Request For Quotation

DCS IMPLEMENTATION OF LUBE-I

REFINERY

March 16, 2016

National Refinery Limited
Korangi Industrial Area Karachi

Plot 7-B, Korangi Industrial Rd, Korangi Industrial Area, Karachi 75600 1/11
 Request For Quotation

Table of Contents
1) INTRODUCTION:......................................................................................................................... 3

2) SCOPE OF WORK: ....................................................................................................................... 3

3) CONTROL SYSTEM SPECIFICATIONS: .................................................................................. 4

4) INSTRUCTION TO BIDDERS: .................................................................................................... 8

5) GENERAL TERMS & CONDITIONS: ........................................................................................ 9

6) ANNEXURE: .............................................................................................................................. 11

Plot 7-B, Korangi Industrial Rd, Korangi Industrial Area, Karachi 75600 2/11
 Request For Quotation

1) INTRODUCTION:
National Refinery Limited is one of the largest petroleum refining and petrochemical
complex producing a wide range of fuels, lubes, BTX (petrochemicals), asphalts and
specialty products for domestic consumption and export. NRL has three main refineries
which include two Lube and one Fuel refinery. Its Lube-I Refinery has a crude oil processing
capacity of 12,000 BPD. It comprises of 5 Units:

 Two Stage Unit

 PDA
 FEU
 MEK
 HFU

NRL intends to upgrade the existing old Instrumentation and Control System i.e. (analog I/O,
digital I/O, T/C signal, indications, alarms) of its Lube-I Refinery with industrially renowned
Distributed Control System in order to achieve efficient and effective controlling.
NRL requires complete engineering approach to the DCS design, fabrication, testing,
documentation and preparation for shipment from the Vendor. DCS configuration shall be
lying in Vendor's scope with NRL's approval and consent at different stages based on IFA
and IFC, with atleast 10 days of review period. The Vendor shall also be responsible for the
integration of all peripheral equipment interfaced with the DCS.

2) SCOPE OF WORK:
The scope shall include the following, but shall not be limited to:

1. Factory fabricated DCS including system cabinets, marshalling cabinets, printers,

power supply for the system and all other peripheral equipment.

2. All necessary interconnecting cables between panel and workstations, with plug-in
connections between system cabinets, HMIs, DCS Ethernet or Optical Fiber cable,
modems and printers, which shall be included in the offer.

3. Engineering and Operator station (number of stations to be decided after the Vendor's
and NRL‟s mutual consent).

4. All DCS testing services including the FAT and DCS staging tests shall be conducted
in the Vendor's premises using the Vendor's utilities and test equipment before
conducting SAT.

5. Training for Maintenance Engineers, Technicians and Operators shall be conducted at

different levels by the Vendor. Training location, duration and training methodology
and practices are to be shared by the Vendor.

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 Request For Quotation

3) CONTROL SYSTEM SPECIFICATIONS:

The following are the general requirements for the system that must be taken into account.
Although the system's specifications are not limited to the below mentioned details:

3.1 GENERAL:
1. The Control System must have the provision for monitoring and controlling of all
field devices.

2. The proposed system shall be based on an 'Open Architecture', with the ability to
interface with any other device via OPC server or any such protocol.

3. The proposed system must include all the accessories and spares for atleast 3 years
operation.

4. Vendor to specify Safety Integrity Level (SIL) for their proposed Control System
after doing detailed analysis of Lube-I Refinery at NRL.

5. The Control System must be flexible i.e. must have the provision to add different
loops and interlocking, as NRL has planned to convert all the existing pneumatic
loops of Lube-I Refinery to electronic loops. Moreover, automation of certain manual
loops has also been planned in the „Second Phase’, once the existing Single Loop
Control System has been upgraded to DCS. So the proposed DCS must have the
capability to incorporate and cater the inclusion and modification of such loops.

6. The system should display and generate diagnosis reports, health status etc for all the
HART based field devices.

7. The system must be capable to provide inter-independency to all the 5 units i.e.
tripping or shutdown of 1 unit should not affect the operation of other units.

8. The Vendor must specify the operational life cycle of the DCS. DCS must be capable
of sustaining an equivalent operational life and be guaranteed by the Vendor to be
capable of being supported for atleast 10 years.

9. The proposed DCS must have a redundant power supply and I/O cards for critical
loops.

3.2 PROCESS CONTROLLERS:

1. All the process parameters i.e. Setpoint, PV range, PID tuning, Control modes
shall be easily configurable in real time via any of the operator or engineering
station.

2. Each process controller must have atleast 4 configurable alarm option.

3. The process controllers shall also support free-format mathematics and free form
logic capability.

Plot 7-B, Korangi Industrial Rd, Korangi Industrial Area, Karachi 75600 4/11
 Request For Quotation

3.3 I/O MODULE:

1. All the analog input modules should be compatible with loop powered (4-20) ma
transmitters.

2. All analog I/O points shall be individually isolated or individually fused on the high
(supply) side through the use of fused terminals.

3. The system must have the provision for adding the I/O modules, atleast 50 % of
existing I/O, without affecting the performance of the DCS and without requiring a
unit shutdown.

4. The digital I/O cards shall be compatible with both 24 VDC and 220 VAC supply.

5. All digital I/O cards shall provide loop status LED indication.

3.4 MARSHALLING PANEL:

1. All field I/O terminations shall be in the marshalling cabinet (incorporating optical
isolators and fuses where applicable). Segregation of 24 VDC and 220 VAC shall be
provided.

2. I/O cards shall be capable of being removed and inserted into the I/O card cage under
power without affecting any other I/O cards.

3. The location of marshalling cabinet i.e. on field or in control room, shall be decided
after Vendor and NRL‟s mutual consent. Vendor to propose the location of
marshalling cabinet in the proposal.

3.5 OPERATOR & ENGINEERING HMIs:

1. Each HMI shall be manufacturer's standard workstation.

2. The basic HMI package shall contain all DCS functionality, including real time
process monitoring & controlling, data collection, alarming, trending, reporting,
archiving etc.

3. HMI housing shall include the CD-ROM drive, disk and tape drives, peripheral
interface ports and driver electronics. Each HMI shall include atleast a 21 inch VDU,
keyboard, configurable function key panel, trackball or mouse.

4. HMI furniture shall also be included in the Vendor's scope.

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 Request For Quotation

3.6 HMI DISPLAY:

1. The Vendor shall share and approve HMI display and graphics design and make-up
from NRL before final implementation.

2. HMI must be easily customizable i.e. PFD's, face plates etc can be altered any time as
per operator's need.

3. As a minimum, the following information should be shown in the graphic portion of

the display:

 Input
 Output
 Setpoint

The following information, as a minimum, shall be shown in the detail portion of the
display:

 Loop identifier
 Loop service description
 Engineering units
 Input (in engineering units)
 Output (in percentage)
 Set point (in engineering units)
 Set point status
 Control status (manual, auto, cascade)
 All alarm points and alarm status
 Tuning parameters
 PV range

3.7 TRENDING:
1. The system must have the provision for displaying trend history atleast upto 3 months
of all the analog inputs.

2. Removable hard disk shall be offered for permanent historical storage of data.

Plot 7-B, Korangi Industrial Rd, Korangi Industrial Area, Karachi 75600 6/11
 Request For Quotation

3.8 ALARMING & EVENTING:

1. All alarms (process, hardware and system) shall be presented to the operator,
regardless of the current display on HMI, as per an operator defined priority basis.

2. A single dedicated acknowledge alarm push button on the operator keyboard shall be
used by the operator to acknowledge the highest priority alarm, thus allowing
reporting of any remaining alarms.

3. Alarm lists shall be printed either on command, periodically or on a length of list

basis.

3.9 REPORTING:
1. The offered system shall store all reports (atleast upto 3 months) on redundant
removable hard disks with the ability to recall any or all reports at a later time. All
reports shall be printable on any system printer based on time, alarm or event
occurrence.

2. Variable format reports shall be user configurable with the ability to include any
system data such as data stored in historical files or real time controller inputs/outputs.

3.10 DOCUMENTATION:
The following are the list of some essential documents that would have to be submitted by the
vendor in hard and soft form. But it is to be noted that the submission of documents will not
be limited to the following.

 Instrument Loop Drawing

 Instrument cable list
 Control System Functional Design Specification
 Instrument Interlock/Logic Block Diagrams
 Programmed Logic of all Loops
 Range, alarm, set-point and tripping list of all loops
 Control Room Equipment Layout
 Control Room Cable Layout
 Control Room Earthing Layout
 Local Panel Layout (If applicable)
 Operation & Maintenance Manual
 FAT Report
 SAT Report
 All Programs backup files

Plot 7-B, Korangi Industrial Rd, Korangi Industrial Area, Karachi 75600 7/11
 Request For Quotation

4) INSTRUCTION TO BIDDERS:

4.1 PRE-BID MEETING:

All the Bidders are advised to visit NRL for Pre-Bid Meeting, which will include detailed site
survey. Bidder to provide NIC # of the visiting personnel prior to the visit, also bring original
NIC on the day of visit.

Visit Date: April 4th, 2016 (Monday), 10:30 am

4.2 TWO PHASE BID:

The bid will consist of two phases:

i. Technical bid
ii. Commercial bid

i. TECHNICAL BID:
The Bidder is advised to specify the following points in its technical proposal:

1. The Bidder shall share its complete profile, relevant experience, client list and copy of its
relevant purchase orders.

2. As NRL in concerned about the downtime required for the project which will affect the
production of the plant. Therefore the Bidder must clearly state the duration for which Plant's
shutdown would be required for the commissioning of the system.

3. The Bidder must arrange visits for NRL team to their designing workshop and plants where
they have installed DCS. It is to be noted that the visits shall be arranged prior to commercial
bid.

4. The proposal shall include a detailed Gantt Chart, philosophy for the project, line of action
and all the necessary details required for the completion of project, which will help us in
evaluating the proposal.

Technical Bid Opening Date: April 18th, 2016 (Monday), 10:30 am

ii. COMMERCIAL BID:

Commercial bids will only be accepted of those who qualify as an acceptable bidder i.e.
proposing and fulfilling all the Technical bid requirements.

Commercial Bid Opening Date: May 16th, 2016 (Monday), 10:30 am

Note:
1. The sealed bid addressed to Manager Projects shall be dropped at the office of
Manager Projects Hall # 15, 3rd Floor. The envelope shall indicate the name and
address of the Bidder to enable the bids to be returned unopened in case it is declared
“Late”.

Plot 7-B, Korangi Industrial Rd, Korangi Industrial Area, Karachi 75600 8/11
 Request For Quotation

2. Bids submission after due date will be treated as null and void.
3. The Vendor shall bring their original CNIC along with one photocopy on the day of
visit.
4. NRL reserves the right to accept or reject any bid without assigning any reason, and to
award the the project to any of the bidder.

Mailing Address: National Refinery Limited,

7-B, Korangi Industrial Area,
Karachi.
Fax No. 9221-35054663

4.3 BID BOND:

The bidder shall furnish, as part of its bid, a Bid Bond in the amount not less than two percent
(2 %) of Bid value. The Bid Bond shall be in the form of pay order or a Bank Guarantee
issued by any Schedule Bank. The successful Bidder‟s Bid Bond will be discharged after the
issuance of PO. The Bid Bond of all the unsuccessful Bidder's will be discharged at the time
of awarding the project to the successful Bidder.

5) GENERAL TERMS & CONDITIONS:

5.1 GENERAL CLAUSES:

a) The Vendor is advised to visit the site before bidding to access the quantum of job.
Any clarification regarding the scope of work, site condition, instrument cabling etc
shall be sorted out.
b) The Vendor will inform the job coordinator/ person responsible of NRL to submit its
manpower list along with a list of tools, equipment, materials and all necessary
resources at least two days before that are needed for proper execution of job and to
enter inside the NRL premises.
c) Vendor for itself and for its sub-contractors shall obtain insurance covering all
damages or compensation payable in respect of, or in consequence of any accident or
injury resulting to any workmen, or any other person, in the employment of the
Vendor or any of its sub-contractors with an insurer approved by NRL.
d) Premium for above insurance policy will be borne by the Vendor.
e) The Vendor shall be solely responsible for any accident sustained by any of
employees whether it be work injury or otherwise and shall be liable for payment of
all compensation under the laws of Government Act from time to time.
f) The Vendor shall supply safety equipment as described by NRL to his labor force at
his own cost. NRL can stop or interrupt the work with no compensation to the
contractor in case it is felt that procedures and wearing safety equipment are not as
prescribed by NRL.
g) Vendor shall arrange security clearance by Police verification for all its employees/
workers who will work at site.
h) Vendor shall arrange the food, transportation and accommodation of their
employees/workers and bear all their expenses on his own account.

Plot 7-B, Korangi Industrial Rd, Korangi Industrial Area, Karachi 75600 9/11
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i) The rate of Vendor‟s quoted / supplied material should be inclusive of GST and all
taxes, stamp duties, license fees.

5.2 PROJECT COMPLETION DURATION:

The project must be completed within the period of 8 months after awarding the job to the
Vendor.

5.3 EFFECTIVE DATE:

“Effective Date of the Contract” means the date of issuance of letter of intent/signing of
contract/work order, whichever is earlier.

5.4 PAYMENT TERMS:

The Vendor shall be paid two running bills as per following:

 1st Bill, 10% advance of total PO amount against advance bank guarantee.
 2nd Bill, maximum of 60% of PO amount on delivery of equipment.
 3rd Bill, 30% after commissioning and training.
10% of each bill will be deducted as retention money and will be released 1-year after
successful commissioning of the project.

Note:
Vendor is bound to execute the entire work in the span of 8 months, otherwise he would be
liable to pay the Liquidated damage (LD) as 0.1% per day up to maximum of 10% of total
PO amount in case of failure. After exceeding the above mentioned amount as LD, NRL will
reserve the right to terminate the project.

5.5 PERFORMANCE BOND:

10% before the issuance of last payment will be held back as performance bond, which will
be released 18 months after successful commissioning of the project.

5.6 COMPLIANCE WITH SAFETY REGULATIONS:

The contractor shall comply with all laws, rules, notifications and standing instructions
issued by the NRL Safety/Operations departments and shall make all safety measures and
appropriate arrangements for safety of man and materials in carrying out the work.

The contractor should provide safety shoes, safety helmets, coveralls, industrial
hand gloves and other personnel protective equipment like goggles, dust masks etc.
to their work force while working at the Refinery.

The contractor while bringing their equipment/ machines, vehicle for any job/ purpose should
ensure that these are fit to use and free from any leakage, contractor‟s vehicles moving inside

Plot 7-B, Korangi Industrial Rd, Korangi Industrial Area, Karachi 75600 10/11
 Request For Quotation

refinery should have proper spark/ flame-arrestor at the exhaust silencer and have an appropriate
vehicle fitness certificate.

6) ANNEXURE:

Following documents have been attached as annexure:

 Annexure A- I/O List

 Annexure B- Junction Boxes Layout

Plot 7-B, Korangi Industrial Rd, Korangi Industrial Area, Karachi 75600 11/11