out on each section of the
pipeline.

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TESTING, INSTALLATION, COMMISSIONING AND SYSTEM ACCEPTANCE
General
This specification defines the basic guidelines for inspection, installation,
commissioning and Site acceptance of fully integrated system. These guidelines
shall also be applicable in all sub-systems, hardware and instruments bought by
Vendor.
On the basis of guidelines specified bidder shall submit their own testing,
installation commissioning and acceptance procedure.
For hardware the
procedure shall include purpose of test, test definition of input procedure, results
expected and acceptance criteria. For software it shall include details of the
method, list of tests, sequence of execution, results expected and acceptance
criteria.
The testing and acceptance of the system shall be carried out based on the
mutually agreed procedures and criterion based on this specification and
Vendors standard procedures.
SYSTEM ACCEPTANCE TEST
Final acceptance of the System is divided broadly into the following stages :

Inspection & Testing at OEMs works by Vendors appointed & HPCL approved
Third Party Inspection (TPI)agency

Site Acceptance Test (SAT)

Trial Run

Stabilization Period

The System shall be accepted after successful completion of all the above stages.
Inspection by TPI Agency
Vendor shall submit the Quality Assurance plan (QAP) to HPCL along with the
Data sheets for approval. TPI agency shall carry out the inspection as per the QAP
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submitted, submit the report to HPCL both in Hard & Soft Copy and issue
dispatch clearance. HPCL reserves the right to be involved and satisfy itself at
each and every stage of inspection. HPCL shall be free to request specific test on
any equipment considered necessary by them although not listed in this
specification, the cost of performing all tests shall be borne by the Vendor.
Vendor shall note that acceptance of any equipment or the exemption of
inspection or testing shall in no way absolve the Vendor of the responsibility for
delivering the equipment meeting all the requirements specified in this
document.
The inspection and testing shall include but not be limited to raw materials,
components, Sub assemblies, prototypes, produced units, guaranteed
performance specifications etc. For factory inspection and testing, Vendor shall
arrange all that is required e.g. quality assurance personnel, space, test gear etc
for successfully carrying out the job by the HPCL and/or his representative at
Vendors cost at the manufacturer's works.
Scope of inspection
Scope of Third Party inspection shall be as per the approved QAP unless
otherwise specified in this document. All inspection and testing shall be carried
out based on the following documents:
a) Approved QAP
b) Relevant standards
c) Purchase Order Specifications
d) Approved Data sheets
e) Approved drawings
SAT is excluded from the scope of TPI & shall be witnessed by HPCL
As a minimum the following checks shall be included in the inspection
Conformance to the approved Data sheet.
Physical verification
Material Of Construction
Make, model no verification
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Functional performance checking.

Third Party Inspection at OEMs factory is mandatory include, but not limited, to
the following items:

Metering Instrument & Accessories as per the inspection scope defined

below
Batch Controllers
Earthing Relay
Power, Signal & Communication Cables
Loading Arms
VFD

The inspection for the Metering Instruments & Accessories shall include PD
meters and accessories, set stop valves, and other associated field instruments
and accessories.
The inspection and testing shall be as under :
a) Material inspection including body and internals.
b) Visual inspection checks.
c) Tests for material, welding, leakage (by hydrostatic test) etc.
d) Dimensional inspection.
e) Calibration test of individual instruments / equipment.
f) Meter proving and calibration.
g) Overall batch accuracy test and repeatability tests.
h) Checks for assuring
specifications.

compliance

Vendor shall produce during inspection:

a) Raw material inspection certificate.
b) Manufacturer Test Reports.
c) Statutory certificates as required.

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with

standards

mentioned

in

the

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Batch Accuracy Test
Calibration against Weights & Measures certified prover tank in case of
flowmeter
Generation of pulses per revolution through rotating pulser in case of
flowmeter.
Testing of randomly chosen Set Stop valves in association with batch
controller and flow meter
Program checking and relay output checking with simulator in case of batch
controller
Performance checking of randomly chosen batch controllers in association
with flow meter & Set stop valve.
The Vendor shall demonstrate the functionality of the system hardware and
software. No materials shall be transported to site until all required tests have
been successfully completed and the material / equipment have been certified
ready for shipment by TPI.
The Metering BAT shall be carried out for 10% of the Metering Units covering all
covering all combination of batch accuracy related equipments randomly picked
up by HPCL for the purpose of BAT.
Vendor to note that acceptance of any equipment or the exemption of inspection
testing shall in no way absolve the bidder of the responsibility for delivering the
equipment meeting all the specified requirements.
Delay, if any, for verification and approval by third party inspection agency shall
be on account of vendor and HPCL shall not be responsible for the same.
Any testing required or recommended by third party needs to be carried out by
vendor in government approved labs or in factory premises at no extra cost to
HPCL.
Vendor may deploy more than one inspection agency for carrying out the above
inspections as per the requirement.

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Third party inspection reports and dispatch clearance shall be submitted to
HPCL/PMC in hard copy and soft copy (scanned image) for all the items with back
up test reports.
Approved Third Party Inspection agencies are
BV / EIL /DNV /ICS /Lloyds /IRS
Vendor shall include all incidental charges towards facilitating third party for
inspection like lodging, boarding, travelling etc and applicable taxes and duties
under respective items. No Separate payment shall be made towards TPI

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INSTALLATION, TESTING AND COMMISSIONING:

Vendor shall deploy its installation team, which would install the equipment/
instruments, lay the interconnecting cabling, check out, testing and
commissioning the system.
Vendor shall prepare Site Acceptance Test documentation covering hardware,
software, and system functional, testing and submit it three months in advance
for HPCL/PMC review and approval.
All technical personnel assigned to the site by the Vendor shall be fully
conversant with the supplied system and software package and shall have both
hardware and software capability to bring the system on line quickly and
efficiently with a minimum of interference with other concurrent construction and
commissioning activities.
Vendors responsibility at site shall include all activities necessary to be
performed to complete the job as per bid documents including, but not limited
to the following:

Receipt of hardware /software and checking for completeness of supplies

Installation of the complete system.

Checking out of the equipment installation.

Checking of interconnection, hardware and software configuration, overall

system function etc., self-diagnostic test on individual equipment.

Loop checking.

Field tests.

Commissioning and on-line debugging of the system.

Performance of final acceptance test.

Test run.

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Test report

Supply, installation, commissioning, calibration & testing of all equipments as

per the scope of Vendor.

LOOP CHECKING:
i.

Loop check shall be carried out by the vendor for checking the
interconnection, configuration and overall system functioning.

ii.

Vendors scope of work in loop checking of interconnection

between
instrument/equipment,
ferruling,
tagging
of
interconnecting cables up to control room, ferruling of field cables
in control room and performing overall loop performance check.

iii.

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.

FIELD TESTING:
All the equipment shall be checked thoroughly after its receipt at site. The
tests as a minimum shall include:
i.

Visual and mechanical testing.

ii.

Complete system configuration loading.

iii.

Demonstration of all system functions.

iv.

Checking of loop configuration.

v.

Checking of OIC displays.

vi.

Checking of correct functioning of all key-boards.

vii.

Demonstration of all system diagnostics.

viii.

Checking of correct changeover of redundant devices.

ix.

Complete checking of loading operational sequence.

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xii.

Demonstration of proper operation of system at specified power

supply specifications.

xiii.

Loadings of Users data formats and check out of results.

CALIBRATION OF EQUIPMENT:
Vendor shall make available all consumables, instruments, and equipment
necessary for testing, calibration, maintenance, etc. as required by the defined
scope of works .All instruments and equipment used for the above purpose shall
be of standard make with accuracy better than the accuracy expected from the
calibrated/tested instruments and certified by standard testing agencies. These
instruments and equipment shall be provided as & when required during testing
calibration, maintenance of instrument & equipments in commissioning, testing,
warranty & comprehensive AMC.
All equipments which need calibration either once or on regular periodic or non
periodic time interval shall be calibrated by OEM approved standard guidelines
and procedures. The document specific to project for calibration of the
equipments proposed shall be submitted along with the datasheets. Also the
methodology to verify the calibrated instruments shall form part of datasheets
which shall be submitted for approval. Datasheets of such equipments without
the calibration and verification document shall be not be considered in submitted
category.

TEST RUN / TRIAL RUN:

Vendor shall conduct trial run of his system for a minimum period of 15 days
after the mechanical completion of job. These trial runs are conducted to verify
the satisfactory performance of the system. In case of major failure in the system
or non-achievement of consistent accuracy, the trial run shall be repeated for a
period of another 15 continuous days.
After trial run site acceptance test (SAT) will be conducted. The project is deemed
to be complete after the compliance of pending points of SAT.

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In case of non availability of Ethanol during trial run, the vendor shall
demonstrate the performance of additive system using MS/ HSD in lieu of
additive. In case of non availability of ethanol during commissioning, the vendor
shall demonstrate performance of ethanol dosing system using MS as an
alternate product. In both the above cases, the Corporation shall make available
the products required for trial run/ commissioning.

QUALITY CONTROL TEST

Quality control tests shall be carried out to ensure quality of all components and
modules in accordance with Vendor's quality controls and assurance procedure.
Vendor shall submit the QAP along with Data sheets of individual equipment.
QAP for site work shall be submitted min 30 days before the start of Site work.
All assemblies shall be aligned and adjusted and all test observations shall be
recorded as per manufacturer published set ups and testing methods.
SITE ACCEPTANCE TESTS (SAT)
SAT will be conducted at the location for duration of minimum 3 to 5 days.
Vendor shall submit the common test procedure at least 60 days prior to the
acceptance test to HPCL for review and modifications, if any, these procedures.
Vendor shall resubmit the procedure incorporating the revisions for approval by
HPCL/PMC. SAT shall be carried out as per the approved procedure. Any
additional tests, though not specifically mentioned in the SAT procedure, but
required by HPCL/PMC shall also be part of SAT.
Vendor shall notify in writing HPCL minimum 15 days in advance for SAT
SAT shall include the following minimum tests
o
o
o
o
o

All hardware checks

All Software integration checks
Checking for completeness of supplies
All functional checks individual as well as integrated
Verification of individual equipments like metering system, Densitometer
etc.

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o Verification of Site works like Cable laying
o Verification of all site documents
STABILIZATION PERIOD
After successful commissioning of the entire system, the system shall be
observed for faultless working for a period of 90 days. If the Tank truck loading
system remains down for more than 24 hours in a day then the system shall be
observed for a further period of 90 days for stabilization after rectification/
replacement of the same by the Vendor.
However, during the stabilization period, in case of fault in any individual
equipment which does not result in complete breakdown of the above subsystem
or any other subsystems, the same shall be rectified within 48 hrs of breakdown
and restored back to operation and such fault will not be considered as major
fault & stabilization period will not be restarted. Record shall be maintained for at
least 50% of Trucks loaded & all tanks during this period to establish the same.
The stabilization will be ended only once the reliability, consistency & accuracy of
the system performance is established. At the end of stabilization period, vendor
shall handover the entire system in fully working condition with accuracy of flow
metering system as per W&M/ Legal Metrology regulations.

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TECHNICAL SPECIFICATIONS FOR FORGED BENDS AND CONCENTRIC REDUCERS.

SCOPE :
Forged 90 deg.(1.5D) and 45 deg. bends and concentric reducers of SCH 40 thickness
with bevelled ends conforming to ANSI B 16.9. Material for the fittings shall conform to
ASTM A-234 Grade WPB.
Inspection by approved Third Party Inspection agency
Scope of inspection shall include the following :
Fittings shall be inspected for dimensional accuracy , uniform surface, edge preparation,
bevel angle etc. They shall be within permissible limits specified in the relevant
standards.
Hydrostatic test certificate of pipe used for making the bends to be submitted and
verified at the time of third party inspection.

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Failure of equipments
Following action shall be taken in case of failure of listed equipments. For other
instruments failure vendor shall advise the action taken in FDS document for
approval or modification

DCV failure: Though DVC is fail safe, still the failure may occur due to
diaphragm failure. In such case, the pumps of that particular product &
header line MOV shall be tripped by system with alarm logged in the
alarm section with alarm of DCV and pump tripping specifying the reason.
The method to restart the tripped pump sets shall be submitted by
vendor. Same shall be possible from soft and hard buttons.

Excess filing above preset quantity : incase of excess filling over the preset
due to failure of DCV, pulsar failure or batch controller or loss of
communication, the said problem clearly identified shall be logged in the
alarms. In case of filled quantity exceeding preset quantity by 10 litres ,
the pumps of that particular product shall be tripped by system indicating
alarm (Product ,specify) pumps tripped ,excess filling loading point(no,
specify). In all cases of pump tripping the alarm shall specify the root
cause of pump tripping .

Card reader: System shall have inbuilt diagnostic tools which shall be put
in system health screen to diagnose health of card reader through
software. The system shall detect the hardware and software( drivers etc)
healthiness.

Failure of any command: Incase of failure of execution of any command

sent to field devices or control room devices , the same shall be generated
by system on real time basis under system alarm category.

Low pressure in header line: The system shall stop the loading of product
at all loading points of particular product in case the header pressure falls
below the set pressure. Such set pressure shall be configurable in the
system. Such events shall be captured under events screen. The alarm

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generated shall display loading stopped at (product points, specify
product) due to low pressure in header.

Batch Controller : whenever any batch controller goes in manual mode the
same shall be advised to user through popup indicating which loading
point has gone in manual.

Manual loading: Incase manual loading through batch controller needs to

be carried out then the procedure shall be as follows :the batch controller
shall ask for password. Upon successful validation of password the BC
shall read supervisor card no thru card reader. Unless and until the
supervisor card no is read and validates the manual loading shall not
proceed. The successful validation will then advise user to enter truck no.
Upon such validation only then manual loading shall be permitted.
Whenever system comes in remote mode back then data should be
updated automatically without any pressing of button and same shall be
also available in manual load report

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PLANT OPERATION AND MAINTENANCE MANUAL
Vendor shall submit to HPCL for review and approval of the draft of the operating
manual for the facilities as per requirements listed in contract documents. Final
operating manual shall only be issued after approval on draft is obtained. Five
sets of final approved operating and maintenance manual shall be made available
before commencing the commission of the plant.
The operation manual shall have two parts. One shall give the details of the
individual instrument/ equipment. The other part shall contain the system details.
The objective of the manual is to assemble under one bound cover all the
instructions, data and drawings necessary for the operations personnel to start,
operate, control, shut down and maintain the systems under normal and
emergency conditions in a safe manner. It is desired that the instructions to be
written for clarity and simplicity.

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PERFORMANCE GUARANTEE (Defect liability Period)

Vendor shall be responsible for proper design, quality, workmanship, operation &
maintenance of all equipment, accessories, etc. supplied by the Vendor for a
period of 24 months from the date of commencement of Stabilization. In case
commencement of stabilization is delayed due to non availability of products or
any other reason not attributable to Vendor, then warranty shall be 30 months
from the date of mechanical completion only for that equipment in question.
Further Vendor shall provide written guarantee that the back-up engineering,
maintenance and spare parts shall be available for a minimum period of 8 years
after warranty period for all equipment supplied by the Vendor. In the event of
non-availability of spares due to fast obsolescence of hardware and software, the
vendor shall arrange to upgrade/ replace the equipments with equivalent or
higher hardware and software at no additional cost till end of this 8 year period.
It shall be obligatory on the part of the Vendor that during the defect
liability/warranty period, Vendor will take complete responsibility for any defect
observed in the system supplied by the Vendor, any modification and/or
replacement of any hardware from the supplied equipment and attend to the
maintenance of the system, free of cost, during start-up and on-line operation of
TAS. Any emergency requirement shall be attended by Vendors Senior Team
within one day notice. The replacement of any sub-system, modules and or entire
system shall be attended within one day.
Cost of all spares, equipment, instruments & services, (be preventive &
breakdown) to take care of the above points has to be borne by the Vendor
during the warranty period In case of failure to attend to these promptly, these
will be attended through alternate agency at vendors risk and cost.
All road permits for supply of any spares/ materials during CAMC shall be in the
Vendors scope.

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The vendors resident engineer will check and service of each equipment &
instrument and its accessories and maintain them in good working condition. Any
consumables required for servicing the equipments shall be arranged by the
Vendor at no extra cost to HPCL during Warranty
Vendor shall maintain minimum consumables for smooth working of equipment/
instrument supplied by them.
Printer cartridge, Stationary papers shall not form part of consumables to be
maintained by the vendor at site.
W&M stamping of the electronic metering system during the warranty period
shall be in the scope of Vendor. All incidental charges for W&M stamping shall
be in the scope of the Vendor. Statutory fees shall be reimbursed by HPCL
against submission of Original receipt. The receipt shall be in the name of HPCL
location. Any additional W&M stamping required, apart from the yearly
stamping, due to reasons attributable to automation equipments like change in
calibration, K factors, replacement of pulsars etc. shall be in the scope of Vendor.
Vendor shall provide Resident Engineer (Min. degree holder) with minimum one
year experience / familiarity in erection/ commissioning/ maintenance of TAS
should be positioned at the location during working hours for taking care of
normal system operation, all Preventive & Breakdown maintenance during the
total warranty period. The Resident Engineer shall submit fortnightly report on
the System operation, preventive & breakdown maintenance carried out. This
includes backup coverage for such engineers for vacations, illness, training etc at
no additional costs.
The Resident Engineer shall assist the Location in verification of metering system,
etc as & when required by the location.

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POST WARRANTY COMPREHENSIVE ANNUAL MAINTENANCE CONTRACT (CAMC)

The system( all equipment supplied by the Vendor including

interface/integration) is to be maintained for a period of five years after expiry of
warranty period. Cost of all spares, equipment, instruments & services,
(Preventive & Breakdown) to take care of maintenance, has to be borne by the
Vendor during the CAMC period. In case of failure to attend within 2 days, these
will be attended through alternate agency at vendors risk and cost.
The post warranty comprehensive AMC shall be a separate contract for the 5
years period and shall be signed at beginning of the respective year. The post
warranty Comprehensive AMC rates quoted in price bid for 5 years shall be
included in the evaluation.
6 Nos. normal visits (once in two months) and 4 No. emergency visits per annum
(as & when required) are included in scope of C.A.M.C. (Comprehensive Annual
Maintenance Contract). HPCL will have the right to reschedule the visits and
adjust the total no. of regular and emergency visits.
The vendors service engineer will check and service of each equipment &
instrument and its accessories and maintain them in good working condition. Any
consumables required for servicing the equipments shall be arranged by the
Vendor at no extra cost to HPCL during CAMC.
Vendor shall maintain minimum consumables for smooth working of terminal
automation system
Printer cartridge, Stationary papers shall not form part of consumables to be
maintained by the vendor at site.
HPCL can terminate the annual maintenance contract by giving three months
notice in advance to the vendor.
During the CAMC, Vendor will hold the inventory of minimum spares inventory at
the site required for maintaining the system in operating condition. The vendor
shall ensure availability of spares (at minimum) at all times at the site. The vendor
shall always promptly replenish the spares as & where the same are used. The
vendor should do proper spares management by carrying out periodical testing
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of the spares, safeguards against obsolescence, any up gradation, timely
replenishment, etc.
W&M stamping of the electronic metering system during the warranty period
shall be in the scope of Vendor. All incidental charges for W&M stamping shall
be in the scope of the Vendor. Statutory fees shall be reimbursed by HPCL
against submission of Original receipt. The receipt shall be in the name respective
HPCL location. Any additional W&M stamping required, apart from the yearly
stamping, due to reasons attributable to automation equipments like change in
calibration, K factors, replacement of pulsars etc. shall be in the scope of Vendor.
Vendor shall furnish Bank Guarantee equivalent to the rates quoted for 5 year
comprehensive Annual Maintenance Contract. This Bank Guarantee shall be
submitted 2 months before the expiry of warranty period failing which retention
money shall stand forfeited. BG for CAMC shall be valid for minimum 62 months
or till the end of 5th year AMC whichever is later.
The vendor shall ensure availability of spares for the Automation System for a
minimum period of 8 years after warranty period. In the event of non-availability
of spares due to fast obsolescence of hardware and software, the vendor shall
arrange to upgrade/ replace the equipments with equivalent or higher hardware
and software at no additional cost till end of CAMC period.
The Vendor must note that all commissioning spares and the spares /
consumables during warranty and comprehensive CAMC shall be supplied by the
vendor free of cost.
All road permits for supply of any spares/ materials during CAMC shall be in the
Vendors scope.
Agreement for the Post warranty CAMC shall be entered before the start of each
year. HPCL reserves the right to sign the post warranty AMC for all 5 years or part
of it or none or to extend the contract after 5 years.
The CAMC charges shall be quoted in absolute amount (not in %).However
the CAMC charges for 5 years shall be at least 10 % of the total Capital cost
to ensure that the system is maintained throughout the CAMC period as
envisaged. If the Vendor quotes less than 10% as AMC charges, minimum of

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10% of the total capital cost for 5 years period shall be considered as AMC
charges, keeping the total cost (Total capital cost + CAMC) as quoted by the
vendor. In case the vendor quotes higher amount of CAMC, the quoted
amount shall be retained. The composite rate quoted by vendor for 5 years
CAMC period shall be split year wise in the following percentage for
payment purpose
Year 1 :
Year 2 :
Year 3 :
Year 4 :
Year 5 :

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10% of CAMC cost of 5 years

15% of CAMC cost of 5 years
20% of CAMC cost of 5 years
25% of CAMC cost of 5 years
30% of CAMC cost of 5 years

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SAFETY PRACTICE

SAFETY / SECURITY OF MATERIALS

The responsibility of safety and security of materials and equipments brought or
installed by the contractors (till they are handed over to us) will remain with
contractor and any claim, of what so ever nature due to any loss or otherwise, will
not be entertained. The contractor will have to hand over completed job in its
entirely as per work order.
SECURITY OF CONTRACTORS MATERIALS
HPCL shall not be responsible for the security of Contractors materials /
equipment.
SAFETY PRECAUTIONS AND HOT WORK
Contractor shall have to take all safety precaution for carrying out hot work in the
premises after obtaining hot work permit from location in charge at his own cost
as directed by the Engineer-In-Charge. Necessary safety equipment such as
safety belts, helmets, etc., and other safety instruments are to be positioned by
the contractor and the same shall be used by the work force as per work
requirement. The contractor has to enforce the same.
Safety distance as per CCE Rules and Oil Industry Safety Directorate shall be
maintained strictly.
Any casualty or damage caused to property or person by any untoward incidents
while executing this contract will be at the contractors risk and cost.
The contractor shall strictly follow safety practices during construction as per the
OISD 192.
HOT WORK PERMIT
No hot work is permitted without issuance of hot work permit by location incharge. The hot work permit will be issued in the HPCL approved format on a
day-to-day basis.
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After completion of work, the site should be cleared of all scrap, contractors
equipment and machinery used in fabrication.

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OTHER TECHNICAL REQUIREMENTS:

Flexibility should be kept in the software to re-designate each tank, pump for a
new product which will in turn maintain the stock accounts as per the change.
The security access for the engineering./configuration database, other terminal
database master maintained in the system, should support additional security
protection other than password protection for the authorized access.
System initialization and setup parameter for entry of the database for tank farm
specifications including system security shall have user friendly interface. System
should have appropriate user interface for data entry of tank calibration charts as
per standard format and bidder shall use the same for tank farm system
configuration.
All commissioning and start-up spares required up to commissioning, system
acceptance and handing over of the system to the HPCL shall be in the Vendors
scope.
The Vendor shall be fully responsible for proper selection of equipment,
engineering performance and successful operation of the complete system
including all bought out equipment, subsystems supplied by them when
integrated with the overall Automation System meeting the functional
requirements.
The operational requirements as specified in this tender conditions/specifications
might undergo certain revisions during detail design and engineering. Also there
may be minor variations from depot to depot. The Tenderer must ensure that the
offered system software packages have the capability and flexibility to take care
of these requirements without any major software changes.
The Tenderer has to make his own estimate of quantity of the cables and
erection hardware requirement, based on the layout drawing enclosed and his
own site assessment.

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The system shall be internally protected against system errors and hardware
damage resulting from electrical transients on power wiring and signal wiring
which may be generated by switching large electrical loads or by power line
faults, and connecting & disconnecting devices or removing or inserting printed
circuit boards in the system.
The system design shall permit for future expansion, on line addition of new
systems/ subsystems without any disruption to either the operation or system
communication.
Vendor shall obtain all the required approvals from statutory bodies like CMRI,
CCOE, W & M etc at no extra cost to HPCL. Annual calibration including
coordination with local W & M inspector is included in the scope of the Vendor.
However the stamping charges will be paid by HPCL (Location) on proof and
production of original receipt during Warranty & AMC period.
A corrosion resistant nameplate will be securely fastened to the equipment in a
visible and accessible place. Nameplate shall bear the following data:

Manufacturers Name
Model Number
Serial Number
Size, rating (s) and Range (s)
Electrical data (where applicable)
Approval for Electrical Area Classification (with approving authority's
monogram where applicable)
HPCLs Tag Number.

Detailed Design and Engineering for various items involved for the total project
for Instrumentation and automation including detailed material specifications /
requisition, project specific drawings, obtaining necessary approvals and
preparation of detailed report is in the scope of the Vendor .
Documentation of the entire system including detailed specification of the
system configuration, system Architecture, technical philosophy, equipment,
detailed drawings, trouble shooting charts, general maintenance guidelines etc
shall be submitted by the Vendor.

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OTHER FUNCTIONAL REQUIREMENT

Product life cycle
Datasheets of the following components (specific to model no. offered), software
shall be submitted with the following details apart from technical specifications
Equipments list :

Batch controller

LRC servers

Client PC

Windows software

Terminal server

Ethernet switch

VFD

Densitometer

PLC

Card reader

RIT

Pressure Transmitters

Following information is required to be attached along with datasheet. The dates

need to be certified by OEM before submitting datasheet. OEM letter or email
shall form part of the datasheet.
Equipment name:
Model number :
Date of launching product : DD-MM-YY or MM-YY

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Likely Date of discontinuation of product : MM-YY or YY
Spares availability till : YYYY
All datasheets shall be submitted with the technical product catalog in hard and
soft format. Datasheets of such equipments without the product life cycle
document shall be not be considered in submitted category.

Trending
The trending feature shall be of various types like Single Bar, Multiple Bar, X-Y,
Numeric, etc. The module shall be able to show at least
Real Time Trending
Historical Trending
Archived Historical Trending
Cursor Read Out
Zoom & Scroll
Trend Comparisons

Trending feature is required for minimum following parameters

Gantry area
Header pressure for all products
Flow rate for individual loading point
Temperature for individual loading points
Each loading point totaliser readings
VFD & energy Management System

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Tank farm area
Water level for all tanks
Oil level for all tanks
Average temperature of product for all tanks
PT reading of all tanks
Density of the product for all tanks
Multispot readings of temperature for all above ground tanks

Product pumps, Fire water pumps (tank truck filling pumps , Additive
dosing pumps, ethanol pumps, fire water pumps)
Each pump running hours

All trends can be plotted as individual or combination of the above points. TAS
system shall provide a seperate tab for Trends in the index. Once user clicks
Trend tab then screen for various options shall be displayed. The options shall
include above menus Gantry area, TFMS area, Product pumps and fire water
pumps with sub headings or submenus as defined above or the same can be
achieved through drop down menus. The user shall have the facility of plotting
any one feature in menu or all features in one menu or combination of some or
all features for one or more menus. In any given case if user wants to plot
multiple menus as gantry and TFMS in one single sheet the same shall be
possible however all lines representing individual dedicated parameters shall
have different colours .In the event when cursor is pointed on the line in the
trend graph , system shall show the item name its value and the time . The facility
of export of trend to MS office or Star office or office viewer shall be provided.
The size of trend screen shall be minimum 75% of the total screen size and
customized zooming facility shall be provided without blurring of original line,
dimensions, colour and the text . For zooming , the software shall provide the
options in drop down box or user entry upto 400 % of original size. A legend
needs to be provided indicating the acronyms used if any and the colour of the
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line. Acronyms shall not be used as far as possible and the colour of the line shall
be chosen as close as possible to product colour wherever trend is of feature
which involve product.
The trend screen when plotted shall display the trend for the chosen parameters
and in the balance 25% of the screen area corresponding table shall be shown
which shall depict the value of that particular feature
The software shall plot the trend for current date data as well as for historical
data.
A Trend Set display shows Historical information, of the point/tag such as PV, SP,
OUTPUT, for up to eight related points. The information is displayed in an
appropriate manner, such as:
Bar graphs
Line graphs
Numerical list of historical data
X-Y plot of the value of one point against another (that is, one point on the Xaxis and the other on the Y-axis)
Each trend set is identified by a number, and has a descriptive title.

HISTORISATION PHILOSOPHY

Software shall store the values of points over time to create a history of plant
process. There are three types of history which shall be configured.
Fast History
Allowing to store 5 seconds snapshots of a point parameter i.e. PV, SP, OUTPUT
etc
Standard History
In this, snapshots of a point parameter can be configured for 1min/6min/1hour/8-hour/24 hour intervals.
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Extended History
In this, snapshots of a point parameter can be configured for 1hour/8-hour/24
hour intervals.
The type of parameters and the type of history required shall be advised to
successful bidder .
USER PROFILES
In all the client and server machines ( including gateway server) two profiles shall
be available. One profile is for administrator login and other profile shall be
group profile. When the machine ( client or server ) is booted then the machine
shall display group profile of TAS users only. Log in screen shall contain three
fields viz user name , profile and password. In the profile field shall be non
editable and TAS group to be displayed , User name shall be selectable from
drop downmenu which shall display the name of all the users who have been
configured for that location. User needs to enter the password and upon
successful validation of the password the system shall direct the user
automatically to software login. Users in TAS group shall have the facility of
logging in , logging off and shutdown of the machine only. No TAS user shall be
allowed by TAS profile to access or work upon OS , TAS software files.
For administrator login : Whenever ctrl+ alt+delete is pressed the system shall by
default go in TAS group profile. When different set of keys are pressed then only
administrator profile is enabled which also requires password authentication. In
administrator profile the administrator needs to enter two passwords for
successful login ie his user id password and transaction password. Upon
successful validation of both the passwords the administrator shall log in the
system. It is mandatory that login password and transaction password for the
administrator shall be different. The TAS software shall record the log in time of
administrator , log off time of administrator and shall record the files name
accessed ,modified with date and time stamping. Such events of administrator
activities shall be separately recorded in reports also and in events under
subhead administrator events.

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Backup and retrieval of TAS software with database

All exe. files in TAS software and database shall be stored on every month basis in
all clients in separate folder named as backup folder. The password protection is
required for the folder. The folder shall contain the sub-files or sub-folders
indicating name and year of the backup. Nomenclature of such subfolders shall
be first three letters of month name followed by last two digits of year for
example backup subfolder of January 2010 shall be named as jan10. The backup
folder shall reside in D drive of all the client machines . After every one year of
the subfolder creation date the old subfolder shall be deleted so that the space
constraint does not happen in client machines. The client machines shall be
suitably selected such that the graphics updatation time, data updation time are
not affected due to backup data stored in client machines.
After every month end , the system on the first day of the next month shall
prompt the user to take backup in DVD or data storage media by a pop up on
the screen if end of month has not been performed by user on the last day of
month after operation are over. The pop up shall indicate clearly that system shall
not proceed further unless and until the backup is taken on media. Software
check to be ensured that card allocation should not be possible till the time data
backup is taken .The backup functionality to be provided inline with description
of end of month requirement also.
Retrieval of TAS software and database
In case of crash of any of the servers wherein data is lost or TAS software needs
to be reloaded or the machine needs to be formatted the retrieval facility shall be
provided.
In case of formatting of machine the user shall be able to load the operating
system with the help of Operating system provided. After loading of OS , the user
shall be able to load the In case of TAS software reloading, the same shall be
possible to load with the help of restore CD .Such restore CD shall be given apart
from the TAS software with necessary CD key and license by TAS vendor. The
restore CD will have all required drivers, communication IPs etc so that once the
restore CD installation is complete the system should start functioning with all
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features , functionalities. Each restore CD shall be site specific as communication
IPs and various other parameters will be different from other site. The restore CD
shall be created by vendor and given to each site after successful completion of
stabilization period. After the TAS software is restored the software retrieval tool
should retrieve the data from the path of client machine. The software shall
provide the facility for user to select the time period for which data is required. In
case of any failure, crash of operating system, TAS software /crash or corrupted
database and the problem is not getting resolved by the above methodology the
vendor shall depute their competent engineer to site within 24 hours of such
event to restore the facilities at no extra cost to HPCL. Such urgent deputation to
site can be during project execution stage, stabilization, warranty and CAMC
period.
In case of failure or corruption of TAS software the same shall be possible to
retrieve with the help of restore CD as mentioned above along with database
methodology as mentioned above.
In case of data required which is not in server database the user shall have the
facility to restore database for days or months with the help of database in client
or from the backup media. Software shall be provided with separate screen for
retrieval of data with date option From XX-XX-XX To CC-CC-CC . Wherever the
user is asked dates option whether in reports, trends or retrieval the dates shall
be selected from standard calendar which will come as popup from calendar icon.
Typing of dates with format DD-MM-YYYY shall also be acceptable. Once data is
retrieved from such sources , all reports & trend etc shall be made available for
such duration also.
After successful completion of SAT , vendor needs to handover DVD/data storage
media containing all files of TAS folder and database as on SAT date. The media
shall be made such that ghost image of the entire TAS folder is taken . Software
etc if any required for providing the same shall be in the scope of vendor.
TFMS file generation security
The TAS software shall generate the TFMS file either automatically on EOD
command or it can be generated manually by the user. The system shall
generate the file automatically incase the EOD is done automatically by system.
The TFMS file can be generated once a day based on date and time of data . In
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case the user gives command to generate the file ,after the file has been
generated manually or automatically the system shall not allow second
generation. The facility to generate TFMS file in case of manual generation shall
ask user id and password again even if the user is logged in the system. The time
along with date stamping , user id shall be recorded in events.

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Synchronization of database
The database in the primary and backup server shall be same at any given point
of time when both the servers are in working condition. The database shall be
synchronized in both the servers on real time basis in auto mode. The toggle
switch shall be provided in the system status screen to switch over from auto
mode to manual mode. The system status screen shall also show the state of
database as either synchronized, not synchronized or synchronizing. Further a
separate screen shall show the following details
Last synchronized on
Synchronisation lost at : ( specify time)
Synchronised status :
The above data shall always be on real time basis.
Also a hot standby monitor to be developed on screen which shall show the
following for both LRC servers on real time basis. The screen shall be auto
refreshed. The data for each server to be fetched from respective server. Vendor
during FAT shall demonstrate the source of data , data path for both the fields.
Description
Data for server 1
Data for server 2
Current FAN no
Current load no
Current Batch result number
Current alarm number
Current event number
Current audit number
In case of loss of synchronization of data shall be classified under emergency
alarms.
Tank truck loading gantry and various interlocks

All the Tank Trucks (T/T) will come to the Terminal and report at S & D
counter.
The load is planned by JDE operator and sent to JDE sever.
The load is sent from JDE server to TAS LRC through gateway server.

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Once the preload packet is received the LRC displays the truck details ,
customer name and number, and quantity of product to be loaded and
load segregation based on compartment capacity. Compartment
allocation logic and preferred bay configuration logic needs to be part of
TAS software.
TT is allocated proximity card number. The facility to allocate card shall be
dual i.e. by card reader and through keyboard pads.
TTES allocates Bay no., based on total no of T/T inside and 1 + 2 criteria
(User Configurable) for TLF bay. TTES operator can override the bay
allocation, if required. Card reader at TTES reads Card number for printing
on FAN (filling advice note). LRC sends a visual communication by means
of display on electronic display unit in T/T parking area, asking T/T to
report for filling bay. FAN is printed by TTES operator and handed over to
the driver along with card and seals. Validity of card vis-a-vis time elapsed
since time of issue & expiry of FAN should also be programmed. The
display to EDU and announcement shall be programmed so that it is in
line with the printing of FAN ie truck whose FAN is printed first shall be
displayed and announced first .
T/T enters through main Gate of the terminal / depot at TLF entry gate
Barrier.
Driver shows the card at barrier gate card reader. Card validation is done
by LRC. Gate opens on command from PLC based on clearance from main
computer of control room, and the T/T enters the licensed premises.
T/T reports for filling at the allocated bay. The Red lamp in the RIT is ON at
particular TLF bay. T/T driver shows the card at the card reader provided at
the bay. LRC checks its validity, downloads the loading information to
batch controller. If card is not current or valid, Batch controller displays
invalid card or un -authorised card or Go to bay no XXX and RIT will
display steady red lamp. Upon successful completion of identification
sequences, truck registration no is displayed on batch controller.
Driver connects earthing to the T/T.
T/T driver inserts loading arm in the first compartment of T/T i.e. Starting
from T/T cabin side.
Batch controller checks for safety permissive interlocks. RIT lamp
changes from Red to yellow. Batch controller shall simultaneously display
truck no, compartment number and preset quantity. Driver need to
acknowledge once per compartment.

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Driver prepares for loading and acknowledges by pressing yellow push

button on RIT. LRC checks for tank, which is in withdrawal mode to supply
particular product.
Green lamp on RIT is ON
Driver presses green PB for actual start of loading operation. Flow of
product should not start unless all the mandatory checks are complied
with.
(Step 9 to 13 are repeated till the loading is complete for all compartments
of T/T)
Batch controller uploads all other product meters of the bay and will only
permit flow of designated product. Batch controller continuously updates,
present, remaining & volume loaded during loading operation. If a
multiple load is started on a multiple products bay, the driver may be
allowed to fill both products simultaneously. This should be supported as a
configurable option with LRC, which can be set for only one product active
on bay.
After the T/T loading is complete, Supervisor at TLF checks sealing of all
chambers of the T/T, signs the FAN. T/T drives out of the bay and moves
towards TLF exit gate barrier.
LRC computer will release the bay and meanwhile TDM operator prepares
the challan at the Marketing room
Supervisors will have unique card, which can be read at the bay reader to
locally load the TT for any given quantity after setting the qty. in batch
controller. All historical data pertaining to such type of fillings will be
recorded in the LRC and at the bay, LRC will generate a report for the
same i.e., the Bill of lading (BOL)
T/T comes out of licensed premises, goes to security gate. Meanwhile T/T
driver collects the challan from marketing room. T/T driver hands over
Gate pass copy of challan and card to the security , who in turn shows the
card to the exit barrier card reader. LRC checks up in its database, whether
the challan for the particular truck has already been printed from the
Marketing room and all clear signal sent to PLC for opening of the exit
gate at TLF. TT exits through gate barrier.
Entire system will work on real time mode and will register entry, filling &
exit time of each Tank truck.

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Failure of equipments
Following action shall be taken in case of failure of listed equipments. For other
instruments failure vendor shall advise the action taken in FDS document for
approval or modification

DCV failure : Incase of DCV failure , the pumps of that particular product
shall be tripped by system with alarm logged in the alarm section with
alarm of DCV and pump tripping specifying the reason. The method to
restart the tripped pump sets shall be submitted by vendor. Same shall be
possible from soft and hard buttons.

Excess filing above preset quantity : incase of excess filling over the preset
due to failure of DCV, pulsar failure or batch controller or loss of
communication, the said problem clearly identified shall be logged in the
alarms. In case of filled quantity exceeding preset quantity by 10 litres ,
the pumps of that particular product shall be tripped by system indicating
alarm (Product ,specify) pumps tripped ,excess filling loading point(no,
specify). In all cases of pump tripping the alarm shall specify the root
cause of pump tripping .

Card reader: System shall have inbuilt diagnostic tools which shall be put
in system health screen to diagnose health of card reader through
software. The system shall detect the hardware and software( drivers etc)
healthiness.

Failure of any command : Incase of failure of execution of any command

sent to field devices or control room devices , the same shall be generated
by system on real time basis under system alarm category.

Low pressure in header line : The system shall stop the loading of product
at all loading points of particular product incase the header pressure falls
below the set pressure. Such set pressure shall be configurable in the
system. Such events shall be captured under events screen. The alarm
generated shall display loading stopped at (product points, specify
product) due to low pressure in header.

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Batch Controller : whenever any batch controller goes in manual mode the
same shall be advised to user through popup indicating which loading
point has gone in manual.

System health screen shall also capture the input power supply to UPS (both),
PLC on screen. In the event of main power failure the UPS shall draw the power
from batteries. The DG set provided by vendor shall run after preconfigured time
of mains power failure. In the event there is no power backup due to UPS except
from batteries, the UPS shall give command to TAS servers for shutdown at
preconfigured time before the batteries are completely discharged. The time shall
be user configurable in system health screen. All field equipments and control
room equipments which are connected through various sub links shall be shown
live on the system health screen. Any failure of link or sub link shall be shown in
red colour on real time basis. System shall also indicate mode of UPS batteries.

All RIT stops shall be recorded in the event section of TAS software. In case
emergency stop is pressed at loading point once, the loading shall resume only
after the supervisory card is shown at the gantry.
Manual loading : Incase manual loading through batch controller needs to be
carried out then the procedure shall be as follows :the batch controller shall ask
for password. Upon successful validation of password the BC shall read
supervisor card no thru card reader. Unless and until the supervisor card no is
read and validates the manual loading shall not proceed. The successful
validation will then advise user to enter truck no. Upon such validation only then
manual loading shall be permitted. Whenever system comes in remote mode
back then data should be updated automatically without any pressing of button
and same shall be also available in ma

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PLANT OPERATION AND MAINTENANCE MANUAL
Vendor shall submit to HPCL/PMC for review and approval of the draft of the
operating manual for the facilities as per requirements listed in contract
documents. Final operating manual shall only be issued after approval on draft is
obtained. Five sets of final approved operating and maintenance manual shall be
made available before commencing the commission of the plant.
The operation manual shall have two parts. One shall give the details of the
individual instrument/ equipment. The other part shall contain the system details.
The objective of the manual is to assemble under one bound cover all the
instructions, data and drawings necessary for the operations personnel to start,
operate, control, shut down and maintain the systems under normal and
emergency conditions in a safe manner. It is desired that the instructions to be
written for clarity and simplicity.
Separate operation and maintenance manual shall be furnished for each
terminal/ depot.

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PERFORMANCE GUARANTEE (Defect liability Period)

Vendor shall be responsible for proper design, quality, workmanship, operation &
maintenance of all equipment, accessories, etc. supplied by the Vendor for a
period of 24 months from the date of commencement of Stabilization. In case
commencement of stabilization is delayed due to non availability of products or
any other reason not attributable to Vendor, then warranty shall be 30 months
from the date of mechanical completion only for that equipment in question.
Further Vendor shall provide written guarantee that the back-up engineering,
maintenance and spare parts shall be available for a minimum period of 8 years
after warranty period for all equipment supplied by the Vendor except
Computers and Servers for which the minimum period shall be 5 years after the
warranty period. In the event of non-availability of spares due to fast
obsolescence of hardware and software, the vendor shall arrange to upgrade/
replace the equipments with equivalent or higher hardware and software at no
additional cost till end of this 8 year period.
It shall be obligatory on the part of the Vendor that during the defect
liability/warranty period, Vendor will take complete responsibility for any defect
observed in the system (i.e. in instrumentation software, hardware,
communication & networking medias/protocol interfacing with ERP etc.), any
modification and/or replacement of any hardware from the supplied equipment,
modification the operating system software, Automation software, and any other
software, and attend to the maintenance of the system, free of cost, during startup and on-line operation of TAS. The Tank Farm system along with Valve sub
system shall also be integrated with the software as & when hardware are
erected, installed & handed over. Any emergency requirement shall be attended
by Vendors Senior Team within one day notice. The replacement of any subsystem, modules and or entire system shall be attended within one day. All the
proximity Cards shall be reprinted every year by the Vendor during 2 year
warranty period.
Cost of all spares, equipment, instruments & services, (be preventive &
breakdown) to take care of the above points has to be borne by the Vendor

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during the warranty period In case of failure to attend to these promptly, these
will be attended through alternate agency at vendors risk and cost.
The vendors Resident engineer( Min. Engineering Graduate) will check and
service of each equipment & instrument and its accessories and maintain them in
good working condition. Any consumables required for servicing the equipments
shall be arranged by the Vendor at no extra cost to HPCL during Warranty
Vendor shall maintain minimum consumables for smooth working of terminal
automation system.
Printer cartridge, Stationary papers shall not form part of consumables to be
maintained by the vendor at site.
Any software modification required to incorporate additional facilities such as
Tanks, Pumps, MOV, TLF bays including changes in product assignment should
be carried out by the Vendor without any extra cost to HPCL during the Warranty
Period & comprehensive AMC period.
Any Software up-gradation required shall be included in the scope of Warranty
period
W&M stamping of the electronic metering system, 2 KL mobile Prover Tank
during the warranty period shall be in the scope of Vendor. In case of Black Oil,
the Mobile Master flow meter shall have W&M model approval and shall be
calibrated at FCRI yearly or as & when demanded by W&M whichever is earlier.
This Mass Flow meter shall then be stamped by local W&M. Only Master Meter is
required to be calibrated at FCRI yearly. Other MFM shall be calibrated at FCRI
before installation only.
Stamping of these equipments by state W&M
Department & the entire coordination shall be in the scope of the Vendor during
Two year Warranty period. All liaison & incidental charges related to W&M
approval, FCRI approval, to & fro transportation cost shall be borne by the
Vendor. Statutory fees shall be reimbursed by HPCL against submission of
Original receipt. The receipt shall be in the name respective HPCL location. Any
additional W&M stamping required, apart from the yearly stamping, due to
reasons attributable to automation equipments like change in calibration, K
factors, replacement of pulsars etc. shall be in the scope of Vendor.
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Vendor shall provide Resident Engineer (Engineering Graduate) with minimum

one year experience / familiarity in erection/ commissioning/ maintenance of TAS
should be positioned at the location during working hours for taking care of
normal system operation, all Preventive & Breakdown maintenance during the
total warranty period. The Resident Engineer shall submit fortnightly report on
the System operation, preventive & breakdown maintenance carried out. This
includes backup coverage for such engineers for vacations, illness, training etc at
no additional costs.
The Resident Engineer shall assist the Location in verification of metering system,
Tank gauging system etc as & when required by the location.
Warranty of the Add-ons provided by the Vendor in the free issue items for
making it compatible with TAS shall be included in the scope of the Vendor.

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POST WARRANTY COMPREHENSIVE ANNUAL MAINTENANCE CONTRACT (CAMC)

The system is to be maintained for a period of five years after expiry of warranty
period. Cost of all spares, equipment, instruments & services, (Preventive &
Breakdown) to take care of maintenance, has to be borne by the Vendor during
the AMC period. In case of failure to attend within 2 days, these will be attended
through alternate agency at vendors risk and cost.
The Tank Farm system along with Valve sub system shall also be integrated with
the software as & when hardware are erected, installed & handed over.
The post warranty comprehensive AMC shall be a separate contract for the 5
years period and shall be signed at beginning of the respective year. The post
warranty Comprehensive AMC rates quoted in price bid for 5 years shall be
included in the evaluation.
Min. 6 Nos. normal visits (once in two months) and 4 No. emergency visits per
annum (as & when required) are included in scope of A.M.C. (Annual
Maintenance Contract). HPCL will have the right to reschedule the visits and
adjust the total no. of regular and emergency visits.
The vendors service engineer will check and service of each equipment &
instrument and its accessories and maintain them in good working condition. Any
consumables required for servicing the equipments shall be arranged by the
Vendor at no extra cost to HPCL during CAMC.
Vendor shall maintain minimum consumables for smooth working of terminal
automation system
Printer cartridge, Stationary papers shall not form part of consumables to be
maintained by the vendor at site.
HPCL can terminate the annual maintenance contract by giving three months
notice in advance to the vendor.
During the AMC, Vendor will hold the inventory of minimum spares inventory at
the site required for maintaining the system in operating condition. Vendors are
required to confirm compliance towards stocking of minimum spares at site as
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per quantity indicated in spare parts list format enclosed in the tender & submit
the same duly filled along with bid documents. These spares shall need to be
positioned at site before commencement of Stabilization & kept at site till the
end of AMC period. These Spares at the end of AMC shall be handed over to
HPCL & shall be property of HPCL. The vendor shall ensure availability of spares
(at minimum) at all times at the site and in the custody of HPCL location-incharge. The vendor shall always promptly replenish the spares as & where the
same are used. The vendor should do proper spares management by carrying out
periodical testing of the spares, safeguards against obsolescence, any up
gradation, timely replenishment, etc. All the proximity Card shall be reprinted
every year by the Vendor during 2 year warranty & 5 year CAMC period.
W&M stamping of the electronic metering system, 2 KL mobile Prover Tank
during the warranty period shall be in the scope of Vendor. In case of Black Oil,
the Mobile Master flow meter shall have W&M model approval and shall be
calibrated at FCRI yearly or as & when demanded by W&M whichever is earlier.
This Mass Flow meter shall then be stamped by local W&M. Only Master Meter is
required to be calibrated at FCRI yearly. Other MFM shall be calibrated at FCRI
before installation only.
Stamping of these equipments by state W&M
Department & the entire coordination shall be in the scope of the Vendor during
5 year Comprehensive AMC period. All liaison & incidental charges related to
W&M approval, FCRI approval, to & fro transportation cost shall be borne by the
Vendor. Statutory fees shall be reimbursed by HPCL against submission of
Original receipt. The receipt shall be in the name respective HPCL location. Any
additional W&M stamping required, apart from the yearly stamping, due to
reasons attributable to automation equipments like change in calibration, K
factors, replacement of pulsars etc. shall be in the scope of Vendor.
In the event of HPCL requiring the services of vendors resident engineer during
the CAMC, the vendor is required to position one resident engineer at site at 10%
higher rate than quoted by the Vendor for the 2nd Year of the Warranty period.
Vendor shall furnish location wise Bank Guarantee equivalent to the rates quoted
for 5 year comprehensive Annual Maintenance Contract. This Bank Guarantee
shall be submitted 2 months before the expiry of warranty period failing which
retention money shall stand forfeited. BG for CAMC shall be valid for minimum 62
months or till the end of 5th year AMC whichever is later.

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Any software modification required to incorporate additional facilities such as
Tanks, Pumps, MOV, TLF bays etc including changes in product assignment
should be carried out by the Vendor without any extra cost to HPCL during the
Warranty Period & comprehensive AMC period.
The vendor shall ensure availability of spares for the Automation System for a
minimum period of 8 years after warranty period. In the event of non-availability
of spares due to fast obsolescence of hardware and software, the vendor shall
arrange to upgrade/ replace the equipments with equivalent or higher hardware
and software at no additional cost till end of CAMC period.
The Vendor must note that all commissioning spares and the spares /
consumables during warranty and comprehensive CAMC shall be supplied by the
vendor free of cost.
Agreement for the Post warranty CAMC shall be entered before the start of each
year. HPCL reserves the right to sign the post warranty AMC for all 5 years or part
of it or none or to extend the contract after 5 years .
Vendor shall quote 5 year composite rate for CAMC . The composite rate quoted
by vendor for 5 years CAMC period shall be split year wise in the following
percentage for evaluation & payment purpose
Year 1 :
Year 2 :
Year 3 :
Year 4 :
Year 5 :

10% of CAMC cost of 5 years

15% of CAMC cost of 5 years
20% of CAMC cost of 5 years
25% of CAMC cost of 5 years
30% of CAMC cost of 5 years

Incase HPCL intended to extend the CAMC beyond 5th year, the amount for 6th year
onwards shall not be greater than 15% of cost of previous year cost of AMC.

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SAFETY PRACTICE
HPCL AUTOMATION OF TERMINALS/DEPOTS
SAFETY / SECURITY OF MATERIALS
The responsibility of safety and security of materials and equipments brought or
installed by the contractors (till they are handed over to us) will remain with contractor
and any claim, of what so ever nature due to any loss or otherwise, will not be
entertained. The contractor will have to hand over completed job in its entirely as per
work order.
SECURITY OF CONTRACTORS MATERIALS
HPCL shall not be responsible for the security of Contractors materials / equipment.
SAFETY PRECAUTIONS AND HOT WORK
Contractor shall have to take all safety precaution for carrying out hot work in the
premises after obtaining hot work permit from location in charge at his own cost as
directed by the Engineer-In-Charge. Necessary safety equipment such as safety belts,
helmets, etc., and other safety instruments are to be positioned by the contractor and
the same shall be used by the work force as per work requirement. The contractor has
to enforce the same.
Safety distance as per CCE Rules and Oil Industry Safety Directorate shall be maintained
strictly.
Any casualty or damage caused to property or person by any untoward incidents while
executing this contract will be at the contractors risk and cost.
The contractor shall strictly follow safety practices during construction as per the copy
of OISD 192 enclosed along with the tender document.

HOT WORK PERMIT

No hot work is permitted without issuance of hot work permit by location in-charge. The
hot work permit will be issued in the HPCL approved format on a day-to-day basis.

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After completion of work, the site should be cleared of all scrap, contractors equipment
and machinery used in fabrication.
Necessary assistance shall be provided by the contractor at the time of commissioning
of the tank / pipelines by providing required manpower / equipment as per the
requirement of the site engineer / location in charge.

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HEALTH, SAFETY
AND ENVIRONMENT
REQUIREMENTS

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SAFETY , HEALTH & ENVIRONMENT POLICY

SPECIFICATION FOR HEALTH, SAFETY AND ENVIRONMENT (HSE)

MANAGEMENT

CONTENTS
________________________________________________________________
CLAUSE NO. TITLE

PAGE NO.

1.0

SCOPE

2.0

REFERENCES

3.0

REQUIREMENT OF HEALTH, SAFETY AND

ENVIRONMENT (HSE)
3.1

MANAGEMENT RESPONSIBILITY

3.2

HOUSE KEEPING

3.3

SAFETY, HEALTH & ENVIRONMENT

4.0
DETAILS OF HSE MANAGEMENT SYSTEM
BY CONTRACTOR
4.1

ON AWARD OF CONTRACT

4.2

1.0

DURING JOB EXECUTION

SCOPE

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This specification establishes the Health, Safety and Environment (HSE)

management requirement to be complied with by the Contractors during
construction.
Requirements stipulated in this specification shall supplement the requirements
of HSE Management given in relevant Act (s) / legislations. General Conditions
of Contract (GCC), Special Conditions of Contract (SCC) and Job
Specifications. Where different documents stipulate different requirements, the
most stringent shall be adopted.
2.0

REFERENCES
This document should be read in conjunction with following:
-

General Conditions of Contract (GCC)

Special Conditions of Contract (SCC)
Job Specifications
Relevant IS Codes (refer Annexure I)

3.0

REQUIREMENTS OF HEALTH, SAFETY & ENVIRONMENT (HSE)

MANAGEMENT SYSTEM TO BE COMPLIED BY BIDDERS

3.1

MANAGEMENT RESPONSIBILITY
3.1.1

The Contractor should have a documented HSE policy to cover

commitment of their organization to ensure health, safety and
environment aspects in their line of operations.

3.1.2

The HSE management system of the Contractor shall cover the HSE
requirements including but not limited to what is specified under Para
1.0 and para 2.0 above.

3.1.3

Contractor shall be fully responsible for planning and implementing

HSE requirements. Contractor as a minimum requirement shall
designate / deploy the following to co-ordinate the above :

No. of workers deployed Up to 250

- Designate one safety supervisor

Above 250 & up to 500

- Deploy one qualified and experienced

safety Engineer / officer

Above 500

- One additional safety engineer/officer as

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above.
(for every 500 or less)
Contractor shall indemnify & hold harmless Owner / HPCL & either representative
free
from any and all liabilities arising out of non fulfilment of HSE
requirements.
3.1.4

The Contractor shall ensure that the Health, Safety and Environment
(HSE) requirements are clearly understood & faithfully implemented at
all levels at site.

3.1.5

The Contractor shall promote and develop consciousness for Health,

Safety and Environment among all personnel working for the
Contractor. Regular awareness, programme and fabrication shop / work
site meetings shall be arranged on HSE activities to cover hazards
involved in various operations during construction.

3.1.6

Arrange suitable first aid measures such as First Aid Box, trained
personnel to give First Aid, Stand by Ambulance or Vehicle and
install fire protection measures such as : adequate number of steel
buckets with sand and water and adequate fire extinguishers to the
satisfaction of HPCL/Owner.

3.1.7

The Contractor shall evolve a comprehensive planned and documented

system for implementation and monitoring of the HSE requirements.
This shall be submitted to HPCL/Owner for approval. The monitoring for
implementation shall be done by regular inspections and compliance to
the observations thereof. The Contractor shall get similar HSE
requirements implemented at his sub-contractor(s) work site/office.
However, compliance of HSE requirements shall be the sole
responsibility of the Contractor. Any review / approval by HPCL/Owner
shall not absolve contractor of his responsibility / liability in relation to
all HSE requirements.

3.1.8

Non-Conformance on HSE by Contractor (including his Sub-contractors)

as brought out during review/audit by HPCL/Owner representatives
shall be resolved forthwith by Contractor. Compliance report shall be
provided to HPCL/Owner.

3.1.9

The Contractor shall ensure participation of his Resident Engineer /

Site-in-Charge in the Safety Committee / HSE Committees meetings
arranged by HPCL/Owner. The compliance of any observations shall be

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arranged urgently. He shall assist HPCL/Owner to achieve the targets
set by them on HSE during the project implementation.
3.1.10 The Contractor shall adhere consistently to all provisions of HSE
requirements. In case of non-compliance or continuous failure in
implementation of any of HSE provisions; HPCL/Owner may impose
stoppage of work without any Cost & Time implication to Owner
and/or impose a suitable penalty for non-compliance with a notice of
suitable period, up to a cumulative limit of 1.0% (one percent) of
Contract Value with a maximum limit of Rs. 10 lakhs. This penalty
shall be in addition to all other penalties specified else where in the
contract. The decision of imposing stoppage work, its extent &
monitory penalty shall rest with HPCL/Owner & binding on the
Contractor.
3.1.11 All fatal accidents and other personnel accidents shall be investigated
by a team of Contractors senior personnel for root cause &
recommend corrective and preventive actions. Findings shall be
documented and suitable actions taken to avoid recurrences shall be
communicated to HPCL/Owner. Owner / HPCL shall have the liberty to
independently investigate such occurrences and Contractor shall extend
all necessary help and co-operation in this regard.
3.2

HOUSE KEEPING
3.2.1 Contractor shall ensure that a high degree of house keeping is
maintained and shall ensure inter-alia the followings:

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a.

All surplus earth and debris are removed/disposed off from the
working areas to identified location(s).

b.

Unused/Surplus Cables, Steel items and steel scrap lying

scattered at different places within the working areas are
removed to identified location(s).

c.

All wooden scrap, empty wooden cable drums and other

combustible packing materials, shall be removed from work
place to identified location(s).

d.

Roads shall be kept clear and materials like: pipes, steel, sand
boulders, concrete, chips and bricks etc. shall not be allowed on
the roads to obstruct free movement of men & machineries.

e.

Fabricated steel structural, pipes & piping materials shall be

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stacked properly for erection.

3.3

f.

Water logging on roads shall not be allowed.

g.

No parking of trucks / trolleys, cranes and trailers etc. shall be

allowed on roads which may obstruct the traffic movement.

h.

Utmost care shall be taken to ensure over all cleanliness and

proper upkeep of the working areas.

i.

Trucks carrying sand, earth and pulverized materials etc. shall be

covered while moving within the plane area.

HEALTH, SAFETY AND ENVIRONMENT

3.3.1

The Contractor shall provide safe means of access to any working

place including provisions of suitable and sufficient scaffolding at
various stages during all operations of the work for the safety of his
workmen, and, HPCL/Owner. Contractor shall ensure deployment of
appropriate equipment and appliances for adequate safety and health of
the workmen and protection of surrounding areas.

3.3.2

The Contractor shall ensure that all their staff and workers including
their sub-contractor(s) shall wear Safety Helmet and Safety shoes.
Contractor shall also ensure use of safety belt, protective goggles,
gloves etc. by the personnel as per job requirements. All these gadgets
shall conform to relevant IS specifications or equivalent.

3.3.3

Contractor shall ensure that a proper Safety Net System shall be used
at appropriate locations. The safety net shall be located not more than
30 feet (9.0 metres) below the working surface at site to arrest or to
reduce the consequences of a possible fall of persons working at
different heights.
Contractor shall ensure that flash back arrester shall be used while
using Gas Cylinders at site. Cylinders shall be mounted on trolleys.

3.3.4

3.3.5

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The Contractor shall assign to his workmen, tasks commensurate with

their qualification, experience and state of health for driving of
vehicles, handling and erection of materials and equipments. All lifting
equipments shall be tested certified for its capacity before use.
Adequate and suitable lighting at every work place and approach there
to, shall be provided by the Contractor before starting the actual
operations at night.

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3.3.6

Hazardous and/or toxic materials such as solvent coating, or thinners

shall be stored in appropriate containers.

3.3.7

All hazardous materials shall be labeled with the name of the

materials, the hazards associated with its use and necessary precautions
to be taken.

3.3.8

Contractor shall ensure that during the performance of the work, all
hazards to be health of personnel, have been identified, assessed and
eliminated.

3.3.9

Chemical spills shall be contained & cleaned up immediately to

prevent further contamination.

3.3.10 All personnel exposed to physical agents such as ionizing radiation,

ultraviolet rays or similar other physical agents shall be provided with
adequate shielding or protection commensurate with the type of
exposure involved.
3.3.11 Where contact or exposure of hazardous materials could exceed limits
or could otherwise have harmful affects, appropriate personal protective
equipments such as gloves, goggles, aprons, chemical resistant clothing
and respirator shall be used.
-

A Crche where 10 or more female workers are having

children below the age of 6 years.

Reasonable Canteen facilities are made available at appropriate

location depending upon site conditions.

3.3.13 Suitable facilities for toilet, drinking water, proper lighting shall be
provided at site and labour camps, commensurate with applicable Laws
/ Legislation.
3.3.14 Contractor shall ensure storage and utilization methodology of materials
that are not detrimental to t he environment. Where required Contractor
shall ensure that only the environment friendly materials are selected.
3.3.15 All persons deployed at site shall be knowledgeable
with the environmental laws, rules & regulations
hazardous materials substances and wastes. Contractor
release or otherwise discharge or dispose off any
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of and comply
relating to the
shall not dump,
such materials

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without the express authorization of HPCL/Owner.
4.0

DETAILS OF HSE MANAGEMENT SYSTEM BY CONTRACTOR

4.1

On Award of Contract
The Contractor shall prior to start of work submit his Health, Safety and
Environment Manual or procedure and HSE Plans for approval by
HPCL/Owner. The Contractor shall participate in the pre-start meeting with
HPCL/Owner to finalise HSE Plans including the following :

4.2

Job procedure to be followed by Contractor for activities covering.

Handling of equipment, Scaffolding, Electric Installation, describing
the risks involved, actions to be taken and methodology for
monitoring each activity.

HPCL/Owner review / audit requirement.

Organization structure along with responsibility and authority records /
reports etc. on HSE activities.

During job execution

4.2.1

Implement approved Health, Safety and Environment management

procedure including but not limited to as brought out under para 3.0.
Contractor shall also ensure to:

arrange workmen compensation insurance, registration under ESI Act,

third party liability insurance etc., as applicable.

arrange all HSE permits before start of activities (as applicable) like
hot work, confined space, work at heights, storage of chemical /
explosive materials and its use and implement all precautions
mentioned therein.

submit timely the completed checklist on HSE activities, Monthly

HSE report, accident reports, investigation reports etc. as per
HPCL/Owner requirements. Compliance of instructions on HSE shall
be done by Contractor and informed urgently to HPCL/Owner.

ensure that Resident Engineer / Site-in-Charge of the

Contractor shall attend all the Safety Committee / HSE
meetings arranged by HPCL/Owner. Only in case of his
absence from site that a second senior most person shall be

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nominated by
HPCL/Owner.

him

in

advance

and

communicated

to

display at site office and work locations caution boards, list of

hospitals, emergency services available.

provide posters, banners for safe working to promote safety consciousness.

carryout audits / inspection at sub contractor works as per approved

HSE document and submit the reports for HPCL/Owner review.

assist in HSE audits by HPCL/Owner, and submit compliance report.

generate & submit HSE records / report as per HSE Plan.

appraise HPCL/Owner on HSE activities at site.

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TERMINAL AUTOMATION PROJECT

ENCLOSURES

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HINDUSTAN PETROLEUM CORPORATION

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TERMINAL AUTOMATION PROJECT

ATTACHMENT-1

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HINDUSTAN PETROLEUM CORPORATION

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TERMINAL AUTOMATION PROJECT

VFD DATA SHEET (Refer Separate Sheet)

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HINDUSTAN PETROLEUM CORPORATION

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TERMINAL AUTOMATION PROJECT

ATTACHMENT II
MINIMUM LIST OF SPARES TO BE KEPT AT THE TERMINAL DURING WARRANTEE &
ANNUAL MAINENANCE PERIOD
S.N

ITEMS

PROPOSED
SPARES QTY
(NOS.)

1.

Batch controller

a.

CPU card, motherboard

b.

Digital Input cards

c.

Power supply card

d.

Display board

e.

Meter Pulse Board

f.

Keypad assembly

g.

Analog Input Board

h.

Digital Output cards

i.

Cards for ethanol , additive blending

2.

PD Meter ( 3 )

a.

Bearing plate assembly

b.

Complete Measuring Chamber Set

c.

Seals

PD Meter (1 1/2 )

a.

Bearing

b.

Complete Measuring Chamber Set

c.

Seals

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HINDUSTAN PETROLEUM CORPORATION

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TERMINAL AUTOMATION PROJECT
4

Strainer cum Air Eliminator

a.

Strainer Basket

b.

Gasket / Seals Set

c.

Float & Reed Assembly

d.

Differential Pressure Gauge

e.

O rings set

Set Stop Valves/ Digital control valve

a.

NO / NC Solenoid Valve (SET)

b.

Rubber Kit of solenoid Valve

c.

Springs

d.

Diaphragm

e.

O-Ring for outer case

Earthing Relay

a.

Earthing relay board

b.

Earthing Clamp with cords of 3 m length.

c.

Lamp cover with lamps (red, green)

RIT

a.

Indicating lamp RED, GREEN & AMBER (Set)

b.

Push Button Set- Red , yellow, green

Access Control System

a.

Proximity Card

10

b.

Card Reader

c.

Electronic card for card reader

d.

Power supply module

e.

Access control unit (incase of Nexwatch system)

Density meter

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HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
a.

Density meter electronics module

14.

Electronic Display Board

a.

Communication Card

Spares indicated above are minimum requirement. Any additional items required
during the warranty and CAMC period, the same shall be maintained at site by TAS
vendors. The spares shall be sited/ delivered at each site before the start of
stabilization. The spares shall be replaced as and when it is consumed.
Additional quantity may be kept at the terminal by the Vendor based on OEM
recommendation. Tenderer to specifically indicate the spares / items which are not
applicable to the equipments offered by then in technical bid document.

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HINDUSTAN PETROLEUM CORPORATION

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TERMINAL AUTOMATION PROJECT

ATTACHEMENT - III
APPROVED VENDOR LIST FOR HPCL DEPOT AUTOMATION PROJECT
Batch Controller
Positive Displacement Meter
Pulse Transmitter
Strainer
Air Eliminator
Bulk Air Eliminator

Daniel, Smith, Contrec, FMC

Liquid Controls, Smith, , Brooks, FMC, Brodie
Liquid Controls, Smith, Daniel, FMC
Liquid Controls, Smith, Brooks , Cryogenic
Liquid Controls, Smith, Brooks, FMC
Flash point, Smith, Bopp & Reuther, Liquid
Controls, Brooks, Cryogenic
Digital Control Valve for White oil
Bermad, Smith, Liquid Control, Daniel,FMC
Limit switches
Telemechanique,
L&T,
Siemens,
BCH,
Honeywell, Danfoss, Osna, Chemtrol, DAG
Hi-Hi Level Switch
Emerson, Krhone, E&H
Actuator
Rotork, Biffi, Auma or Limitorque
Triple Offset Butterfly Valve
Virgo, Vanessa, Adam, Fouress, L&T
Push Button Station
Sudhir, Shyam, Baliga, FCG. Etc.
Solenoid Valve
ASCO, ASCO Joucomatic, Rotex, Herion Werke
Proximity Card reader
Nexwatch , Daniel, Stahl, FMC
Remote Interaction Terminal
Baliga, Teltech, FEPL, Sudhir Switchgear Pvt. Ltd
RTD with Thermowell
General
Instruments,
Nagman,
Altop,
Pyroelectric
Earthing Relay
Scully, Anderson, Daniel, Baliga, Stahl, Enraf,
Advance Systek
Differential Pressure Gauge & Pressure Switzer, Gen. Instruments., Waree, AN
Gauge
Instruments, Manometer (I) Ltd, Hirlekar,
Bourdan, Forbes Marshall
UPS
Hirel, Emerson, Liebert, Fuji, APC, DB Power
Batteries
HBL Nife, Exide, Pansonic, AMCO, UPlus
Mobile Prover Tank
Flash Point, Teltech, Cryogenic, Liquid Controls,
Toshniwal
Pressure transmitters
Rosemount, ABB, Yokogawa, foxbro
Density meter with Transmitter/ Solatron, Sarasota, Smith, Emerson, Bopp &
Mass Flow meter
Reuther, E&H, Lemis Baltic
Radar Gauge with Tank side Indicator Rosemount Tank Radar, Enraaf
Averaging Temp Sensor for Tanks
Rosemount Tank Radar, Enraaf
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HINDUSTAN PETROLEUM CORPORATION

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TERMINAL AUTOMATION PROJECT
Water
Interface
Measurement Rosemount Tank Radar, Enraaf
Sensor
Density Probe for U/G Tank
Solatron, Lemis Baltic
Radar Gauge (Water Tank)
Rosemount Tank Radar, Enraaf, SBEM, E &H,
Bliss Enterprise
Portable Tank Gauging equipment
Lemis, Honeywell, Emerson
Density meter with Transmitter/ Solatron, Sarasota, Smith, Emerson, Bopp &
Mass Flow meter
Reuther, E&H
ORIFICE PLATE & ACCESSORIES
BALIGA/ I.L., PALGHAT/ MICRO PRECISION/ GI/
FMC
Process & Safety PLC
Honeywell, Siemens, GE, Schneider, Rockwell,
Allan Bradely, ABB, Yokogawa, Mitsubishi, RTP,
Hima
ALARM ANNUNCIATOR
IIC/PROCON/ MINILEC/ APLAB
VFD
Rockwell/ L&T/ ABB/ Siemens/ Mitsubishi
Control consoles, panels & Accessories
Chemin, Lotus, Pyrotech, Instrumentation
Limited ,Siemens Limited, Rittal
ISOLATOR/ BARRIERS
MTL/ STAHL/ P&F
Relays
Omron, Tele Mechanique, Honeywell, Allan
Bradly, Paramount, Denki, OEN
Junction Box& Cable Gland
Baliga, CEAG Flameproof control gears, Ex
Protecta, Flameproof eqpt. (p) Ltd, Flexpro
Electricals (P) Ltd, Sterling Switch gears controls
(po) Ltd, Sudhir Switch gears (P) Ltd, Shyam
Swich Gear Pvt. Ltd
Signal cable & Control cable
Delton, Universal cable, RPG, Gemscab,
Polycab, , Radient cables, Havell, cords, KEI,
Thermocables
RTD cable
LAPP, Delton, Universal cable, RPG, Havells,
Gemscab, Polycab
Power cable, earthing cable
Universal cable, Finolex, Fort Gloster ,CCI,
Delton, Cord,RPG, Havell, Gemscab, Polycab,
cords, Thermocables
MCT Block
Roxtec, A B Transits, Brattberg
LAN Cable
AMP, Lucent
Fiber Optic cable
Lucent, Optel, Finolex, Avaya, HCLcomnet, ABB,
Siemens, D-Link, RPG

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HINDUSTAN PETROLEUM CORPORATION

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TERMINAL AUTOMATION PROJECT
CABLE TRAY

Barrier Gate
Pressure relief valve
Gauge Glass & Cocks
Receiver Instruments

Alarm annunciator

Pressure Switches
Orifice Plates, R.O., Flanges

Instrument Tubing

Client system Computer

Server system
Printer
ETHERNET SWITCHES AND TERMINAL
SERVERS
Proximity Switches
Thermal Relief Valve
Ball Valves
COMPRESSION FITTING
VDU
233 | 2 3 8

GRAM ENGG./ HOPES METAL/ PREMIER POWER

PRODUCT/ INDIANA/ GLOBE ELECTRICALS / MM
ENGG.
Heidz India, Technica, Metachem
Instrumentation Ltd., Keystone valves Ltd.,
Sebim valves, Tyco Sanmar
Bliss Anand (P) Ltd., Chemtrols Engg. Pvt. Ltd,
Levcon Instruments
ABB, Instrumentation Ltd., CG-ELSAG Bailey Ltd ,
Rosemount (India) Pvt.Ltd, Seimens Ltd ,
Honeywell Automation (I) Ltd., Yokogawa
Bluestar Ltd
Electronic corporation of India Ltd, Industrial
Instruments
&
Controls,
Procon
Instrumentation(P) Ltd., Minilec
Indfoss (India) Ltd , Switzer Instruments Ltd ,
Bourdan, Asco Joucomatic
Baliga Lighting Eqpt., Micro Precision products,
Placka Instruments & Controls (P), Ltd. ,
Starmech Controls (I) Ltd. Engineering
Specialities Pvt. Ltd., Hydropnuematics,
Instrumentation Ltd., Mahindra & Mahindra
Ltd.
Apex Tubes Pvt Ltd , Jindal Saw ,Heavy Metals &
Tubes Ltd., Maharashtra Seamless Ltd , Nuclear
Fuel Complex, India, Ratnamani Metal & Tubes
Ltd , ABB , Zenith Ltd, Swagelock
HP, Dell, Wipro, IBM, ACER
Dell, HP, IBM
Wipro, TVSE, Epson, Panasonic, HP, Epson
IBM/ EMULEX/STALLION/FOXBORO/ D-LINK/
CISCO/ 3 COM/ MOXA/SYSTECH
(OEM)/Nortel/L&T
P & F, Turck, Honeywell, Daniel
Keystone/Sebim India/ Fainger Leser/Tyco
Sanmar/Instrumentation Ltd./ BHEL
Audco, Virgo, Flow Chem, KSB, BDR
EXCELISOR/ RELIANCE ENGG. / EXCEL HYDRO
PNEUMATIC
Magneto dynamics,IRA,BEL

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
S S pipe
SS tubes

Start /Stop switch/ push button

Isolators, SFU
AC power contactors
Protective relays
Thermal overload relays
Timers, Aux contactor relays
MCB, ELCB,MCCB, MPCB
CONTROL VOLTAGE TRANSFORMER
LT BUS DUCT
OVERLOAD RELAYS WITH SPP
AMMETER
VOLTMETER

Ratnamani/ Modern Tube

Kalindi bright steel tubes /Choksy tubes/
Ratnamani/ Maharashtra seamless/Apex
tubes/Saw pipes/Swagelock/ Modern Tubes
L&T /Siemens /English electric /
Technic/ABB/GE
Siemens / L&T / Schiender electric/ GE power
controls/ Indo Asian Fuse Gear Ltd.
Siemens / L&T / Schienderelectric / GE power
controls/ ABB/ Control Switch Gear
Alstom India (EE) / ABB
Siemens / L&T / Schiender electric/ GE power
controls
Siemens / L&T / Schiender electric/ GE power
controls / BCH
MDS / Indokopp /S&S /Siemens/ Schiender
electric/ GE/L&T/Crompton/Legrand/Havells
SIEMENS/SOUTHERN ELECTRIC /
KAPPA/SWAMY TRADERS
C&S/ BEST&CROMPTON / STARDRIVE / SIEMENS
SIEMENS / L&T/ TELE-MECHANIQUE BCH / ABB
AE/IMP/MECO/ R!SHAB
AE/IMP/MECO/ FZISHA.B

MICRO PROCESSOR BASED METERS

ADDRESSABLE TYPE ENERGY METERS
PUSH BUTTONS, INDICATION LAMPS

CONZERV/ABB/SIEMENS

CT'S

SIEMENS/AE/INDCOIUKAPPA/INTRANS

TERMINAL BLOCKS

ELMEX / ESSEN /CONNECT WELL / WAGO/

PHOENIX

Indicating meters
Control/selector switches
Indicating lamps/ Push Button

AE /IMP /MECO
Siemens/ Sulzer /L&T /Alstom /Kaycee
Siemens /L&T /Control Switch Gear/ SchinderElectric
Elmex control / C&S
Chemtec /Enraf /any other equivalent make
having valid CCOE approval

Terminal blocks
Additive block

234 | 2 3 8

VAISHNO/CONCORD/SIEMENS/L&T/ TT TEKNIC
/ SALZER

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
Additive pump
FLP motor for Additive Pump
DOL starter
Hi Wall Split AC

235 | 2 3 8

V K Pumps / Shapatools / Grosvenor / Dencil

Kirloskar / Crompton Greaves /Siemens
L&T/ ABB/ Siemens/ FCG
LG/Voltas/ Carrier/Hitachi/Samsung/BlueStar

HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT

ATTACHEMENT- IV

LIST OF FACILITIES

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HINDUSTAN PETROLEUM CORPORATION

LIMITED
TERMINAL AUTOMATION PROJECT
PRODUCT PUMPS ON VFD
SR

1
2
3

PRODUCT
N
O
MS
HSD
SKO

NOS OF PUMPS

LPM

RATING(KW)

3(2+1)
7(6+1)
3(2+1)

3600
4800
2400

55
75
37

NB : 3(2+1) indicates that total 3 nos product pumps are there of which 2 shall be
running and 1 standby.

TENTATIVE BAY CONFIGURATION

Bay
9
10
11
12
13
14
15
16

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Product-1
HSD
HSD
HSD
HSD
HSD
HSD
HSD
HSD

Product-2
MS +Ethanol
MS +Ethanol
MS +Ethanol
MS +Ethanol
HSD
HSD
HSD
HSD