TENDER DOCUMENT FOR

Design, Engineering, Procurement,

Supply of Hardware, Fabrication of Panels,
Software Development, Testing, Inspection,
Installation, Commissioning,
Training & Documentation
of
Distributed Control System (DCS) with
SIL3 certified PLC
for
Main Plant
of
Heavy Water Plant Tuticorin, TN

st
1 may 2017
 Section: 1

Co n t e n t s
Section Title
1. CONTENTS
2. INDEX
3. DESCRIPTION OF WORK
4. ARCHITECTURE OF PROPOSED SYSTEM
5. GENERAL SYSTEM DESCRIPTION AND
TECHNOLOGY REQUIREMENTS
6. FUNCTIONAL REQUIREMENTS OF SYSTEM
6.1 PART-A: FUNCTIONAL REQUIREMENTS OF DCS
6.2 PART-B: FUNCTIONAL REQUIREMENTS OF PLC
7. CONFIGURATION AND TECHNICAL SPECIFICATIONS
OF DCS-PLC SYSTEM
8. STANDARDS & CODES
9. RECOMMENDED QUALITY ASSURANCE PLAN (QAP)
10. INFORMATION FROM VENDOR
11. SCOPE OF SUPPLY AND SUPPORT SERVICES
12. LIST OF DOCUMENTS TO BE SUBMITTED AFTER
PLACEMENT OF PO
13. CONDITIONS AND REQUIREMENTS OF BIDDING
14. SECURITY RELATED SPECIFICATIONS FOR SYSTEM

Annexures:

A Table of Bill of material( BOM) and Schedule of rates

B1 Specification of servers
B2 Specification of Workstation
B3 Specification of Annunciator
C Vendor list for Bought out items
D1 Layout of Control room
D2 Relay panel layout - Existing
D3 Existing Pump & Compressor Relay Panel System
D4 Relay Panel Details
D5 20K41/42
D6 GC&GB Compressor
D7 Specifications of signal, power and FO cables
 Section 2

Index

Sr.No. Description Page

No.
Section-3 Description Of Work 5
3.1 Description Of Work 5
3.2 Brief Description Of Site Location 5
3.3 General Site Conditions 5
3.4 Brief Description Of Existing System Details And Overview Of 5
Architecture Of The System

Section-4 Architecture Of Proposed System 9

4.1 Architecture Of Proposed System For HWP Tuticorin 10
4.2 Objective 10
4.3 Summary Of The Total Configured I/O’s Required 10
4.4 Methodology Of Counting Of I/O Modules 10
4.5 Detailed Architecture Of The Proposed Systems 10

Section-5 General System Description And Technology Requirements 12

5.1 Scope 12
5.2 Panel’s Details 12
5.3 Involvement Of Purchaser’s Personnel 12
5.4 Involvement Of Purchaser’s Personnel 12
5.5 Single Source Responsibility 12
5.6 Programming Of Software 12
5.7 Abbreviations 13
5.8 Technology & Obsolescence 14

Section-6 Functional Requirements Of System DCS With SIL3 Certified PLC 16

6.1 PART A Functional Requirements Of DCS 16
6.1.1 Introduction 16
6.1.2 Control Equipment 16
6.1.3 Functional Requirement Of CPU 16
6.1.4 Type Of Functions Of CPU 18
6.1.5 System Loading 19
6.1.6 Redundancy & Hot Swappability 19
6.1.7 Input Output System 19
6.1.8 Details Of Input Output Cards 20
6.1.9 Specification For I/O Modules 21
6.1.10 Trip Isolators 23
6.1.11 Power Supply System 23
6.1.12 Scan Time 25
6.1.13 Overall Response Time Of System 25
6.1.14 Response Time On Change Over Of Component 25
6.1.15 Communication Systems 26

1 
 
6.1.16 Specs Of Server, OS & View Client 27
6.1.17 Operator Station 27
6.1.18 Control Desk 29
6.1.19 HMI Features 29
6.1.20 Engineering Station 32
6.1.21 Event Recording System 33
6.1.22 Printer 34
6.1.23 Real Time Trend Display 34
6.1.24 System Alarms 35
6.1.25 Report Generation 36
6.1.26 Programme Storage 36
6.1.27 On-Line Testability Requirement 37
6.1.28 Reliability Requirements 37
6.1.29 Software 37
6.1.30 Operator Workstation Update Time 38
6.1.31 Systems Maintenance Support 39
6.1.32 System Security 39
6.1.33 Spare Capacity & Expansion Capability 40
6.1.34 On-Line Help 40
6.1.35 System Clock & Synchronization 40
6.1.36 Safety Requirement 40
6.1.37 Self-Diagnostic Requirement 41
6.1.38 Maintainability Requirement 41
6.1.39 Communication 41
6.1.40 Environmental Conditions 42
6.2 PART B: Functional Requirements Of SIL3 Certified PLC Or Its Equivalent 42
6.2.1 Introduction 42
6.2.2 Functional Requirements 42
6.2.3 Central Processor Unit (CPU) System 43
6.2.4 Type Of Functions 43
6.2.5 System Loading 43
6.2.6 Redundancy & Hot Swapping 43
6.2.7 Input Output System 43
6.2.8 Details Of Input/ Output Cards 43
6.2.9 Specifications Of SIL3 Certified Input/Output Modules 44
6.2.10 Trip Isolators 45
6.2.11 Power Supply System 45
6.2.12 Scan Time 45
6.2.13 Overall Response Time Of System 46
6.2.14 Response Time On Changeover Of Components 46
6.2.15 Communication Systems 46
6.2.16 Operator Station 46
6.2.17 Engineering Station 46
6.2.18 Software For Controller 46
6.2.19 Event Recording System 47
6.2.20 First Out Alarm Feature 47

2 
 
6.2.21 Alarm /Printing 47
6.2.22 System Alarm 47
6.2.23 Programme Storage 47
6.2.24 On-Line Test Ability Requirement 47
6.2.25 Reliability 47
6.2.26 Off-Line Test Ability Requirement 48
6.2.27 Systems Maintenance Support 48
6.2.28 System Security 48 
6.2.29 Spare Capacity & Expansion Capacity 48 
6.2.30 On-Line Help 48 
6.2.31 System Clock & Synchronization 48 
6.2.32 Safety Requirement 48 
6.2.33 Self Diagnostic Requirement 48 
6.2.34 Maintainability Requirement 48 
6.2.35 Communication 48 
6.2.36 Environmental Conditions 48

Section-7 General Configuration And Technical Specifications Of DCS-PLC 49

System
7.1 Overall Configuration 49
7.2 Communication Between CPU & I/O Modules 49
7.3 Controller Sub-System 50
7.4 Operator/Engineering Work Station 50
7.5 Workstation Failure Security 50
7.6 Reports And Printers 50
7.7 Storage Devices 50
7.8 Interface With Third Part Devices & Other System 51
7.9 Miscellaneous 51
7.10 System Integrity Features 51
7.11 Cabinets Offered For The System 51
7.12 General Requirements 51
7.13 System Power Supply And Earthing/Shielding Details 52
7.14 Signal Transmission And Galvanic Isolation 52
7.15 Grounding 53
7.16 Maintenance 53
7.17 System Environmental Conditions 53
7.18 RF Interference & Fault Protection 53
7.19 General Guidelines For Hardware/Engg 54
7.20 Wiring 54
7.21 Acceptance Requirements 54
7.22 Installation. Testing & Commissioning 55

Section-8 Standards & Codes 57

Section-9 Recommended Quality Assurance Plan 58

3 
 
Section-10 Information/Documents To Be Submitted By Vendor Along With 63
Bid
10.1 Vendor Qualification Criteria Related Documents To Be Submitted 63
Alongwith Bid
10.2 Technical Documents To Be Submitted Alongwith Bid 63

Section-11 Scope Of Supply & Support Services 66

11.1 Scope Of Work 66
11.2 Civil Work 67
11.3 Removal Of The Existing System 67
11.4 System Checkouts And Acceptance Test 67
11.5 Scope Of Hardware And Software 67
11.6 Supply Of Bought Out Items 67
11.7 Documentation 68
11.8 Manuals 68
11.9 Kick-Off Meeting 68
11.10 Spares 68
11.11 Maintenance Tools And Aids 68
11.12 Training 68
11.13 Support Services, Software & documentation Updates and Other 70
Software Terms & Conditions
11.14 Warranties & Guarantees 71
11.15 Annual Maintenance Contract 72
11.16 Services Supplied By HWPT During Erection 72

Section -12 Document Schedule 74

Section-13 Conditions & Requirements Of Bidding 77

13.1 Language 77
13.2 Acceptance Of The System 77
13.3 Vendor Qualification Criteria 77
13.4 Technical Criteria For The System To Be Supplied 77
13.5 Manpower And Experience Of Key Persons 78
13.6 Pre-Bid Vendors Visit To The Site 79
13.7 Dispatch & Commissioning 79
13.8 Post Supply Inspection 79
13.9 Prices 79
13.10 Payment Terms 79
13.11 Submission Of Bids 80
13.14 Tender Evaluation Criteria 80

Section-14 Security Related Specifications for System 81

14.1 Security Related Requirements 81
14.2 Security Requirement during Testing of the System. 84
14.3 Security Requirements during Installation & Commissioning of the System 87
14.4 Security Related Documents to be submitted along with the offer 88

4
 Section-3
DESCRIPTION OF WORK
3.1 Description of Work:
Tenders are invited from eligible and experienced suppliers for the following works:

Sr No. Name of Work Period of completion

1. Design ,Engineering, Supply of Hardware, 1) Supply of system: within 05 months from date
Fabrication of Panels , Software placement of PO.
Development, Testing, Inspection,
Installation, Commissioning, Performance 2) Installation: within 07 month from the date
testing , Training, Documentation of placement of PO.
Distributed Control System(DCS) with
SIL3 certified PLC Heavy Water Plant 3) Commissioning & acceptance: within 10
Tuticorin. months from the date of Placement of PO.

3.2 Brief description of site location.

The city of Tuticorin lies on the Coromandel Coast off Bay of Bengal in the state of Tamil Nadu. The
name of the nearest railway station is Tuticorin of Southern railway and an Airport of AAI. It is located
about 135 kilometers south of Madurai and 190 kilometers northeast of Thiruvananthapuram
(Trivandrum). Tuticorin has an extensive transport network and is well-connected to other major cities
by road, rail and air. Its seismic zone classification is Zone-II

3.3 General Site Conditions:

a. Max. Ambient Temperature : 50 degree C
b. Min. Ambient Temperature : 20 degree C
c. Max. R H : 97%
d. Min. R H : 30%
e. Altitude : 84 Feet above Mean Sea Level.
f. Hazardous area classification of the plant area- IIC T3

3.4 Brief Description of existing system details and overview of architecture of the system

Instrumentation & Control system at HWP (Tuticorin) consists of the following:

a. Pneumatic based Field Instruments for Process variables.
b. Pneumatic based Main Control panel Instruments for process control.
c. Hard wired relay logic for discrete/sequential/Trip control.
d. Electronic Recorders for Temperature monitoring.

The Pneumatic Instruments are used for:

1. PID Controllers/Manual loaders
2. Indicators
3. Recorders
4. Field transmitters
5. Level Trols
6. Control Loop elements for mathematical functions and Logic interlocks etc.
7. Final Control Element with pneumatic positioner.

Hard wired relay logic are used for:

5
 1. Motor controls circuits
2. Trip circuits
3. Auto starts circuits
4. Annunciation
5. Timers
6. ISRs (Intrinsic Safety Relay)
7. Motorized Valves’ control circuits

The present control system of HWP (Tuticorin) are to be replaced with Distributed Control System (DCS)
& SIL3 PLC for Critical logics as a safety manager as per tender specification.

6
Details of existing system to be replaced and proposed system to be installed is as given below

First floor of control room (Refer Ann – D1)

Existing indicator and controller based system on first floor of control room (drawing of first floor
enclosed as Ann D1)

1. The first floor of Central Control Room ( CCR) consists of 25 Control panel of size 1.0 Mtr (
length) x 1.5 Mtr ( Depth) 3 Mtr ( height) are equipped with dedicated single loop pneumatic type
controllers and control loops for Operation , Control and Monitoring the system

2. At present all main plant analog parameters (signals) are communicated to control room through
pneumatic signals and are shown in the form of indicators and controllers. They all will be
replaced with electronic signals taken into DCS on the first floor and displayed in control room on
HMIs on the first floor . The replacement of pneumatic to electronic signal in the field is not
in the scope of bidder. The removal of indicators and controllers & old panel is also not in
the scope of suppliers.

3. On the indicator and control panel several annunciator are also available which are generated
from pneumatic analog signals (through receiver switches) as well as relay based panels of the
ground floor. These annunciators will be now generated directly from new DCS & PLC panels and
terminated into new annunciators on control desk. The number of annunciator required has
already been taken care in BOM. The required cabling upto new annunciator is in the scope of
supplier

4. All the signals for GB/GC compressor are presently terminated at behind the old panel on the
first floor for relay based system for GB/GC compressor. These signals are now to be terminated
into a Junction box by supplier and then brought into the SIL3 PLC panels at ground floor.

Ground floor of control room (refer Ann – D2)

Existing relay based system at ground floor of control room

1. There are eighteen number of relay based panels on the ground floor of control room (Refer Ann-
D4 for panel details). These panels include relay based logics for complete main plant and relay
based logics for pumps, compressors, PM action etc.. The installation drawing of the panels
having these relay based logics is as per enclosed Ann – D3 .

2. All the fields switches (DIs) are getting terminated into these relay based panels. The contacts
from analog pneumatic parameters are generated through receivers which are lying on the first
floor of control room. These signals are then taken into relay based panels at the ground floor for
relevant logics through cables.

3. From these relay based logics/Panels some annunciator signals are generated and brought to
annunciator panel on the first floor of control room.

4. After processing of logics in these relay based panels , the digital output for MCC of pumps and
compressors is taken out from these panels

Proposed modifications in the relay based logic system (In supplier’s scope)

7
All these relay based panels are to be removed and new PLC Panels to be provided in tits place.
Removal of old panels and installation of new panels is in the scope of supplier. Following major
changes are required

1. Panel no. 01 contains Control logic power distribution and Program matrix-1 & matrix-2. Program
Matrix 1 & 2 action logics are to be removed & the interlock for the same shall be included in soft
in PLC.
5. Panel no. 02 contains Alarm Annunciator cards, SPIC (Compressor) Trouble interlock for GB
Shut down & 11th Unit Drier interlocks. They are to be removed and the interlock for the same
shall be included in soft in PLC.
6. Panel no. 03 contains Alarm Annunciator cards, 11th unit drier interlocks & Test set-up for relays
& timer. Panel no 3 components shall be removed completely and the interlock for the same shall
be included in soft in PLC.
7. Panel no. 04 contains 12th unit control logic supply & 12T1/T2 Level relays. 12T1/T2 Level relays
shall be removed and new level relays shall be provided in the new PLC panels . However the
supply of new level relays is are not in suppliers scope and will be provided by purchaser.
8. Panel nos. 05, 06, 07, 08 & 09 contain 12th unit control logic supply, 12th unit Alarm
Annunciation cards and interlocks & 12th unit pumps interlocks. These panel’s components shall
be removed and the interlock same shall be included in soft in PLC.
9. Panel nos. 10, 11 contain 14th, 16th & 17th unit alarm cards and interlocks. Components of these
panels are to be removed & the same shall be included in soft in PLC.
10. Panel no. 12 contains Program matrix-3 (17th unit) & 17th unit alarm cards and interlocks & 19K3
Interlocks. Components of these panels are to be removed & the interlock for the same shall be
included in soft in PLC
11. Panel no. 13, 14, 15, 16 contain 19K3, 20K41/42 & 20K5 interlocks, Alarm cards and Control
logic power distribution, 22P41/42/43 interlocks and Alarm cards, 26P81/82 interlocks &
27K01/02/11/12 interlocks and alarm cards. Components of these panels are to be removed &
the interlock for the same shall be included in soft in PLC
12. Panel no. 17 contains 27K02&13 interlocks and alarm cards, 30 and 31 unit control logic supply
distribution, 30K03/04 interlocks & 38th unit pump interlocks. Components of these panels are to
be removed & the interlock for the same shall be included in soft in DCS/PLC
13. Panel no. 18 contains 31, 32,33, 37 & 38 unit Interlocks and Control logic power distribution &
27K2 Interlocks. Components of these panels are to be removed & interlock for the same shall be
included in soft in DCS/PLC.

Wherever components are removed and logics are shifted to PLC, incoming and outgoing cables
to be used as it is. These cables need to be terminated in new panels. For this whatever
additional JBs etc are required, the same shal be in the scope of supplier. Further some signals
will be required to be communicated with new DCS panels as well as new annunciator .

Approx. 500 DI&DO signals are expected to be interfaced between PLC panels (on ground floor)
and DCS panels , annunciators & JB for GB/GC compressor signals on first floor . Accordingly, 1
km multicore (12 pair) of cable has been asked in the BOM to take care of these new interfacing
signals. Bidder has to supply these cables and terminate these signals. If cable requirement
exceed 1 km , the extra 12 pair cable shall be supplied by purchaser

A table showing existing panels installation components and proposed panel installation components is
as per Ann – D4 enclosed

8
 Section: 4
ARCHITECTURE OF PROPOSED SYSTEM
VC 1

OS 1 OS 2 OS 3 OS 4

Printer Firewall

Ethernet switch Red Ethernet switch

200 mts. FO Cable

Engg
Ex. Proof
SERVER 1 SERVER 2 HMI on LCP
of GB/GC
Panel

Ethernet switch Red Ethernet switch

Ethernet switch Red Ethernet switch

Safety PLC Safety Red PLC DCS Red DCS

I/O rack1 I/O rack1

I/O rackN I/O rackN

TYPICAL ARCHITECTURE 9
 4.1 Architecture of proposed system for HWP, Tuticorin
The proposed architecture of the system is given at page no 9 The system consists of one redundant
controller based DCS system and one redundant controller based SIL3 certified PLC system. Apart
from this there are four operating station, one view client, one engg station common for both DCS
and PLC. Three nos. of OS communicate to DCS & SIL3 CPU through redundant servers.One OS
shall communicate directly with CPU of DCS and PLC

4.2 Objective:
The main objective of the plant and its control system is to safely, reliably and continuously produce
on-specification product.

4.3 Summary of the total configured I/O’s Required

HWP ( TUTICORIN )
SR. DESCRIPTI PLC for
DCS PLC for Main Plant
NO. ON Compressor House Total IOs
R NR R NR R NR
AI (AI + (165X2) (8X2)
1 442 - - - 788
RTD + TC) 330 16
Pig tail
2 - 80 - - - - 80
Temp (AI)
(165X2)
3 AO - - - - - 330
330
(407X2) (209X2)
4 DI - 96 81 88 1497
814 418
(253X2) (22X2)
5 DO - 64 110 55 779
506 44

TOTAL 660 682 1336 191 462 143 3474

3474
GRAND TOTAL
~ 3500

No. of Channels: For all I/O cards no. of I/O channel shall be as per manufacturer’s standard. The
maximum no. of channels for Analog cards shall be 8 and for digital cards 16.

Except for Pigtail temp AIs (80 nos ), sr no2 above , the channel density of max 32 channel per card
can be used.

4.4 Methodology of counting of I/O modules is as follows

The methodology of calculation of modules is explained below:
“Channel counted for each module shall be 100 % of module capacity. E.g. If I/O count is 100 and
module capacity is 16 then no of module is 100/16=6.3. The module considered shall be 7 for this
purpose (next higher integer)”.
All the racks shall be loaded to 80 % capacity. Accordingly no of racks to be provided

4.5 Detailed Architecture of the proposed systems:

Proposed system architecture has been indicated at section 4.1. However, Vendor shall do the
detailed engineering with regard to the system offered by them. Vendor can provide their own
architecture meeting all the requirements.

10
Apart from the architecture shown following points should also be taken into consideration in the
architecture.
a) The architecture of the proposed safety PLC system shall be followed for maintaining a high
reliability system as per SIL-3 architecture requirements. The system shall have
architecture according to Safety Integrity Level SIL-3 as per IEC 61508 standards. The
architecture proposed for achieving SIL3 should have certification by reputed agency like
TUV for overall SIL-3 compliance of the system.
b) Redundancy shall be provided at Controller, Power supply unit, I/O modules (wherever
asked in specifications) and communication bus level. Each of these redundancies should
be preferably independent of each other i.e. say failure of PS module of one CPU system
should not make a changeover to other CPU system.

c) The Ethernet network of OS with the servers shall be different from the network of the
CPU of DCS and PLC with Servers.
d) The redundant Industrial Ethernet switches (used for PLC to Server communication shall
be separate from redundant Industrial Ethernet switch used for DCS to Server
communication.
e) Each Server should have minimum six Ethernet ports. Two for communication with PLC
Ethernet switches, two for communication with DCS Ethernet switches and two for
Operating stations Ethernet switches.
f) Additional Provision for direct communication of parameters between DCS and PLC CPU
racks to be provided using the separate communication ports from the CPU racks.
g) Out of the four OS, One OS shall be connected directly to CPU of DCS & PLC. Normally
servers will be in line. If both the Servers fail then this OS which is directly communicating
with CPU will be helping for normal/emergency operations of the Plant. If this option is not
available in the supplier’s System, then alternative method shall be suggested to meet this
requirement.
h) Communication between redundant controllers shall be preefrbaly redundant .
i) All AI, AO, shall be terminated through Isolator-barrier as per area classification and DI &
DO through interposing relay/ Barriers.
j) Wherever signal repetition is required due to redundancy requirements , it shall be
achieved through separate termination modules for DI & DOs & AOs and Isolators for AIs. .
Whatever components required for achieving the redundancy of the loops shall be in the
supplier’s scope.

k) No single fault should result in the system failure & affect the plant safety system. The
system shall be programmed for FAIL-SAFE mode such that in case of total DCS & PLC
failure the plant goes for a safe shut -down.
l) Ethernet switches should be taken as part of Communication system and should be
redundant.
m) All the Ethernet switches wherever used shall be of Industrial grade.
n) SIL3 PLC should be from the same supplier as of DCS.
o) Approximate no of controllers, indicators, pumps, compressor, MOVs etc to be provided in
DCS are 1500-2000 in nos.

11
 Section: 5
GENERAL SYSTEM DESCRIPTION AND REQUIREMENTS

Features required in the New System:

5.1 SCOPE:
This specification covers general requirements for the Distributed Control System along with
Programmable Logic Controller & its auxiliary equipment to be supplied for the above project.
The scope includes Design, Engineering, Supply of Hardware, Fabrication of Panels,
Software Development, Testing, Inspection, Installation, Commissioning, Performance
testing, operation, Integration, Guarantee and other necessary items to make the system
operable & complete to the satisfaction of purchaser.

The scope also includes the Installation of new DCS panels, Removal of existing Relay
based panels and installing new PLC panels in its place along necessary cabling etc of these
panels.( also refer section3 for the same). The bidder shall give detailed plan regarding the
same in their offer.
The detailed Scope of work is explained in Section 11

5.2 Panels Details: The suppliers shall supply all DCS-PLC panels, input/output panels, and
marshaling racks complete with marking of cables and internals. The DCS-PLC and the
various panels shall be designed, manufactured and tested in accordance with this
specification, the relevant Data Sheets and documents.

5.3 Involvement of Purchaser’s personnel: During detailed engineering work & building of
graphics the suppliers is obliged to involve the purchaser’s personnel in order to ensure a
smooth hand over of the DCS-PLC after its successful commissioning. This should also
include training/ troubleshooting in maintenance and reconfiguration of the system.
Supplier’s representative may have to stay at site for carrying out the HMI & Logic
development work.

5.4 Suppliers engineers involved in Engg /development and FAT should be the part of the team
sent for installation and commissioning at site.
o
5.5 Single Source Responsibility: The supplier shall assume single source responsibility for
supply of complete system as specified by customer-supplied documentation.

5.6 Programming of Software: It is also within the supplier's scope of supply to perform all the
necessary application programming including the graphic process flow sheets.

12
 5.7 Abbreviations

Abbreviations: SDV Shut Down Valve

A Ampere SIL Safety integrity level
AC Alternate Current SMPS Switch Mode Power Supply
AI Analog Input SOE Sequence of event
AK Acknowledge SOER Sequence of event recording
AMC Annual Maintenance Contract SOV Solenoid operated valve
AO Analog Output T/C Thermocouple
AUX Auxiliary TCP/IP Transmission control protocol/ Internet
AWG American wire gauge protocol
CCD Central Control Desk UL Underwriters Laboratories
CPU Central Process Unit UPS Uninterrupted power supply
CRT Cathode ray tube VHF Very high frequency
CT Current Transformer XU-I Exchange Unit-I
DC Direct Current XU-II Exchange Unit-II
DCS Distributed Control System
DI Digital Input
DO Digital Output
EMC Electromagnetic Compatibility
EMI Electromagnetic Interference
EN European norms
EWS Engineering Work Station
FAT Factory Acceptance Test
FCS Field Control Station
HART Highway addressable remote terminal
HIC Hand Indicating Controller
HWPM Heavy Water Plant, Manuguru
I/O INPUT/OUTPUT
IEC International Electrotechnical
Commission
IEEE Institute of electrical and electronics
engineers
IS Indian Standards
IST Indian Standard Time
LAN Local Area Network
mA milli Ampere
MCB Miniature Circuit Breaker
min Minimum
MIS Management Information system
MOV Motor operated Valve
MTBF Mean time between failure
MTTR Mean time to repair
NIT Notice inviting tender
O/P Output
OC Operator Console
OS Operating Station
OSAT On Site acceptance test
P&I Process and instrument diagram
PLC Programmable Logic Controller
QAP Quality Assurance Plan
RF Radio frequency
RFI Radio frequency Interference
RTD Resistance Temperature Detector

13
5.8 TECHNOLOGY AND OBSOLESCENCE:
 Guarantee for freedom from obsolescence: The DCS-PLC system to be supplied shall
incorporate latest state of art technology that shall guarantee support for the system up to
10 years after obsolescence.
 Latest in Product Range: The DCS-PLC to be offered shall be the latest in the product
range of the principal of the supplier. A letter regarding same to be submitted by
supplier
 Use of standard Procedures:
a) The system shall be composed of manufacturer’s standard hardware, systems
software and firmware, which can be configured to meet the stated requirements.
b) Supplier’s standard operating system software shall not be modified to meet any of
project’s requirements.

 Field Proven Systems:

All hardware, software and firmware supplied with the system shall be field proven prior to
placement of order. Documentary proof of the same to be submitted as asked in the
required documents.

 Software Protection.
No software locking mechanisms, which restrict the user for copying the software source or
compiled executable code from the storage media, shall be employed. No software locking
mechanisms, which restrict the user from booting (Starting Up), shall be employed. This
means that no “key disks” or password shall be required to use the software supplied as
part of the system.

 Software Revision Levels

The suppliers’ standard software ( HMI & Logic) delivered to the installation site shall be
the most recent field proven revision level available at the beginning of the Pre – Factory
Acceptance Test (FAT) which is applicable to the system hardware.

 Third Party Equipment

All third party equipment provided as part of this system that is not manufactured by the
Supplier’s shall be currently available for sale from the original and well-established
manufacturer at the time of placement of contract or order. All such equipment shall meet all
applicable project specifications and standards referenced in this specification.

 Safety Requirement
In order to ensure plant safety, system shall ensure fail-safe state of the outputs in case
irrecoverable internal failures.

 Fault Tolerance Requirement

No single fault should result in the system failure & affect the plant safety system. The
system shall be programmed for FAIL-SAFE mode such that in case of Total DCS or PLC
failure the plant goes for a safe shut -down.

 Self-Diagnostics Requirement
All types of required self-diagnostic features, (that include but not be limited to I/O Diagnostics,
CPU Diagnostics, Power distribution Diagnostics, Communication Diagnostics, Processor
Diagnostics, DCS cabinet etc.), to detect all possible faults (shall be available in system.

14
 Maintainability Requirement
a) Modular Construction: System will be modular type in design so that identification and
replacement of faulty modules will be easy and quick.
b) Trouble shooting aids: On Line diagnostics shall be made available in the system
c) Off Line card Test System (Test Jig): An off-line card test system shall be provided with
the system so that suspected failed modules can be tested on the system.

 Reliability and availability:

MTBF of the system excluding the printers, plotters, IT hardware shall be preferably 10-15
years with an availability of 99.9% or better. The details of the same for all the modules are to
be submitted along with the offer. MTBF for printer and plotter shall be 1 year.

 High noise immunity

High noise immunity due to radio frequency interference shall be provided. The supplied
electronics shall have a susceptibility of less than 0.5% of span for a frequency range of 20-500
MHz in field strength of 20 volts / mtr.

15
Section: 6

FUNCTIONAL REQUIREMENTS OF SYSTEM DCS WITH SIL3 CERTIFIED PLC

6.1 Part A: Functional requirements of DCS

6.1.1 INTRODUCTION:
The objectives and broad guidelines laid down in this section define end goals of the purchase of
the system. This section of the Tender shall prevail over all subsequent sections. The
configuration of the DCS system shall be such as to provide a plant network with modules for
Operator / Engineering Stations, CPUs, input/output, etc. All communication shall be dual
redundant. The system shall be modular and shall be easily maintainable.

6.1.2 CONTROL EQUIPMENT (CPU):

The primary control device shall be microprocessor based controller made up of modular
hardware components and a predefined set of algorithms (Blocks, LD etc.) configurable by the
user. The Hardware design shall be suitable for Industrial control & monitoring applications.

6.1.3 FUNCTIONAL REQUIREMENTS of CPU

a. Central Processor Units (CPUs) system: A redundant, hot-standby pair of CPUs
(Controllers) shall be provided. One such redundant set of CPU is envisaged for the
Operation & control of complete plant.
b. CPU system shall be designed with a dual redundant architecture. It shall have preferably
two Racks each having its own CPU, Memory, I/O modules/ports, Communication
modules and power supplies.
c. REDUNDANCY IN CPU SYSTEM (Hot standby): The CPU system shall be provided
with redundancy. In case of failure of any one CPU module of a CPU sub system, the
other shall automatically take over the operation without affecting system performance.
One set of CPU sub system (one of the redundant system) should have one CPU
module, two Ethernet ports/modules, two I/O communication port/modules, two power
supply modules .In addition, vendor shall guarantee the non-existence of any non-
redundant device whose failure might affect the whole CPU systems’ operation or reduce
the operators monitoring capability. Redundant cards of every kind shall be kept on line
all the time and shall take over instantaneously and automatically in case of failure of the
active card. Design must ensure that data integrity is maintained during switch over and
no portion of data to be transferred is corrupted before and during switch over to the
backup CPU.
d. HOT STANDBY FEATURE: Vendor can use any method to achieve main/hot standby
functions of CPU system. Both the CPUs namely Active and Standby shall have latest
state of input/output and all other intermediate calculation. However only the Active CPU
shall set the outputs. The CPU system shall be designed and configured in such a
manner that it shall be tolerant to any conceivable fault in either of the CPU. Both CPU
shall communicate to each other by high-speed communication. Application Software
loading shall be in main CPU, standby CPU shall get the application software
downloaded automatically without the requirement of reloading it.
e. During the initial power ON when the standby CPU recovers from active CPU, it shall
check for software version & if there is a mismatch in both CPUs of CPU sub-system it
shall be displayed on OS with an alarm.

16
f. The CPU shall be capable of reading of Inputs, execution of the control logic, transmit to
output devices, communication with I/O cards & other required interface devices namely
operator station, Engineering station, performing the functions like arithmetical, logical
Boolean and control functions required to implement the logic scheme described. All the
above control functions shall be configurable by the user.
g. The CPU shall have sufficient memory capacity (preferably 16 MB) for storing the
programs for logic execution. The memory capacity shall be mentioned by the vendor.
h. Watchdog timer: Watch dog timer shall monitor the performance of the processor so as to
ensure CPU executes all its tasks within a predefined time frame. It shall include the data
integrity of the processor memory and the voltage range of the supplied power (both over
and under voltage). The watchdog timer shall report and reset to de-activate the safety-
critical output interfaces of the system.
i. The system should be capable of communicating with other system. In this case it shall
be possible to communicate with PLC that will be supplied against this tender and the
PLC shall be treated preferably as one of the node of the network (i.e. PLC and DCS
shall preferably work with same bus, no bus conversion shall be there between DCS and
PLC).
j. The total system loading for CPU and other subsystem shall not exceed 50-60%. The
loading indicated here is the worst case of high system activity referred to the use of
memory, CPU time and communication capacity for the sub-system.
k. It shall be possible to download the data contents of the CPU on to a mass storage
device.
l. Failure of any CPU should be indicated / printed on Operator / Engineering station with
audible / voice alarm and shall be displayed locally. The system should reboot
automatically itself if the power is restored.
m. The CPU shall be a self-contained unit and will provide programming languages as per
IEC61131-3. This CPU will also do I/O scanning and inter-processor and peripheral
communication functions.
n. The CPU systems can be provided in either two chassis system (as described above) or
single chassis system. In a single chassis system, all system modules and support
modules including power supply shall be distributed on a single motherboard or back
plane. No interconnecting wiring between these modules via plug-terminated jumpers
shall be acceptable.
o. The CPU within the system shall perform internal diagnostic checking and give visual
indication to the user w.r.t healthy as well as faulty condition.
p. All system modules, main and expansion chassis shall be designed to provide for free air
flow convection cooling.
q. All modules within the system shall be mechanically interlocked to prevent easy insertion
or removal of modules under power which in turn helps to prevent damage to the
modules and/or system.
r. Controller Updating Time (Scan time): The controller updating time( scan time) shall be
preferably 50 to 300 m sec (preferably user definable) for all the loops connected to it.
s. Output hold facility: The controller should have the user configurable output facility in
case of failure of both the main/redundant controller. The I/O card can be configured to
fail-safe condition in case failure of both main/redundant Controller & modules.
t. Fault diagnostics such as I/O channel failure, broken analogue signals, overloading /
Short circuiting of Outputs, I/O Processor or Main processor failure, Watchdog failure,
Power supply failure, Memory corruption / fail (Checksum) shall be available for user in
form of tags accessible for user logics, eventing etc.

17
u. Self-diagnostic features shall be included in the controller to ensure the healthy operation of
the controller unit and in no case the erroneous data should be allowed to enter for control
manipulation.

6.1.4 TYPE OF FUNCTIONS of CPU:

a. The control station(CPU) shall have the following functions:
1. P/PI/PID/PD control, Bump-less transfer from Auto to Manual and Manual to Auto,
Programmable control action (direct / reverse) Auto tuning of controllers. Split range
control and multi loop control output Anti-reset wind up. Manual overrides and
external reset. Provision for ON-OFF control ,Cascade Control, Ratio Control ,Feed
Forward Control , manual loader, Manual loader with auto manual station Overriding
control logic, Adaptive control as optional. External/ internal set point selection.
2. Set point and PV tracking shall be a standard feature. The controller shall be able to
operate in either manual, auto, cascade mode. Mode changeover in either direction
shall be through non-complicated procedure and bump less. It shall be possible to
change set point, tuning constant, controller mode, and controller configuration from
operator/Engg. Station with required security levels.
3. Signal selectors, computing functions like linearization, sq. root, average,
multiplier/divider, weighted additions, exponential, logarithmic lead / lag calculating
unit, velocity limiter, cascade switching, totalisation, over ride, first out. It shall be
capable of providing signal conditioning, & computing functions
4. Logic functions like AND, OR, NOT, EXOR High/Low selector functions, Logic
function such as 2/3 logic , flip flops, Timers, preferably also available l ,Auto tuning
Logging of all Digital status including generated from analog values ,Text strings for
alarm and event logging etc.
5. All the above Control logics shall be programmed through software using readymade
software blocks.
6. Analog Input Block with minimum facility for scaling and giving the alarm set points
(HH, H, LL, L) & dead band as inputs and Alarm bits at the outputs to be available.
Each parameter shall be available for display in Operator’s console
7. The programmable blocks/languages shall be as per IEC 61131-3.
8. In the logics which will be developed by the supplier, comments facility should be
available and comments to be provided to have better understanding of the logic.
9. Readymade software blocks along with face plates should be available for Analog
inputs, controllers & control valves ,pumps, motorised valves etc.
b. The system shall have computational capabilities such as:
a. Pressure & temp. compensation for compressible fluids
b. Totaliser, Integration with the time (for flow measurement application)
c. Transformation into different engineering units.
d. User definable computations
e. In cascade loops, primary controller shall be able to track the set point and output of
the secondary controller when secondary controller is not operating in cascade
mode.
f. FAIL SAFE OPERATION (user configurable): The design of the DCS will adhere to
the principle of failsafe operation i.e. under no circumstances the safety of the plant
personnel/equipment should be jeopardized while at the same time the system shall
prevent occurrence of false trips.

18
 g. In case of broken sensor, analog value should be programmable (fail to Hi, Lo, Last
Value). The Broken sensor alarm indication should be available on the OS.
h. Whenever any changes are made in any of the parameters (settings etc.), the same
should happen in controller.

6.1.5 SYSTEM LOADING

The total system loading for controller and communication -system shall not exceed 50% This is
required for future expansion of the system as it is planned to include more units in future to the
system. The loading indicated here is the worst case of high system activity referred to the use of
memory, CPU time and communication capacity for the sub-system.

6.1.6 REDUNDANCY & HOT SWAPPABILITY :

Redundancy of all the components shall be asper architecture and I/Os and shall be as per
section 4. In addition, vendor shall guarantee the non-existence of any non-redundant device
whose failure might affect the whole systems’ operation or reduce the operators monitoring
capability.

Hot swappability of all cards shall be possible without disturbance in the system. i.e., Online card
removal / insertion shall not interrupt the plant status. The system shall have sufficient diagnostic
features for both hardware and software functions to show the removal/insertion of the cards.

6.1.7 INPUT-OUTPUT SYSTEM:

It consists of a process interface rack consisting separate network controller which will house the
I/O modules on the same rack. These I/O modules first communicate the network controller
through the back plane bus and then the I/O controller shall communicate with the main controller
through the external communication bus. It may be noted that in this case the network controller
or communication port on network card should also be redundant. Power supply of each rack
shall be redundant.

The field inputs to the system shall be but not limited to mA, resistance, mV, contact, signals, 0-
10V or 0-5 V signals & 0-1 A signals. The signal conditioners (included in galvanic isolator cum
barriers) shall suitably convert the input conditions to a signal acceptable to the I/O modules. The
output signals from the system shall be but not limited to 4-20 mA DC signals to be used for I/P
convertor or positioner in the field, and potential free contacts for 24V supply for SOVs in the field,
annunciator in control desk & for interlock systems etc.

Power supply to all field mounted components shall be from Isolators cum barriers & relays which
are used as interface between I/O modules & Field instruments. Both power supply and signal
shall be communicated through two-wire system. The power supply system for the Isolators and
for relays shall be redundant. For SOV power shall be supplied using Relays as interface
between I/O modules & SOVs. The power supply system shall be redundant. All the input output
modules shall be mounted in a multi rack system connected to a common redundant
communication highway.
a. All critical closed loop controllers shall be in DCS with I/O redundant facility as per I/O count
table in section 4.
b. All trip parameters DIs/AIs shall be included in SIL-3 certified PLC with I/O redundant facility
as per I/O count table in section 4.

19
6.1.8 DETAILS OF INPUT/OUTPUT CARDS:
a. The I/O card shall be user configurable to fail-safe condition in case of failure of both
main/redundant CPU cards.
b. Each input shall be provided with necessary signal conditioning circuitry like filters, , etc.
c. All types of I/O’s from unsafe area shall be provided with suitable Isolator cum
barriers/relays of MTL / P &F/STAHL for analog and relays for digital signals . Inputs from
safe areas are also to be provided with Isolators. The BOM for the same is brought out
in SOR (Ann - A ) Arrangement of trip isolator unit shall be made wherever required( as
per BOM.
d. Each I/O shall be protected against polarity reversal of I/O power voltage.
e. Each I/O rack shall have a separate independent dual redundant power supply system.
f. Each I/O shall be short circuit proof and protected by visual indicating fuses / MCBs.
g. I/O card shall have LED indication for healthy card/fault, communication healthy / fault.
h. I/O card racks shall have expandability. The card rack shall not be loaded for more than
80% capacity.
i. DETAILS OF I/O COUNT: Refer total I/O count is listed in section 4 of this document.
j. Separate card shall be provided for Analog inputs, Analog outputs, digital inputs & digital
output signals.
k. Each DO channel shall be provided with standard relays/relay board (24 V DC 5 A, 1 NO,
1 NC). Further for motor circuit (pumps and compressors) & MOVs, separate relays
with the required contact rating shall be provided Relay contact ratings required for DOs
of pumps and compressors. Voltage: 110 V DC Current - 5 A (2 NO 2 NC). For SOVs
24 V DC 5 A. (2 NO 2 NC).

l. All Input and Output relays shall have

i. Freewheeling diode protection and coil on indication.
ii. Insulation resistance: 100 MΩ at 500 V DC between contacts to coil.
iii. Dielectric strength of relay: 500 V AC RMS for 60 secs between contacts to
coil/body.
m. MCB Fuse: Each main power distribution point shall be protected by MCB and fuse.
Subsequent current distribution point should be protected by fuse. Fuse terminal block
should be with LED indicator. Provision for spare fuse should be available in the terminal
block. The similar arrangement should be available for 24 V DC supply required for two
wire transmitters. The entire DIs & AIs from field and AOs &DOs to the field shall have
individual fuse protection. Fuse Indication should also be available on the fuse

n. No. of Channels: For all I/O cards no. of I/O channel shall be as per manufacturer’s
standard. The maximum no. of channels for analog cards shall be 8 and for digital cards
16. Except for Pigtail temp AIs( 80 nos ) the channel density of max 32 channels per card
can be used.
o. Diagnostics: All the I/O cards shall have the diagnostic features for sensing the channel
failure
DI: channel open circuit, channel/group failure, card fail
DO: channel /group fault, short circuit, card fail
AI: Channel fault, over range or broken wire, card fail
AO: channel fault, open circuit, card fail
p. All I/O racks shall have dual Power supply modules & dual communication cards/ports for
I/O communication bus extension.

20
 q. For Redundant I/O modules, separate interface modules should be used which will
contain the required circuitry for distribution of signal. Distribution of signals shall not be
done by using Y joint cables
r. All the Analog Modules should be Factory calibrated and a certificate in this regard shall
be submitted by the supplier.
s. In case of failure of both the redundant DO modules, failsafe contact should go from DO.
The failsafe contact should be user programmable.
t. On line Analog and Digital signal blocking for Input as well as output should be available.
u. Status of output on resuming of power shall be user programmable.
v. In redundant current signal input /output modules and Digital I/O modules, the loop shall
not be broken on removal of the input card.

6.1.9 SPECIFICATIONS FOR I/O MODULES

a. Analog Inputs module for all channels (except 80 no of pigtail temp AIs):

i. All the analog input channels will be preferably individually isolated from each
other and from system.

ii. Isolation shall be provided at two levels viz: At marshalling cabinets with the help
of isolators and at I/O Module itself

iii. A/D conversion & resolution shall be preferably 16 bits.

iv. Overall accuracy shall be better than +0.1% of full-scale measurement in overall
temperature range.

v. Isolation level shall be minimum 300 Volts D.C.

vi. The drift due to change in ambient temperature shall be within standard
admissible limits.

vii. Analog close loop cards shall be redundant type as per I/O count given in section
4.

viii. Isolation provided on board shall be preferably optical type

ix. Card should have facility to show that individual channel is healthy and signal is
within range of 4 to 20 mA (Around 5% tolerance shall be provided on both ends).
i.e., 3.2mA to 20.8mA is considered as healthy). Beyond this, error should get
generated. Also LED for card healthy, communication healthy to be provided.

Broken sensor shall be detected, evented and also shall be available in user
x. program to carry out specific activities. Also facility shall be available to user to
latch or set the analog value to a constant.

b. Digital Inputs

21
 i. All Digital Input channels shall be preferably individually isolated.

ii. Interrogation supply for Digital Inputs shall be 24 V D.C.

Isolation level of Digital Inputs with internal circuits shall be preferably

iii.
minimum 300 V. D.C.

Potential-free contact inputs from field shall be terminated on Termination

iv.
Modules in Marshalling Cabinets.

Adequate protections shall be provided to digital input signals against

v.
transients and high voltages

LED indications shall be provided on preferably on Termination Modules and

I/O Modules to indicate status of field signals, 24 V.D.C. excitation, and
vi. healthiness of protection circuits. Also LED for card healthy, communication
healthy to be provided.

c. Analog Outputs
i. All Analog Output channels shall be preferably individually isolated.

ii. Signal level of analog outputs shall be 4-20 mA.

iii. Analog output circuits shall be able to drive a load of 600 ohms minimum.

iv. Overload / Open circuit of any channel should reflect in diagnostics and should
be available for user program.

v. Isolation level of Analog Outputs with internal circuits shall be preferably 300
V. D.C.

vi. Resolution & accuracy for analog outputs shall be better than + 0.3% at overall
temp range

vii. The drift due to change in ambient temperature shall be within standard
admissible limits.

All the output cards shall be able to give the output values from -5% to +105%
viii.
i.e. from 3.2 mA to 20.8 mA. Beyond this , error should get generated

ix. Module should have facility to show that individual channel is healthy and
signal is within range of 4 to 20 mA. Also LED for card healthy, communication
healthy to be provided

x. Broken sensor shall be detected, evented and also shall be available in user

22
 program to carry out specific activities.

xi. All the output cards shall be able to give the output values from 3.2 mA to 20.8
mA.

d. Digital Outputs
i. All Digital Output channels shall be individually isolated.

Each Digital output channel is provided with a inbuilt Relay (either in built in the card or by
ii.
providing relay modules. Vendor shall provide 24 V.D.C. relays rated at 5 A. / 24 V.DC (1 NO
and 1 NC) resistive load, duly wired as per engineering requirement. Further some additional
relays are derived from this relay based DO. For pumps & compressors, MOVs,(. Voltage : 110
V DC Current - 5 A (2 NO 2 NC)), for SOVs 24 V DC 5 A (2 NO 2 NC).

iii. Isolation level of Digital Outputs with internal circuits shall be preferably minimum 300 V. D.C.

iv. Digital outputs shall be individually protected against continuous over-current and short circuit.

v. Module Front Facia shall have diagnostic LED indications, preferably dual-colour type, for
individual channel to indicate channel status. Also LED for card healthy, communication healthy
to be provided

e. Analog Inputs modules for Pig tail temp only( 80 nos of AIs):

i. All the analog input channels will be preferably isolated from backplane bus.

ii. A/D conversion & resolution shall be preferably 13 bits.

iii. Overall accuracy shall be better than +0.75 % of full-scale measurement in overall
temperature range.

iv. Isolation level shall be minimum 300 Volts D.C.

v. Isolation provided on board shall be preferably optical type

vi. Card should have facility to show that individual channel is healthy and signal is
within range of 4 to 20 mA (Around 5% tolerance shall be provided on both ends).
i.e., 3.2mA to 20.8mA is considered as healthy). Beyond this, error should get
generated. Also LED for card healthy, communication healthy to be provided.

Broken sensor shall be detected, evented and also shall be available in user
vii. program to carry out specific activities. Also facility shall be available to user to
latch or set the analog value to a constant.

6.1.10 TRIP ISOLATORS shall be provided for generation of alarms contacts from critical
Analog input. These contacts shall then be used on PLC.

23
6.1.11 POWER SUPPLY SYSTEM:
a. All power supplies in the system shall be provided with 100% redundancy.
b. Information of failure and standby take over shall be annunciated on Operator station along
with alarm logging functions.
c. Power input to the DCS and PLC: 110V AC with Steady State variation: ± 10% Frequency: 50
Hz with Steady state variation: + 4%, -6% Permissible Interruption time shall be 20 ms.
d. .Further distribution from 110 VAC to any other voltage required for the system shall be done
with help of redundant power supply units and via redundant power supply bus and the
responsibility of this will be in the scope of vendor. Diode o-ring module shall be used with the
redundant power supplies for putting DC supply on bus.
e. Bidder shall clearly indicate in his offer the load requirement of various sub-systems to enable
the purchaser to check the UPS & battery size.
f. Design of the power system shall be such that minor card failures can be localized for easy
rectification. Philosophy of power isolation and over load protection shall be extended up to
individual card level, if possible to avoid major down time on the system.
g. The voltage level of I/Os, I/O’s rack and accessories for DCS shall be 24 V DC and that of the
CPU shall be as per the requirement of the DCS.
h. The voltage of output from DCS to final relay is 24 V dc. The voltage level of output contacts
to solenoids & motors is as given in section 6.1.8.
i. Power supply to all field mounted components (Wherever mentioned) shall be intrinsically
safe supply from Isolators cum barriers and relays which are used as interface between I/O
modules & Field instruments.
j. Power Distribution Cabinet: Power distribution Cabinet shall be supplied by the vendor. The
source supply from UPS shall be in the Purchaser’s scope. cables from PS distribution to
panels shall be in suppliers scope
k. Earth pits (two numbers) or power & signal and accessories for main control room shall be
made by the supplier.

A. Power distribution in Power distribution panel

A new power distribution panel is to be provided which will include the required MCBs and
fuses for power distribution to individual panel and IT hardware. Brief specs are given
below. Separate power distribution panel shall be provided for DCS and PLC
Sr.
Parameter Specification
No.
1 Incoming Feeder Redundant 110 V AC UPS Supply
2 Incoming Circuit Breaker MCCB, 3 POLE of required rating
Activation/De-activation of ROTARY OPERATING MECHANISM ON DOOR FOR MCCB
3 Incoming Feeder Line Activation/Changeover

4 Panel Indication
5 Internal Distribution
Distribution to Panels/Equipment
6
(via MCB, Fuse & Neutral Links)
7 Distribution wire
7 Panel Lightning
LED LAMP:
VOLTMETER: 0- along with selector switch to select any
feeder
AMMETER along with selector switch to select any
feeder
Bus-bar to Individual MCB
Individual MCB with fuse on live line and NEUTRAL LINK
on neutral line.
Of required rating and color
LAMP

24
 8 Panel specs As brought out elsewhere for other panels

B. Power distribution in each of I/O and CPU panel

Sr.
Parameter
No.
1 Incoming Feeder
2 Incoming Circuit Breaker
Power feed to modules and
3 isolators
Power feed to racks
4 Power feed to fan failure unit
Specification
Redundant 110 V AC UPS Supply
MCB, 2 POLE of required rating with lamp indication
Individual MCB for each of 110v 24 V DC bulk supplies,
red bulk power supplies to be provided with diode o ring
module.
Further individual MCBs for I/O racks
Further individual fuse protection for each module for
each MCB and for power feed modules of Isolators
Individual MCB for each of 110v 24 V DC rack power
supplies
Individual MCBs for fan failure units

7 Distribution wire Of required rating and colour

7 Panel Lightning LAMP
8 Panel specs As brought out elsewhere for other panels

6.1.12 SCAN TIME:

 Scan time for a closed loop shall be the cycle time taken by controller to read and process
input, perform control calculations and update controller output for loops configured within
controllers.
 Scan time for an open loop shall be the cycle time taken by data acquisition system to read
and process input and performs computations of all open loops configured within data
acquisition system. For various normal controls and data acquisition following scan time shall
be used.
a. Close Loops:
Analog Control loops: 200 msec or Less.
Digital control loops: preferably 100 ms or less
b. Open loops:
Analog inputs (4-20 mA): 200 msec or Less.
Digital inputs: Preferably 100 msec or Less,
Temp. Inputs: 200 msec or Less.

6.1.13 OVERALL RESPONSE TIME OF SYSTEM: Less than 300 msec

The Response time is the time taken to set the output from the instant of change input at TB
level. This time includes time taken for Input module ,scan inputs, process the application
logic and set outputs , output module and this include output relay time also. This response
time shall be unaffected by the size and complexity of control logic and shall be preferably
lesser than 300msec even under worst conditions.
The additional capacity of 25% on communication & CPU shall not deteriorate the scan or
response time

6.1.14 Response time on changeover of component

25
 In case of failure of Ethernet connection either at the controller end or at the PC /server end,
the changeover to the redundant Ethernet connection should be bump-less for values on OS
as well as field.
 Changeover from Master server and to redundant server should also be bump-less on the
OS.
 CPU changeover should be bump-less for values at OS as well as in field.
 In case of failure of I/O communication module of one CPU system the changeover to other
CPU system should be bump-less.
 Controllers to maintain the process control in case of failure of Operating Station/ Engg.
Station.
 If both controllers fail, the outputs will automatically held in set values (fail safe) as defined
during engineering. Similar facility should be available in case of failure of I/O modules.
 Speed of the Bus shall be such that so as to fulfil the timing constraints w.r.t. scan, cycle, OS
refresh, alarm and trend time stamping etc.
 Failure of red rack or I/Os shall be also bump less.
 In case of changeover from one Ethernet connection of the server to other Ethernet
connection of the server there should not be any dip in display of values on the operating
station. The changeover to the redundant Ethernet connection should be bump-less.

6.1.15 COMMUNINCATION SYSTEMS

For each of the four bus systems mentioned below, separate bus interface modules shall be
used in the CPU sub systems.
a. Communication Subsystem One: This system interconnects, control equipment
(CPU) with the operator interface, and servers.
The communication sub system will have redundancy with two buses and dual
control circuits. If one bus or associated circuit is faulty, transfer to back up bus is
made and signaled to the operator. The transfer shall be automatic without any break
in communication. The bus shall be flexible & master less. The bus shall support a
large no. of devices. This bus should be preferably an open architecture Ethernet bus
with standard TCP/IP communication protocol conforming to IEEE 802.2. The
components used in the system shall be such that they should be preferably easily
available from the other suppliers also. A brief description of the bus system
(speed, hardware, protocol etc.) used shall be furnished along with the bid. The
technical details and manuals of the bus and protocol used shall also be
submitted along with the bid.
The system cable shall be armored CAT 6/OFC (wherever applicable) cable and
stations such as Controllers, Operating stations (servers) and process computers can
communicate with one another through process bus.

b. Communication Subsystem Two: The system interconnects control equipment with

the I/O Interface controller.
The communication sub system will have redundancy with two buses and dual
control circuits. If one bus or associated circuit is faulty, transfer to back up bus is
made and signaled to the operator. The transfer shall be automatic without any break
in communication. The bus shall be flexible & master less. The bus shall support a
large no. of devices. This bus should be preferably an open architecture bus using
standard deterministic communication protocols. A brief description of the bus
system (speed, hardware, protocol etc.) used shall be furnished along with the

26
 bid. The technical details and manuals of the bus and protocol used shall also
be submitted along with the bid. The cable should be an industrial grade cable.

c. Communication Subsystem Three: The system interconnects the CPU systems with
other CPU systems of DCS / PLC. The communication sub system will have
redundancy with two buses and dual control circuits. If one bus or associated circuit
is faulty, transfer to back up bus is made and signaled to the operator. The transfer
shall be automatic without any break in communication. The bus shall be flexible &
master less. The bus shall support a large no. of devices.

d. Communication sub system four: The DCS and PLC based system shall consist of
dual redundant CPU. Communication between redundant CPU systems shall
be preferably through redundant, high-speed network based on deterministic
protocol.
The network of OS to servers shall be different from the network of the CPU of
DCS & PLC with the servers. Also a separate network shall be provided for
DCS communication to servers and PLC communication to servers.

e. The DCS/PLC shall be capable of communicating with third party control systems by
using of the following interfaces and protocols:
a. OPC (the required software for the same to be provided for using it as
OPC server and OPC client).
b. Serial Interface (Modbus),RS 485 & Modbus TCP/IP .

6.1.16 For Specifications of SERVER, OS and View Client – Refer Annexure - B1

6.1.17 OPERATOR STATION:

The operator interface shall be a PC based system. It shall consist of five Workstation grade
PCs, 4 in control room for operations/control and 1 view clients only for display of parameters.

Further, there will be one no. of Ex proof (zone 1, IIC gas area certification) 10-11” HMIs to be
provided in the field local panels of compressors. FO cable shall be used to transmit the signal
from CCR to these field HMIs.

The operator consoles (PCs) shall be capable of accessing all the variables of the complete
plant area. Also all the monitors shall support all the functions (i.e. to access all display
overviews, loop trend data, alarm summaries etc.) in an interactive manner. Operator screens
shall be normally updated preferably at 1-2 secs. interval (100 process points) to provide the
operator with rapid identification of process variables and contact status changes.

The communication between Operator station & DCS-PLC CPU shall be done through
Servers. One of the Operating station shall be directly connected to CPU for operation
of the Plant for use in case of failure of both the servers

From view client, operator can only view the plant graphics. All the operations are blocked
from view client. For view client communication to servers, one Firewall (software and
Hardware) is required and the same shall be in bidder’s scope. View client may be installed at

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a far of location from Control room. For this the Ethernet cabling work required from CCR to
the required location, shall be carried out by the purchaser.

Functions of Operator Station:. The Operator Station shall have but not limited to following
functions:

a. The operator shall be able to broadly perform following main functions from these
consoles:
i. Monitoring/controlling of the entire plant. (Regulatory and supervisory).
ii. Trend display
iii. Alarm Display and print out
iv. Report generation
v. Graphics capability.
vi. Computation.
vii. Multi window capability
viii. Dedicated alarm view availability while operating through graphics

b. It shall have all mimic for plant control

c. Control through mimic shall be possible under password control.
d. It shall have facility to search a particular mimic
e. It shall have facility to provide guidance to operator on various plant disturbances,
system failures and malfunctions etc. and shall also help to find out the root cause of
the problem.
f. All type of display, but not limited to, namely dynamic display, area display, group
display, loop display, trend display, alarm display, alarm summary display system
alarm display, graphic display, history display, plant mimic display etc. shall be made
available by Operator station for the operator with current data and if required with
history data.
g. There shall be permanent area on every page providing immediate alarm indication
of abnormal plant condition.
h. Security shall be through login and password..
i. The Operator’s & Instrument engineer’s interface with the system shall be via
Operator. However some of the annunciation panels shall be grouped and located in
Control desk.
j. The operator’s control stations shall be identical each having access to all
information in the system. Failure of any one of the operator’s station will not have
any effect on the operations. The display can be viewed on other Operating Stations.
Removal or replacement of any hardware in the operator’s console will not
necessitate shut down of the system.
k. Trend for the required parameters should be available preferably by clicking on
common Trend key and then double clicking on the parameter whose trend is
required.
l. By calling the trend by group no., online facility for changing the display range of the
trends, online facility for displaying the trends with the given dates and time should be
available.
m. Set point/ Output tolerance check: If Set point of a controller and its output in
manual mode is changed by 10% or more than its previous value, system shall have
facility to warn the operator and ask for confirmation for such change and shall be
software configurable.

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 n. Resolution of values in numeric/ plot/ bar graph form :
i. Numeric form - 0.1 %
ii. Graphic/mimic/ bar graph /plot – 0.2% or better
o. SCADA and Third Party Connectivity
 The system shall include SCADA capability to communicate with third party PLC and
DCS vendors through OPC software. The Software offered should be OPC
compliant. By utilizing these OPC connections to communicate over various
networks, , the system shall provide the ability to log, trend and report data from the
third party PLC and DCS sources.
p. The OS & ES should be operational full-fledged without the help of Keyboard by
using soft keyboard option. All the operations should be possible with mouse.
q. ON line changing of alarm set points e.g. HI, LO, PID setting of the controller should
be possible from OS with pass word protection.

r. Operator station will be common for DCS-PLC system and communication between
the operator and the PLC system shall be done via common operator station and
through which it shall be possible to display the status of the inputs / outputs,
process variables, inactivation / forcing facility with all security features, alarm /
hooter for faulty conditions, reset functions etc. A very few critical alarms shall be
supplied with facility for bypass / Reset / Indication lamps / switches / start-stop
pushbuttons etc.

s. The system shall have flexibility in specifying or changing the tag numbers,
descriptions, ranges, scale factors, or grouping in the various displays

t. The Operator station shall be provided with 2 user devices viz., Keyboard and
mouse.

u. Operator workstation shall be with latest version of Windows based system.

v. Central acknowledgement of alarm & hooter should be possible from any of the OS.
Once the Alarm is acknowledged from one OS, it should get acknowledged at all the
OS. Central Acknowledgement will not affect system performance except OS which
is access data directly from DCS and PLC controller.

w. Each LED screen shall be able to display full alphanumerical tag no. of process
variable. For defining tag no and tag description the minimum character length
available in HMI S/W package shall be 16 and 32 respectively.
Tag No. Description
41PIC349 20P501 PRESSURE

6.1.18 Control desk for operator station: Control desk housing Operator stations shall also have
20 nos. of mushroom type lockable push buttons with protective lid & indications for manual
trip of units and pump start/stop for plant and 144 Annunciator windows (refer Annexure B3
for Annunciator specs) for annunciating critical alarms. It will also house 75 no of ammeters
which will be supplied as free issue by purchaser.

6.1.19 HMI FEATURES

1. Display Hierarchy
Dynamic Display: The dynamic display of the entire parameters will be as given below:

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 i) Overall view: Displays the whole with interconnection of main blocks of the Plant. The
overall view shall also show the area menu icons with drop down menu of complete plant.
Each of these area icons should show alarms/ message etc if it occurs in any of the
parameter in that area. Area menu icons shall be fixed always for HMI page called.
ii) Area or unit Display: Showing the graphic & numerical values with Engineering units
wherever applicable, each parameter (measurement, set point) and alarm status of each
area of the plant.
iii) Group Display: Shall include, apart from those mentioned in area display, the details of
controllers and its alarm status. It shall provide the operator with a display of up to 8 to 12
control instruments per page in a format resembling a conventional control panel. In
addition to controllers certain important indicators may be shown on group display. The
group display shall represent a bar graph and other indications of each loop’s process
variable, set point and output values. The group display shall include the group number
and title, and short description for each loop or variable displayed. The mode of each loop
(Manual/ Auto / Cascade etc.) shall be shown in the group display. It shall be possible to
control process from group display.
Following control actions shall be possible from group display:
1. Increase / decrease set point
2. Change controller mode
3. Change controller output in manual mode
4. For digital points start/stop or open/close command.
iv) Loop Display/Face plates: This shall include the details mentioned in area & group
displays and the complete loop details, which include measurement, set point, output
values, mode of the controller, tuning parameters etc. It shall also include process variable
min. and max. Values alarm set point, limits on set point, output & velocity, controller
action (Direct / Reverse), computational constants like bias, ratio, integrated value (Total),
Engg. Unit. Loop display shall also contain a trend displaying PV, Set value, Output with
sample time of 1 Sec. and full time scale of 60 min. for tuning of process control loops.
Following actions shall be possible from Loop display.
1. Increase / decrease set point
2. Change controller mode
3. Change controller output in manual mode
4. For digital points start/stop or open/close command.
5. Change tuning parameters
6. Change limits on set point & output
7. Change alarm set point
The loop display features shall be available in the face plates designed for Controllers,
Indicators, Pumps, Heaters etc.
Set point/ Output tolerance check- If Set point of a controller and its output in auto / manual
mode is changed by 10% or more with respect to its previous value, then system shall have
facility to warn the operator and ask for confirmation for such change.
The system shall provide a screen update time not exceeding 1-2 sec.( 100 live points) Any
loop with high deviation or high low alarm shall be shown by a visual alarm..

2. Colour Dynamic Graphic Displays

i. These graphic displays shall be able to show graphically the process pipes, equipment, and
relevant instrumentation. About 100 graphic display pages shall be required for plants.
ii. Each display shall be organized in order to show the instrumentation for each process
section and plant area.

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 iii. The following information shall be available from these displays :-
1. Measuring value of each analog variable
2. Status of pumps, on-off valves etc.
3. Symbols of pumps, valves etc
4. Alarm either for analog or digital variables
5. Status of digital input.
6. Controller PV, SP,MC values alon with alrms
iv. Graphic displays shall be interactive type through which it shall be possible to control the
process.
v. It shall be possible to send motor start/stop and pneumatic valve open/close commands
from this display as per job specifications.
vi. The graphics will be built by the vendor on the basis of P & I diagrams which will be supplied
by purchaser.
vii. Dynamic updating shall include changing symbols (such as closed valve position open valve
position, changing levels in vessels), change in colour, and change in values etc.
viii. The graphic panel shall display the real time dynamic display. Updating time shall be
preferably 1-2 seconds with approx. 100 parameters.
ix. Jump keys should be available from the graphic displays to go the detailed displays ( Face
plates) on clicking the specific parameter. It can also be used for jumping to other graphics
display. POPUP facility should be available from the graphic for window display of open
loops & closed loops..
x. The current values of process variables with engineering units shall be displayed in the
objects. Abnormal conditions shall also be displayed in the graphics.. Scaling, scrolling and
zooming of graphics shall also be possible. Number of graphic pages available should not
be a limitation to adequately display the complete process.
xi. Scroll bar facility should be available on the mimics to run thru longer pages.
xii. Inhibiting and enabling of areas of the mimic should be possible with suitable password
protection. In case the area is inhibited , operator should eb able to see the parameter but
should nt be able to operate.

3. Process Alarming
The following Process alarming scheme is preferred. The supplied system should try to cater
to these or equivalent process Alarm requirements.
Alarm shall be indicated at all levels of display with flashing reverse video or any other visual
indication to attract attention of operator. It shall be possible to suppress any single alarm or
a group of alarms without reconfiguration of the alarm set points with password protection.
Indication of an alarm shall be reported to the operator in preferably 1-2 seconds of
occurrence at the control station. New alarms as well as existing alarms shall be indicated to
the operator regardless of which display is reviewed at that moment. For all alarm points
visual attraction shall be associated with audible alarm, however it shall be user configurable
to have audible alarm with an alarm or not. The alarm condition shall be acknowledged by
pressing a soft button or push button at the key board. After acknowledgement alarm tag
shall become steady w.r.t visual attraction to operator.
The control system will provide, as minimum, process variable high-high, high or low-low, low
limits and deviations from set point limits. The limit values will be adjustable at the operator
station. An alarm condition will be indicated to the operator in the manner indicated above.
For the audible alarm separate speakers will be installed in all the operator’s stations.

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 The detailed alarm indication and acknowledge facility shall be as follows. However if at a
later stage a different philosophy is required the same should be configurable in the operating
station.
Each of the Alarm should be displayed in front of Analog indication (say in a small square
form on the mimic. The philosophy of operation should be as follows.
i. Whenever any alarm comes, the indication or symbol defined should start blinking or
through some visual indication on the graphic display which attracts operators attention.
The indication should continue till any operator acknowledges it. After acknowledgement
of the same flashing should stop and steady indication should appear (if the alarm is still
persisting) otherwise it should disappear. The steady indication should go when the alarm
gets reset. If the operator has not acknowledge the alarm and it gets reset then also till
operator acknowledges it, visual indication shall remain.
ii. Along with these displays the message should appear on the Latest alarm window (a
separate screen in operating station). After this the same philosophy as above should be
followed. After the alarm gets reset it should go the alarm history/summary page.
iii. On the alarm message window if the common acknowledge key is pressed then all the
alarms should get acknowledged.
iv. The alarm message (preferably 3 nos) shall appear preferably with date & time of its
generation in the bottom of main HMI pages .
v. It is preferred if the latest alarm is displayed on the graphic display also
vi. Along with the actuation of the alarms, a buzzer should also blow. This buzzer shall get
silenced after acknowledgement of alarm. Separate buzzer stop button should be
available.
vii. The format of alarm message will be:
viii. Tag no, Description of tag, low/high, Time of occurrence, Time of Acknowledge, Time of
reset, whether ack./reset.
ix. System faults as described elsewhere shall be displayed in separate window on the OS.
x. During start-up and shutdown of the plant, it would be convenient if the operator is able to
bypass certain groups of alarms. An alarm system with such feature shall be preferred
with all security features.
xi. All the alarms/events generated in the Controller shall be time stamped at the origination
point i.e. at controller

6.1.20 ENGINEERING STATION:

Following features shall be made available in Engg station
a It shall be possible to make application program ( HMI ,logics etc.) by drag and drop
facility.
b The creation of application program, debugging and editing shall be user friendly and
menu driven.
c The Engineering console shall be used for programming, engineering, loading, updating
and debugging of software, for presetting the parameters etc.
d This shall be a Workstation grade PC system complete with LED, Keyboard, Printer, etc.
with latest configuration shall be considered.
e Engineering tools to build logic shall be available on a standard environment viz. latest
Windows operating system
f The Engineering tools shall facilitate on-line and off-line engineering functions of the
system.
g Auxiliary drive shall be available for system software loading and taking backups.
h Failure of Engineering or operator station shall not cause any trip-out of the plant.

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 i Graphics /Database tools shall comprise of easy use of GUI (Graphic Users Interface)
Icons/Menus.
j It should be possible to take the backup of the logic along with the Register contents
(containing configuration parameters) so that , the backup can be used afterwards for
plant operation say after a long shutdown by downloading the backup again in the
controller. Password protection should be available for performing these tasks.
k From the Engg. Station one should be able to call the logic sheets and should be able to
see the real time parameters. One should be able to make true online changes on the
Logic software.

l Online updating of logic and databases shall be possible through engineering station
with password protection.
m It shall be possible to create, modify, delete the pictures preferably through interactive
sessions on-line in user-friendly atmosphere. The graphics modules shall enable the
creation of static (plant schematics) and dynamics (process variables). Standard
building blocks / templates pertaining to a process industry like pipeline, valves, pumps
etc. shall be provided and the user shall use these standard blocks to create graphics
without the help of any programming language. It shall also be possible to add user-
defined symbols to the library of templates.
n Single Engg station should be sufficient to carry out the engg for CPUs, Servers and
HMI clients and the changes are down loaded in these respective machines form engg
station.

6.1.21 EVENT RECORDING SYSTEM( This shall be available for both DCS and SIL3 PLC)
1. Alarms
a) The system shall have inbuilt sequence of events (SOE) capability for all the alarms.
This is required for Trip/shut down analysis and system maintenance.
b) STORAGE DURATION: The system shall be dedicated and have sufficient capacity to
store at least three months data of all the alarms occurred in the chronological order of
occurrence. All changes in logic status, including changes of status, of input, activation of
inputs, trip/alarm values (Analog), etc. shall be recorded. There shall be a facility for on
demand viewing & printing of these stored events.
c) TIME STAMPING RESOLUTION: All printout messages shall include time stamping in
the order of its occurrence (in day/hour/min./msec) for each Tag No. The time stamping
resolution shall be in the order of scan time for Digital inputs of PLC. For DCS inputs the
resolution shall also be as per the scan time mentioned in the DCS specifications
d) There shall be synchronization between PLC and DCS timings.
e) The Event Recording System shall be integral part of DCS/ PLC.
f) It shall be possible on request to view & take printout of all events occurred between the
specified time requested by the user.
g) The I/O cards shall have facility so that the channel terminated on them shall be able to
software configurable for event recording as well and no duplicate wiring shall be needed
for configuring any particular channel for event recording.
h) The reporting in general shall be same as alarm format described in the earlier section

Events: All the operator action & non critical alarms should be available as events. These
events should be displayed along with the alarms generated from CPU( facility should also be
there to show these events separately from alarms). These should also get logged on to the
Printer & OS in chronological order.

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 Any change of analog trip value made from the Engg. Station, overrides done from Engg.
Station shall also be logged.
On demand, a chronological record of events (e.g. operator action, set point changes, on/off
scan, alarms etc.) shall be displayed on the monitor. The pages of the log shall be scrolled
and. It shall be absolutely impossible for the operator to erase any part of the event log.

3. First out alarm feature :

First out annunciators are used to indicate which one alarm out of a group of alarm points
operated first. To achieve this, the visual display indication for the alarm point that operates
first must be different from the visual display indication for subsequent alarm points in that
group.

For annunciator windows programmed in OS, Status of the variables shall be annunciated in
the standard first out feature format as per ISA 18.1. Option F3 with AMR options as per ISA
std should be available.

4. Other features related to Alarms are

a) Manual forcing On / Off of any input shall be possible from keyboard. In case of any I/O
being in forced condition, the same shall be indicated distinctly on the LED screen.
b) Any change in trip settings / forcing On / Off etc. shall be possible for only limited access
persons through a password / key lock security feature.
c) The OS shall also display any PLC diagnostic error messages with a distinct audible alarm.
d) separate windows should be available for process alarms, Events and system alarms in
OS

6.1.22 PRINTER (Alarm & event RECORDING)

1. A self-contained dot matrix printer shall be provided for online logging of significant events
such as occurrence of process alarms and subsequent return to normal alarm
acknowledgement, operator’s change of parameters, equipment and power failures, system
start and restart operations. The printer shall also produce alarm summary and loop list on
demand. The printing shall be alphabetic, numeric and symbols. Alarm print out shall be
black only. The logging and alarm time and date shall also be printed. Actual data and time of
alrms to be printed .

2. Printer for History Logging

History recordings of alarms, variables, Events and operator’s functions shall be available.
The system should store about three month data for most recent alarms and most recent
operator changes & events. These shall be printable any time as and when required by the
operator. The vendor shall provide a full and comprehensive database operations procedure
for backups, reports generation, graphics operation, data-protection, securities etc.

6.1.23 REAL TIME TREND DISPLAY

1. Real time process trends shall be displayed on the HMI
 The display time base shall preferably be variable from 10 secs to 12 hours to
observe the process dynamics.
 The real time trending shall be available for all the parameters of all the loops of the
plant. However user has the flexibility to assign or reassign any of the loops to the
real time database.
 Additional information associated with the trend shall be loop tag no., engineering
units span, present value of trended point, Average, min & max values.

34
  In each trend group it shall be possible to display simultaneously at least 6 trends plot
groups on one screen. Trend recording can be displayed for 6 points on one group.
 Updating time shall be preferably once in one second or better.
 Variables like process input, set point and manipulated output can be displayed on
real trend panel. On line changing of time range should be possible.
 Online creation of new trend should be possible.
 Magnification up to 10 times of part of the plot should be possible.
 Trend display should display value & time on cursor movement.

2. Historical Trend Display

 All the variables shall be possible to be selected for historical trend recording
purposes.
 Input variables for historical trend recording shall be process, set points and
manipulated ones.
 The display time range shall be from 10 secs hours to 12 hours.
 Magnification of part of the scale upto 10 times should be possible.
 The historical trends should preferably be available from real time trend screen by
changing the date & time. At any time minimum of last three months data should be
available.
 The storage of trend data should be possible for at least 3 months. After this it
should be possible to take backup of the trends on CDs. Backup should be able to
reloaded and watched again on the same OS/server.
 Stored data will be available for display any time. There shall be no interference
between historical data storage and real time trend display.
 The storage and reloading procedures will be such that operating personnel not
familiar with the inner working of the system can easily perform these functions.
System reloading time should not exceed 30 seconds.

6.1.24 SYSTEM ALARMS:

a. System shall have capability of on-line self-diagnosis. There shall be extensive self-
diagnosis to monitor healthiness of all the cards / channels / communication
links/equipment/system etc. Healthy indication shall be provided on card as well as on
the operator station.
a. Any abnormal conditions in subsystems shall be displayed as system alarm message on
operator console irrespective of the display selected.
b. Diagnostic display: Graphical representation of system components with dynamic display
shall be provided. (Like CPU, communication bus redundancy, I/O nest, power supply
status) .On the operating station special screens shall be built which will show the
complete hardware diagnostics of the system. The system shall be shown in a graphical
form and the indications of various components of the systems are shown in the
Red/green colors depending upon the status of the Hardware. The details to be shown ,
not limited to are as follows:
a. Status of CPU.
b. Status of I/O modules.
c. Status of each channel of the I/O modules.
d. Status of Power supply modules, communication modules etc.
e. Status of I/O racks.
f. Status of other modules of the CPU subsystems.

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 g. Status of Operating stations
h. Status of the Servers
i. Communication between Servers and OS.
j. Communication between Servers & CPU.
k. Communication between CPU & I/O Racks.
l. Status of Ethernet switches.
The Alarms for these Diagnostics shall be also available on the Printer.
Following system alarms shall also be made available on the HMI with alarm messages
 Bus Fault identification and automatically switching over to the redundant bus system shall be
available at Controller, I/O module and OS level. The indication for the faulty bus along with
the switchover to the standby should be available on the operating station.
 Master and Standby indication of controllers, BUS and I/O modules should have
corresponding status indication on the OS & on the respective modules.
 Under range and over range of the signals should generate a software alarm and also to be
shown as change in color on displays or any method to attract operator’s attention.. Fixing of
signal values to lower, upper (Burnout facility) or last value hold should be possible. For alarm
purposes, it shall be possible to define burn out up-scale or down scale.
 Card status should also be displayed on the respective display of the indication. For all the I/O
modules, channels status (healthy/faulty) should also be available on the OS. Whenever a
channel fails, it should be displayed on the OS with an alarm. Card fault should also generate
a software alarm
 The system shall provide automatic detection of open circuit detection of the thermocouple.
 Removal or replacement of a faulty card will not require any shutdown i.e. all the modules
shall be hot plug in type and generate an alarm.
 The status indication of these switches shall be available on the OS. Redundant switches shall
be provided.

6.1.25 REPORT GENERATION:

Reports:
Following reports are required on demand as well as automatically:
1. Shift/Daily/Monthly reports of different process variables.
2. Hourly avg., hourly total, hourly max/min., instantaneous values of certain process
variables.
3. The reports shall be printed automatically at a specified time. On demand report shall be
printed with demand from operator station.
4. System diagnostic reports in case of failure of any module / component of the system
both current and historical.
5. Log of operator initiated actions, on demand.
6. Alarm and trip review reports.
7. The formats and other details of the various reports shall be designed in consultation
with the purchaser.
8. Apart from pre-formatted reports mentioned above, there shall be preferably a report
writer with SQL (Structured Query Language)-like commands to retrieve and generate
reports in user definable formats. Number of reports should not be a limitation.
9. The reports shall have a configurable retention of generally 3 monthss. There shall be
facility for storage of above reports whenever required on a DVD and read back facility
should also be available.

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6.1.26 PROGRAM STORAGE
a) All operating system software including system monitoring and diagnostic software shall be
stored in EPROM memories.
b) All application software, working memory and storing intermediate results shall be stored in
EEPROM or battery backed RAM . The capacity of EEPROM / battery backed RAM utilized for
storing application software shall be maximum utilized up to 50%..
c) Tools and tackles shall be made available by vendor for online program entry, debugging,
editing etc.
d) RAM memory shall contain battery backup capable of retaining all stored program data in case
of Power failure for preferably one month. The capability shall exist to remove all batteries from
the system without removing system power card.
e) LOW BATTERY INDICATION: A low battery condition must be detectable and must be
preferably annunciated but shall not automatically generate a major fault. Vendor shall indicate
the type of battery with its working life and shelf life.
f) The operator should be able to backup volatile memory, including data and program logic onto
either a hard disk /DVD.
g) ON LINE PROGRAM UP LOADING: Complete logic, Modified database etc. which shall be
developed and debugged off-line, should be able to get uploaded in the system with simple
commands on line.
h) Backup & Restore: For taking backups of various individual software programs required for
running the entire system and plant specific logics, provision is to be made to take backups on
CD/Hard Disk in zipped format. The same should be able get restored as and when required
basis in user-friendly atmosphere.

6.1.27 ON-LINE TESTABILITY REQUIREMENT

To ensure the system healthiness for on line monitoring following, but not be limited to,
indications shall be provided.
a) The Led requirements for I/O modules has been already brought out earlier.
b) There shall be preferable LED indication on CPU card for showing the healthiness of
batteries (used for RAM), if any battery is used.
c) Test and Monitoring points shall be preferably available for checking healthiness of power
supplies at the front fascia of power supply modules.

6.1.28 Reliability Requirements

DCS system shall be the heart of the plant & therefore highly reliable system is needed. To
achieve this few requirements, but not be limited to, are as follows:
a) The system shall operate reliably under all conditions and under no circumstances there
shall be erroneous output leading to unsafe plant operation.
b) Vendor shall quote their field proven system. For substantiate their claim sufficient amount
of back up data and documents shall be provided by vendor.
c) MTTR and MTBF data shall be submitted for DCS and PLC I/O , CPU, communication, PS
etc. modules.
d) System shall comply international standards for quality assurance of software and
hardware of system.

6.1.29 SOFTWARE.
a) Operator interface & software configuration:

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 The HMI software used at the operating station should be preferably the suppliers own make
This HMI software should be used with Windows based Operating System It should have
the following basic specifications.
The Software should be capable of preferably handling Unlimited I/O Points, Distributed &
Client server Architecture, Intuitive Man-Machine Interface, 100 % Data Integrity, Real time
Process Monitoring, Supervisory Control & Data Acquisition, OPC functionality, User based
Security, Object Oriented Graphics, Alarming & Alarm Management, Comprehensive &
Accurate reporting, Real time & Historical trending, OPC SERVER & CLIENT features
This software is used for engg. station and the operating station.
The system hardware and software shall allow the user’s maintenance personnel to modify
on-line the configuration, data grouping, descriptions, tag numbers, alarm set points, and
other display data as well as drawing of process graphics as required in user friendly
atmosphere.
Software for report generation, system diagnostics, self-documentation shall be provided. All
the software provided shall be licensed to HWB
The software should also have the facility to be used as historian for storing the data for
trend, alarms, parameters , reports etc.
b) CPU software:
a)Application software for CPU :
A standard software package to be used in Main controller( CPU) shall be provided by the
manufacturer of the distributed control system. The software package shall be capable of
executing all the operations necessary for controlling the appropriate process plants.
This software should be accessible from Engg. Station and one should be able to do the
required changes. This involves the possibilities of changing process variables as well as
configuring or constructing loops, hardware configuration. The changes shall be done from
the engg. Station. After making the necessary changes the data shall be downloaded into
the Main Controller. Before downloading the data, simulation option should be available to
check the correctness of the logic changes made. During downloading, the required
response time of the system should not get affected.
Apart from this mode, the pure online mode (password protected) is also required for
checking the functioning of the present system logic. In this mode no downloading is
required. One should be able to see the working of the logic online. Online temporary
changes should also be possible in this mode. In this mode the parameters at each & every
software block shall be visible.
Apart from various other software block mentioned elsewhere, the following should be also
available in the software.
PID, Summer , Rate limit, Multiplier, HI/LO selector, Digital filter, Divider, Signal
selector, Increment ,Derivative, Switch, Totalizer, Lead/Lag, Linearization, Sq. root,
Integrator, ON/OFF delay, Graphic blocks, Sequence logic defined algorithms. Logic
functions like AND, OR, NOT, EXOR, High/ low selector functions, timer functions, Flip
Flops etc.
Ladder diagram logic & ST, IL, SFC should also be available.
The software shall be freely configurable and reliable, user friendly, menu driven to facilitate
configuration and programming function without the need for any particular computer
software knowledge. The software should be as per IEC 61131-3 standard.

6.1.30 OPERATOR WORKSTATION UPDATE TIME

System shall guarantee the following update times:
a) Display page call up time: preferably less than 1-2 sec for non-graphic pages.

38
 b) Graphic page call up time: preferably less than 1-2 sec for a page with less than 100 live
points.
c) Page refresh time: Live points in the actually displayed page shall be refreshed every
second (100 live points approx.)
d) Issue of commands: less than 2 sec from OS to field.

6.1.31 SYSTEMS MAINTENANCE SUPPORT:

These features shall include, but not be limited to, the following:
a Collection of diagnostics database of system automatically or on user demand.
b Live viewing of Logic execution
c Diagnostic message storage with user definable browsing functions
d Forcing of input & output
e ON LINE MODIFICATION: System shall have on line modification facility. It shall enable to
modify to application software, system software & system hardware configuration, while
maintaining the systems critical control function for the operational plant.
f I/O signal forcing: For maintenance reasons it may be desirable to force an input or an o/p
signal to certain fixed state. Forcing of signals shall be possible by password protected
software functions.
g SIMULATION: System shall have simulation facility. Vendor can use any method to achieve
simulation functions of system. However one of the possible alternatives is given below.
Vendor shall indicate in his offer methodology proposed by him for achieving the same.
“Simulator shall be a built in part of System Developer. The user can select the module
including the CPU module for choosing the tags to be modified. The screen shall be divided
in two parts: Left hand side shall show the part of logic where forced simulation shall be
carrying out. The right hand side shall show the tags in HMI ,where effects of simulation shall
be observed. The simulation shall be able to get carried out at near real-time speed or at
enhanced speed whichever is required.”
h The system shall provide suitable diagnostic procedures for troubleshooting. Any card failure
/ abnormality shall be indicated on the operator console as well as on the printout.
i The supplier shall provide required maintenance tools such as the following:
I. Diagnostic software if not included in the main software
II. Diagnostic software instruction manual
III. Adequate maintenance / service manuals, troubleshooting procedures, test
point/signatures etc.

6.1.32 SYSTEM SECURITY

a) The following minimum three levels of security shall be provided by the system:
I. Operator level
II. Supervisory level
III. Engineering level
b) The system shall be designed in a way that minimizes the possibility of a hardware or
software failure. Consequently, in the event of failure, effective diagnostics and error
messages shall be provided to facilitate detection and resolution of the failure. The vendor
based on his knowledge of his equipment shall provide additional on-line diagnostics and
checks in addition to those in the specification.
c) In case of any mal-operation it should be possible to identify from which console the
operator action took place.
d) Power Failure / Auto Restart
I. The stations, controllers and process interface units shall have power-fail

39
 detection. Upon power failure, the hardware /software shall perform the necessary
functions to bring the appropriate equipment to an orderly shutdown, including an
orderly deactivation of all the processing.
II. When data acquisition units and controllers lose power it shall be annunciated
on HMI and logged, along with the time of occurrence on printer.
III When power is restored after power failure, the system should reboot
automatically
e) Memory Protection: The system shall be capable of protecting from being overwritten.
The system software shall also be capable of protecting itself to ensure integrity. The
memories shall have parity check and detection.

6.1.33 SPARE CAPACITY AND EXPANSION CAPABILITY

The DCS system shall be delivered to the installation site with the following minimum spare
capacity and expansion capability.
i) Redundant capacity is not considered to be spare capacity
ii) Each of the I/O modules should be loaded to 100 % capacity.. The no. of I/O modules
should be counted based on the 100 % loading capacity of each module( to next higher
integer).
iii) Each I/O rack should have 20 % spare capacity to house the I/O modules as per the
requirement in future.
iv) There should be a spare capacity in each panel to house 20 % spare Isolators, 20 %
spare DO relays modules, 20 % Terminal boards, wiring ducts etc. Additional wiring for the
10 % of spare components (complete loop form module in racks to TBs) shall be carried
out by vendor which may be used by purchaser at a later date .
v) Spares module as per SOR (Annexure A) shall be provided.
vi) Process control device shall be sized such that no more than 50 % processing capability
and memory, communication system is utilized. The vendor shall provide the estimated
loadings of the communication system to substantiate this requirement.
vii) Each installed communication system shall have 50 % node expansion capability for
future development and still be capable of meeting the requirement of specifications. The
vendor shall provide the estimated loadings of the communication system to substantiate
this requirement.
viii) Minimum spares shall be supplied for the IT related Hardware as per SOR.

6.1.34 ON-LINE HELP

a) An on-line help facility shall be provided at the ES, which shall provide the user information
about the following:
I. System configuration and details.
II. Maintenance manuals/procedures.
III. Software and software features.
System shall have its own documentation so that engineers may not carry manuals to rectify
the fault.
b) Operator help should be available on HMI screens for display of any interlocks etc. related to
that parameter.
c)Process manual including P&I diagrams shall be available on one of the OS.

6.1.35 SYSTEM CLOCK AND SYNCHRONIZATION

Time synchronization: All the participants of DCS & PLC shall be time synchronized (HH:MM:
Sec:msec level) with each other. The time duration of sending the synchronization pulse shall be

40
user programmable. The Server shall act as master for synchronization. If the time
synchronization facility is not inbuilt into the system , then a separate time synchronization server
has to be supplied which will synchronize all the participants of the system.
If signal from clock is not received by controller every hour, it shall generate a system alarm.

6.1.36 SAFETY REQUIREMENT

On complete failure of system, all the outputs of the system shall go to predetermined state (user
configurable).

6.1.37 SELF-DIAGNOSTIC REQUIREMENT

a) To increase reliability of operation and to enable detection and localization of faults self-
diagnostics features shall be incorporated in the system. This shall include, but not be limited to,
power on diagnostics & Online diagnostics for the system.
i) Power On Diagnostics: These shall include CPU and memory related diagnostics,
missing I/O module checks, checking of communication between CPUs. These
diagnostics shall be performed, once every time power is switched on to system. Any
failure detected during these tests shall prevent the system from enabling the outputs.
ii) On Line Diagnostics: These are periodic and performed once in every scan cycle
and shall include tests for checking CPU, memory, communication between CPUs, I/O
address selection mechanism, output feedback checks (namely Output stuck to 1 or 0)
for digital input (open circuit) & Low/High current for analog input), missing module
detection checks etc.
iii) On line diagnostic screen: Dynamic diagnostic screen for overall system shall be
provided for observing system healthiness & quick review of the system.
b) Watchdog timer: Watch dog timer shall be provided for checking the healthiness of operation
of CPU.

6.1.38 MAINTAINABILITY REQUIREMENTS

i) The engineering of the system hardware shall be modular to enable ease in maintenance.
ii) All components, cables and connectors etc. shall be unambiguously marked for ease of
maintenance.
iii) All markings shall be readable from the position in which user can easily view them.
iv) The cables shall be routed in conducive manner for ease of maintenance.
v) All modules within a subassembly in a cubicle shall be plug-in type for ease of maintenance.
vi) If modules of sub-assemblies have front connections for interconnection with other modules
of other sub-assemblies, than the connections shall be taken with suitable flat cable to the
backside for further interconnections.
vii) The modules shall be provided with necessary displays to identify the faulty modules for
speedy replacement of them in case of their failures.
viii) Hot replacement facility shall be provided to replace faulty module. Replacement of faulty
module shall not cause any transient in output of system.

6.1.39 COMMUNICATION:
a) DCS System shall use standard protocols like Ethernet, profibus / Modbus/equivalent. The
system shall be capable of interfacing with foreign control systems like other DCS/PLC
System.
b) Vendor’s standard communications networks shall be fully redundant with automatic switch
over. It shall be possible to monitor the status and active communication path at any time
Failure of one of the redundant cables shall not degrade system performance.

41
 c) Communications error checking techniques shall be incorporated. Communications system
configured as redundant shall either use the backup path continuously to determine if it is
operating normally.
d) Failure or planned shutdown of any one device connected to the communications network
shall not affect the ability of the system to communicate with any module.

6.1.40 ENVIRONMENTAL CONDITIONS

The equipment will be installed in an Air Conditioned room and it shall be suitable to operate
normal lifetime under the conditions mentioned below:
a) The normal operating temperature and humidity condition is normally 26 degree Celsius
and 50% RH. In abnormal situations ie., during air conditioner failure, the condition will be
30 º to 50º Celsius temperature and 20 to 95 % RH non-condensing)
b) The field instruments are located in hazardous area classification IIC, T3.
c) There shall not be any adverse effect in the system functioning due to RF interference
from VHF trans-receiver sets being used in the vicinity / factory premises.
d) The system shall be protected from external high voltage disturbances, lightening, etc.
o o
e) The storage conditions: Temperature: 5 to 50 C Relative Humidity: 20% to 95% non-
condensing.

6.2 PART b: FUNCTIONAL REQUIREMENTS OF SIL3 CERTIFIED PLC. (Separate redundant

SIL3 certified PLC based system to be provided for main plant I/Os and for compressor I/Os .
Refer also BOM for these separate requirements).

6.2.1 INTRODUCTION:
The objectives and broad guidelines laid down in this section define end goals of the purchase of
the system. This Section of this Tender shall prevail over all subsequent sections..
a) All Process interlock & emergency shutdown interlock has been incorporated in the
Programmable Logic Controller. The objective of SIL3 certified PLC is to work as
Emergency Shutdown System by performing all safety interlock operations in safe
manner of HWPT.
b) The PLC system shall be latest microprocessor based modular in construction and user
friendly programmable and shall automatically take actions for safe start up, safe running
and a safe shutdown of the plant with minimum manual interventions.
c) It shall be of latest technology which shall have technical & spares support for at least
another 10 years after obsolescence

6.2.2 FUNCTIONAL REQUIREMENTS

SYSTEM CONFIGURATION:
a) SIL3 PLC shall be a microprocessor-based system which shall be used for safe start up,
safe running and a safe shutdown of the plant. All critical interlocks including compressor/
pump/valve/process trips interlocks & related logics will be incorporated in PLC. The PLC
shall be an independent unit with all accessories dedicated solely for logic
implementation. The system should have very high reliability and minimum downtime.
The architecture of system shall be SIL3 certified as per IEC 61508 std certified by
agency like TUV.
b) The system configuration shall be as per the job specification. The basic system shall
consist of the dedicated Processor Modules, Communication Modules, Memory Boards,

42
 I/O System, Engineering Console etc. However Operation station will be common for
DCS-PLC system.
c) The system shall be designed for high reliability and availability with dual redundant
configuration. The system shall have sufficient diagnostic features for both hardware and
software functions. On line replacement of faulty modules shall be possible without
affecting PLC operation.
d) The system shall be programmed in principle as per the interlock logic scheme given by
purchaser. The vendor shall do the programming with graphical representation as per
purchaser’s requirements
e) A major consideration of the programmable controller system shall be its modular, field
expandable design allowing the system to be tailored to the customer's machine and/or
process control application.
f) The programmable controller system shall be designed and tested to operate in the high
electrical noise environment of an industrial plant.
g) Testability Requirements: The design of PLC system shall be such that On-Line
diagnostics are available
h) Each module of system viz, CPU, communication, Input , output etc shall be individually
SIL 3 certified.

6.2.3 CENTRAL PROCESSOR UNIT (CPU) SYSTEM

All requirements given in section 6.1.3 shall be applicable for CPU system of PLC also. Refer
section 6.1.3 for details. The logic software of the PLC CPU shall be confirming to IEC 61131-3 and
IEC 61508 stds.

6.2.4 TYPE OF FUNCTIONS:

The control station shall have the following functions but not limited to
1. Computing functions like linearization, sq. root, average, multiplier/divider, weighted
additions, exponential, logarithmic lead / lag calculating unit, velocity limiter, cascade
switching, totalisation, override etc. It shall be capable of providing signal
conditioning, & computing functions
2. Logic functions like AND, OR, NOT, EXOR High/Low selector functions. Logic
function such as 2/3 logic, flip flops, Timers, Logging of all Digital status including
generated from analog values, Text strings for alarm and event logging etc.
3. All the Control logics shall be programmed through software using readymade
software blocks for above function of sr no 1 & 2.
4. Analog Input Block with minimum facility for scaling, giving the alarm set points (HH,
H, LL, L) & dead band as inputs and Alarm bits at the outputs to be available. Each
parameter shall be available for display in Operator’s console.
5. All trip parameters shall be included in SIL-3 certified PLC with I/O redundant facility
as per I/Os in section 4.
6. Readymade software blocks along with face plates should be available for Analog
inputs, ,pumps, motorised valves etc.

6.2.5 SYSTEM LOADING

System Loading requirement shall be same as given in section 6.1.5.

6.2.6 REDUNDANCY & Hot swapping

Same requirement as given in section 6.1.6.

43
6.2.7 INPUT-OUTPUT SYSTEM:
Same requirement as given in section 6.1.7. AO related requirements are not applicable for PLC.

6.2.8 DETAILS OF INPUT/OUTPUT CARDS:

All the requirement related to AI, DI & DO signals shall be taken same as given in section 6.1.8.

Except all the I/O cards shall have the following minimum diagnostic features for sensing the
channel failure
DI: Invalid Channel/channel fault, channel wiring problem, card fail
DO: channel overload, channel fault/unsafe, channel status feedback, card fail
AI: Invalid Channel/channel fault, over range or broken wire, card fail

6.2.9 SPECIFICATIONS OF SIL3 CERTIFIED INPUT & OUTPUT MODULES

a. Analog Inputs:

All the analog input channels will be preferably individually isolated from each
a.
other and from system.

Isolation shall be provided at two levels viz: At marshaling cabinets with the help
b.
of isolators and at I/O Module itself

c. A/D conversion & resolution shall be preferably better than 16 bits.

Overall accuracy shall be better than +0.1% of full-scale measurement for overall
d.
temperature range.

e. Isolation level shall be minimum 300 Volts D.C.

The drift due to change in ambient temperature shall be within standard

f.
admissible limits.

Analog close loop cards shall be dual redundant type as per I/O count given in
g.
the tender

h. Isolation provided on board shall be preferably optical type

Card should have facility to show that individual channel is healthy and signal is
within range of 4 to 20 mA (Around 5% tolerance shall be provided on both
i.
ends). i.e., 3.2mA to 20.8mA is considered as healthy beyond which error should
come. Also LED for card healthy, communication healthy to be provided

Broken sensor shall be detected, evented and also shall be available in user
j. program to carry out specific activities. Also facility shall be available to user to
latch or set the analog value to a constant.

b. Digital Inputs

44
 a. All Digital Input channels shall be individually isolated preferably.

b. Interrogation supply for Digital Inputs shall be 24 V D.C.

c. Isolation level of Digital Inputs with internal circuits shall be preferably minimum
300 V. D.C.

d. Potential-free contact inputs from field shall be terminated on Termination

Modules in Marshaling Cabinets.

e. Adequate protections shall be provided to digital input signals against transients

and high voltages

f. LED indications shall be provided on Termination Modules and I/O Modules to

indicate status of field signals, 24 V.D.C./110 VAC excitation, and healthiness of
protection circuits. Also LED for card healthy, fail safe healthy to be provided

c. Digital Outputs
a. All Digital Output channels shall be individually isolated, preferably.

b. Each Digital output channel is provided with a Relay(either in built in the card or
by providing relay modules. Vendor shall provide 24 V.D.C. relays rated at 5 A. /
24 V. DC . resistive load, duly wired( 1 NO , 1 NC), Further some additional
relays are derived from this relay based DO. For pumps & compressors, MOVs
,(. Voltage : 110 V DC Current - 5 A (2 NO 2 NC)) for SOVs 110 V AC 5 A.
(2 NO 2 NC).

c. Isolation level of Digital Outputs with internal circuits shall be preferably

minimum 300 V. D.C.

d. Digital outputs shall be individually protected against continuous over-current

and short circuit.

e. Module Front Facia shall have diagnostic LED indications, preferably dual-colour
type, for individual channel to indicate channel status viz. On / Off / Overload or
Short circuit. Also LED for card healthy, fail safe healthy to be provided

f. Overload or Short circuit of any Digital Output shall be detected, evented and
also available for user program.

6.2.10 TRIP ISOLATORS: Same as 6.1.10

6.2.11 POWER SUPPLY SYSTEM:

Same requirement as given in section 6.1.11.

45
 6.2.12 SCAN TIME
Scan time for a closed loop shall be the cycle time taken by controller to read and process input,
perform control calculations and update controller output for loops configured within controllers.
Scan time for an open loop shall be the cycle time taken by data acquisition system to read and
process input and performs computations of all open loops configured within data acquisition
system. For various normal controls and data acquisition following scan time shall be used.
For SIL3 PLC based system for main plant
Close Loops:
Digital control loop: 100 msec or Less
Open loops:
Analog inputs (4-20 mA): 200 msec or Less.
Digital inputs: Preferably 100 msec or Less,
For SIL3 PLC based system for compressor I/Os
Close Loops:
Digital control loop: preferably 50 msec
Open loops:
Analog inputs (4-20 mA): 200 msec or Less.
Digital inputs: Preferably 50 msec,

6.2.13 OVERALL RESPONSE TIME OF SYSTEM ( definition) :

The Response time is the time taken to set the output from the instant of change input at TB
level. This time includes time taken for Input module ,scan inputs, process the application
logic and set outputs , output module and this include output relay time also. This response
time shall be unaffected by the size and complexity of control logic and shall be as asked
above even under worst conditions. The additional capacity of 25 % on communication &
CPU shall not deteriorate the scan or response time
. For SIL3 PLC based system for main plant I/OS
OVERALL RESPONSE TIME OF SYSTEM: Less than 300 msec( max 300 ms)
For SIL3 PLC based system for compressor I/Os
OVERALL RESPONSE TIME OF this system for compressor I/Os: preferably Less
than 175 msec (max 200 ms).
6.2.14 Response Time on Changeover of Components: Same as 6.1.14
6.2.15 COMMUNINCATION SYSTEMS
Same requirement as given in section 6.1.15.NOTE: All the features asked are to be provided
with required protections as per SIL 3 certifications. If certain features are not available due to
SIL3 certification/ criteria, the same should be brought out clearly and such bids will be
acceptable if the feature is not available due to SIL3 criteria

6.2.16 OPERATOR STATION

Communication between the operator and the PLC shall be done via operator station which will
be common for DCS & PLC systems through which it shall be possible to display the status of
the inputs / outputs, process variables, inactivation / forcing facility, with alarm / hooter for faulty
conditions, reset functions and start/stop self-illuminated pushbuttons etc. All the facilities
available on Operating Station(OS) of DCS shall also be available for PLC. All the features
described for OS for DCS (section 6.1.17, 6.1.19) shall be available for PLC including Trends,
Report and Alarms etc.

6.2.17 ENGINEERING STATION

Engineering station is common for DCS & PLC

46
 Same requirement as given in section 6.1.20

6.2.18 SOFTWARE for Controller: The software shall be SIL3 Certified.

Application Software for Controller shall be configured utilizing standard program blocks for
following functions in general and any specific requirements arising during the system design.
The language used for programming shall be as IEC-61131-3. Apart from various software
blocks mentioned elsewhere (6.2.4) following should be available in PLC
I. Logic language (Gates / Timers etc. based or ladder logic)
II. Limit detection
III. Delay actions
IV. Logging of all Digital status including generated from analog values
V. Text strings for alarm and event logging
VII. Analog signal conditioning and scaling.
VIII. Allocation of engineering unit to Analog inputs.
IX. Analog Signal calculations
X. HMI to facilitate operation
XI. Analog input scaling, Dead band facility, Alarm setting facility.
Trip conditions shall be generally generated by a contact or by an analog input exceeding a
certain value. However a few trip conditions are manipulated analog values and logic functions,
which require program blocks to perform algorithms.

6.2.19 EVENT RECORDING SYSTEM

Same requirement as given in section 6.1.21.

6.2.20 First out alarm feature :

The detailed alarm Philosophy has been brought out in section 6.1.21 point no. 3. The same
should be available for SIL3 PLC also.

6.2.21 ALARM / PRINTING

Same requirement as given in section 6.1.22.

6.2.22 SYSTEM ALARM:

Same requirement as given in section 6.1.24.

6.2.23 PROGRAM STORAGE

Same requirement as given in section 6.1.26.

6.2.24 On-Line Testability Requirement

Same requirement as given in section 6.1.27.

6.2.25 RELIABILITY:
a) The reliability of the PLC system shall be very high. The architecture shall be redundant,
fault tolerant to failsafe. No single failure within the system component or field I/O s shall lead
to a shutdown of the plant. The plant shutdown shall occur only in the case of emergency
situation of the process.
b) The architecture to be followed is for maintaining a highly reliable system. The system shall
have dual redundant architecture with safety Integrity Level SIL-3 as per IEC 61508 standards.
c) PLC system shall be the heart of the plant & therefore highly reliable system is needed. To
achieve this few requirements, but not be limited to, are as follows:

47
 1) The system shall operate reliably under all conditions and under no circumstances there
shall be erroneous output leading to unsafe plant operation.
2) Vendor shall quote their field proven system. For substantiate their claim sufficient amount
of back up data and documents shall be provided by vendor.
3) MTTR and MTBF data shall be submitted.
4) System shall comply with international standards for quality assurance of software and
hardware of system.
6.2.26 Off-Line Testability Requirement
For achieving a low time to repair, an offline card test system integrated test jig shall be
provided for checking healthiness of Critical PCBs, CPU cards, Communication card and I/O
cards etc. This shall not be connected with the system and will work independently for checking
the healthiness of cards.

6.2.27 SYSTEMS MAINTENANCE SUPPORT(with required protections as per SIL 3

certifications)
Same requirement as given in section 6.1.31.

6.2.28 SYSTEM SECURITY

Same requirement as given in section 6.1.32.

6.2.29 SPARE CAPACITY AND EXPANSION CAPABILITY

The PLC system shall be delivered to the installation site with the following minimum spare
capacity and expansion capability. Same requirement as given in section 6.1.33.

6.2.30 ON-LINE HELP

Same requirement as given in section 6.1.34.

6.2.31 SYSTEM CLOCK AND SYNCHRONIZATION:

Same requirement as given in section 6.1.35

6.2.32 SAFETY REQUIREMENT

On complete failure of system, all the outputs of the system shall go to predetermined state
(user configurable).

6.2.33 SELF-DIAGNOSTIC REQUIREMENT (with required protections as per SIL 3

certifications) :
Same requirement as given in section 6.1.37.

6.2.34 MAINTAINABILITY REQUIREMENTS

Same requirement as given in section 6.1.38.

6.2.35 COMMUNICATION:
Same requirement for PLC system as given in section 6.1.39.

6.2.36 ENVIRONMENTAL CONDITIONS

Same requirement as given in section 6.1.40.

Section: 7

48
 GENERAL CONFIGURATION AND TECHNICAL SPECIFICATIONS OF DCS-PLC
SYSTEM

7.1 OVERALL CONFIGURATION

It shall be as per the architecture Section 4 of the document.
a) CONFIGURATION OF DCS SYSTEM: The configuration of the DCS system shall be
such as to provide a plant network with Operator Stations, DCS Controllers, input/output
modules, Servers, etc. All communication shall be dual redundant. The configuration
schematic shall be furnished by vendor. The DCS system shall be predominantly software
driven where functionality and personality of the devices shall be definable at the logical
level rather than through physical interconnection of the devices.
b) CONFIGURATION OF PLC SYSTEM: The configuration of the PLC system shall be
such as to provide a failsafe certified architecture confirming to SIL3 as per IEC 61508.
There shall be a network-based communication between Operator Stations, PLC
Controllers, input/output modules, Servers, etc. All communication shall be dual redundant.
The configuration schematic shall be furnished by vendor. The PLC system shall be
predominantly software driven where functionality and personality of the devices shall be
definable at the logical level rather than through physical interconnection of the devices.
.

7.2 COMMUNICATION BETWEEN CPU & I/O MODULES

a) Communication Medium: Coaxial cable / Fiber optics communication or equivalent
b) DATA TRANSMISSION RATE: Capable of high speed data transfers. The speed should
be such as to achieve the different response times as mentioned earlier in the document.
c) Data communication:
i) The system network shall have a Protocol & industry standard. Vendor’s standard
communications networks shall be fully redundant with automatic switch – over. It shall
be possible to monitor the status and active communication path at any time.
ii) Failure of one of the redundant cables shall not degrade system performance.
iii) Communication Error: Communications error checking techniques shall be
incorporated.
iv) Communications system configured as redundant shall either use the backup path
continuously or check the backup path at least once per minute to determine if it is
operating normally.
v) Failure or planned shutdown of any one device connected to the
communications network shall not affect the ability of the system to
communicate with any other device on the network.
vi) Communications With Other Systems
a. Each external interface and software shall be an established, standard feature of
the system. All devices providing external interfaces shall use standard protocols
and shall provide electrical isolation from the external system.
b. The system shall be capable of interfacing with external control systems. These
systems utilize a microprocessor. Therefore, the interface will be digital andtthe
preferred protocol is Modbus- RTU & MODBUS TCP/IP
c. Communication with view clients: View clients can only see the parameters; it will
not be able to generate the commands.

49
7.3 CONTROLLER SUB-SYSTEM
a) The necessary hardware like I/O cards, processors, electronics etc. for the successful
control of process shall be quoted as required for meeting specifications and achieving
functionality mentioned in the specifications.
b) The loading sheet indicating the distribution of controller and I/O cards for the specified
I/O counts shall be furnished.

7.4 OPERATOR / ENGINEERING WORK STATION

a) 4(four) no. of OPERATOR STATIONS and 1 nos of view clients with 22" color LEDs
shall be provided with the system. In addition one number of Engineering Station for DCS
PLC shall be similar to Operator work Station..
Further there will be one no. of Ex proof (zone 1 , IIC gas area certification) HMIs to be
provided in the field local panels of compressors. FO cable shall be used to transmit the
signal from CCR to these field HMIs.
b) Total no. of work stations required – As mentioned earlier in the document.
c) Failure of any operator/engineering console shall not affect the function of system.
d) OS shall be provided in the consoles with the desk type structure.
e) Each Engg. station shall have an access to global data base.
7.5 WORKSTATION FAILURE SECURITY
Failure or disconnection of a workstation shall not affect the operation of any other device
on the communication system.
7.6 REPORTS AND PRINTERS
This section details the general requirements for system reporting functions and reporting
printers.
1. Report Package:
a) The vendor shall provide utility packages to generate report formats using a
Conversational, fill-in-the blank approach.
b) Software programming shall not be required to generate reports.
c) It shall be possible to use any variable in the system in a report.
d) It shall be possible to activate report on the following bases:
I. On demand (operator's request)
II. Shift, daily, weekly and monthly
III. Event driven
e) It shall be possible for all reports configured to be displayed on a workstation screen
as well as printed on a report printer.
f) It shall be possible to configure a report to accept manually entered data for specified
fields.
2. User Defined Report Generation:
a) Customized Report Generation: The system shall provide facilities to program user
defined reports using a high level programming language and customized reports shall
be generated from the data acquired by the system.
b) Data Sharing With RDBMS, MS-WORD & MS EXCEL etc: System shall allow real
time data sharing with Microsoft word, Microsoft Excel etc in user friendly atmosphere.
3. Hard copy Printer: for graphic & trend (as per BOM Ann A)

7.7 STORAGE DEVICES

a) Hard Disk: shall be as per specifications
b) Backup: DVD / WRITE drive

50
7.8 INTERFACE WITH THIRD PARTY DEVICES & OTHER SYSTEM
The DCS offered shall have provision to be able to be interfaced with other plant Control
System through OPC, Mod buS RTU, Mod bus TCP IP.

7.9 MISCELLANEOUS
Necessary DCS, PLC, Marshalling and Relay cabinets interconnecting cables between
marshalling racks to all their sub-systems, console mounts and etc. shall be provided by
vendor as required.

7.10 SYSTEM INTEGRITY FEATURES

The system shall have inherent integrity to prevent adverse effects on the process arising
out of system or component failures.

7.11 CABINETS OFFERED FOR THE SYSTEM

The vendor shall visit the site before preparing the offer to ensure that available space
would be sufficient.

7.12 GENERAL REQUIREMENTS

Cabinets’ framework fro all the types of panels supplied shall be provided and standardized
in accordance to the following:
i. Panel color should be RAL 7032/7035 shade.
ii. Self-standing type, min. 2.3 mm thick good quality steel plates, with channel base.
iii. The doors, side and back panels shall have 1.6 mm thickness.
iv. Cables entry - From the bottom.
v. Cabinet access - From rear & from front with locked doors complete with keys.
vi. Copper grounding bars. As a minimum, safety grounding and signal grounding shall
be provided with a grounding strip.
vii. Terminals- Weid Mueller/Phoenix 2.5 mm2.
viii. Cables fixing through cable glands of SS 304 material.
ix. Service power socket with 230V AC 50 Hz 500 Watt.
x. Forced Ventilation from top of the cabinets/side of the cabinets are required for all
the cabinets. Fan failure module shall be required for Fan failure indication. Failures
of fans shall not degrade the system performance.
xi. Sufficient clearance for smooth opening and closing the doors shall be provided to
avoid touching of any module or cables.
xii. Internal Light: Duplex fluorescent type complete with switch (on/off) 230 V, 50 Hz.
xiii. Incoming and outgoing cables/wires from and to the cabinets shall terminate at
terminals in the cabinets. All these internal wiring, termination and interconnection
between cabinets, system cabinets and panels shall be executed by Vendor.
xiv. Cable ducts - Dedicated for power, signal and non-signals. Cable ducts shall be of
plastic with cover (150mm) sized to allow loading coefficient of 80% only.
xv. Lifting eye bolts (4 Nos. per cabinet) required.
xvi. All the cabinets shall be of the same type and color, their front and backs shall be
easily inspected by means of removable hinged doors, with key locks.
xvii. The cabinet shall be constructed and designed so as to reduce interconnections to
a minimum.
xviii. Cutout with removable plate (for drilling as required) shall be provided.
xix. Power supply packs shall be positioned so as not to generate electromagnetic

51
 interference to the electronic component and shall be installed on top.
xx. The cabinet shall be supplied complete with all the materials and accessories for
wiring in the most workman like manner, with fixing brackets and cable clamps for
customer’s in/out cables also.
xxi. All cabinets shall be mounted with anti-vibration pads.
xxii. The panels shall be well sealed against dust preferably IP51 as per IEC 529 for
indoor applications.
xxiii. Illumination of 300 lux inside panel is required. Light sources shall be of the
fluorescent type.

7.13 SYSTEM POWER SUPPLY AND EARTHING/SHIELDING DETAILS

a) POWER SUPPLY
I. The power supply for the DCS and PLC system will be provided by the purchaser from
an uninterrupted power supply (UPS) of 110V a.c ± 10% 50 Hz +4%-6%. All further
distribution including cabling to each cabinet are included in the vendor’s scope of supply

Where other voltages are needed, for instance 24 V DC. etc., this must be generated by
power supply units which will be within the scope of supply of the system. The manufacturer
shall ensure complete redundancy (hot standby type) in power supply of different sub
systems like I/O / controller cabinet, LED, other hardware units etc.
The Power supplies wherever used shall be redundant power supplies only. Each Panel
shall have its own 110/ 24 V DC redundant power supplies for interrogation, Isolators etc.

II. It is required that each card/ instrument (smallest consumer) be provided with a separate
switch/fuse unit with a common miniature circuit breaker for a group. This shall ensure that
as far as possible fault in any of minor components shall be isolated at that level itself
instead of affecting other connected boards.

III. Vendor shall also include in their scope power supply and cabling for devices like
annunciators, push buttons etc.

IV. Vendor shall furnish following details related to power supply: Total power supply
requirements (including control desk devices, peripherals, etc.) in VA and KW, Total power
absorbed, Peak power requirement, Dissipation loss, Total no. of D.C. power supplies etc.
Wherever Power supply is used for step up/down by the supplier shall be redundant only.
Single line diagram for the power distribution panel shall be provided.

V. Isolating switches, MCBs / fuses shall be employed to isolate and protect the loads.

VI. EARTHING / SHIELDING SYSTEM: The vendor will design and provide Earthing as per
the "Protecting Earthing System" according to IEC rules and the "Reference Earthing
System" required for functional purposes. The two systems will be completely independent.

7.14 SIGNAL TRANSMISSION AND GALVANIC ISOLATION.

a) The system I/O cards shall have preferably built-in galvanic / opto isolation feature for all
the signals to be interfaced with the field instrumentation.
b) Each node on the system shall also be isolated from the effects of any malfunction.
c) The system shall also be protected from external high voltage disturbances and lightning,
etc.

52
7.15 GROUNDING
All the grounding requirements shall be in the scope of the vendor. Vendor shall submit
grounding scheme for power ground, signal ground and system ground. AC safety ground
and instrumentation circuit ground shall conform to relevant international standards. Ground
buses inside termination cabinets shall be made of solid copper, suitably drilled and tapped
for screw terminals and wire lugs, or fitted with screw – type compression lugs.
New Earthing pits shall be made by the bidder to be used for grounding.
The ground bus bars shall be labelled as follows:
I. “AC SAFETY GROUND” for all exposed metal surface of cabinets, racks, chassis GND
2
connections, etc. Individual wiring interconnections shall be minimum 2.5 mm copper
wire, green or green with yellow tracer insulation.
II. “SHIELD CONNECTION“ for connecting cable and wire shields Interconnections
2
between shield consolidation points and the bus bar shall be minimum 2.5 mm copper
wire, green or green with yellow tracer insulation.
III. “DC REFERENCE GROUND” (i.e. for all DC analog / digital commons).
Interconnections between DC common consolidation points and the bus bar shall be
2
minimum 1.5 mm copper wire insulation to be green or green with yellow tracer. DC
reference ground can be same as SHIELD CONNECTION.

7.16 MAINTENANCE
a) Maintenance tools and aids: The system shall provide suitable diagnostic procedures
for troubleshooting. Any card failure / abnormality shall be indicated on the operator
console as well as on the printout. The supplier shall provide maintenance tools such
as the following:
i. Diagnostic software.
ii. Diagnostic software instruction manual.
iii. Adequate maintenance / service manuals, including trouble-shooting
procedures, test point etc.
b) Maintainability: The system shall be modular and shall be easily maintainable. The
variety and number of cards shall be minimum.

7.17 SYSTEM ENVIRONMENTAL CONDITIONS

a) CONTROL ROOM The DCS, PLC and the cabinets will be installed in the control
Room building. The System layout shall be finalised with due consideration of plant
operation, vendor’s recommendation and the space available. The Control Room
building is provided with air conditioning. However to meet abnormal situation, the
system shall be designed to work in the existing environmental conditions as listed
below:
Temperature: 20 to 50º Celsius
Relative Humidity: 20% to 95% non-condensing

7.18 RF INTERFERENCE & FAULT PROTECTION:

a) There shall not be any adverse effect in the system functioning due to R.F. interference
from VHF trans receiver & Mobile sets being used in the vicinity / factory premises. The
vendor shall state the requirements such as distance, output power, frequency etc. of
normal radio equipment (walkie-talkie) from control room instrumentation.
b) All I/O circuit shall be isolated from backplane by means of Galvanic /opto electronic

53
 coupled devices.
c) Isolation from common over voltage peak shall be at least 300 V rms.
d) All I/O circuits shall be designed so that accidental application of a voltage of 300 V
AC/DC at their terminals causes no damage to the system and any damage should be
limited to that module only.
e) The output circuits shall be fitted with overload protection against inductive loads, over
currents and preferably reverse polarity and short circuit.

7.19 GENERAL GUIDELINES FOR HARDWARE/ENGG

a) All system cables shall be multi-stranded prefabricated with plug in connector secured
well with clamps.
b) All terminals shall be of reputed make such as Weid Muller, Phoenix. Wiring
terminations shall be with lugs.
c) Power supply system shall be designed in such a way that by removal of any unit, other
unit’s functioning shall not be affected.

7.20 WIRING
a) Wiring shall comply with the applicable IEC codes. Wiring of different voltage level
signals or different functions (alarm, shut down, analog signals etc.) will end in segregated
terminal strips and different wire colors will be used.
b) Wiring shall be accomplished with flexible stranded copper wires sized in compliance
with the applicable codes.
c) Terminal strips for entering cables from/to field, substation shall be in strict compliance
with the supplied documents that will contain, but not be limited to, the junction boxes wiring
details and other documents also. Submission date will be established during kick off
meeting.
d) Multi core cables shall be used for interconnection between panels.
e) Terminations, cables, wiring, components shall be properly tagged.

7.21 ACCEPTANCE REQUIREMENTS:

a. QAP: Tests and Inspection shall be carried out as per approved Quality Approved Plan and
Test procedures. Recommended QAP has been made available for vendor’s reference in
section 9. This is the minimum to be followed for testing. QAP shall be approved by
purchaser .
b. Test Procedures: The vendor shall prepare the test procedure for QAP in consultation with
purchaser and same shall be approved from the purchaser. Any documentation for
hardware and software shall be completed and available for the test, in addition to the
purchaser’s reviewed test procedure
.
c. Pre-FAT Tests. Type tests as per relevant standard for all components of the system as
mentioned in QAP shall be done by the vendor & test certificates of type tests shall be
submitted & shall be verified by the purchaser. Inspection and functional testing of system
as per approved QAP shall be as a minimum be performed by the vendor, prior to
customer’s witnessed inspection and report for the same to be submitted for review during
pre -FAT.

d. Factory Acceptance Test (FAT) of SYSTEM Factory acceptance test (FAT) shall be
performed with the purchaser presence at the vendor’s works as per approved procedure
and QAP. The FAT is intended to fully demonstrate that the DCS-PLC system have been

54
 made correctly and completely in accordance with all manufacturing, assembly and software
configurations and that the system performance with the system specifications.. The
satisfactory completion to the satisfaction level of purchaser of the FAT shall be a
prerequisite to system shipment. Dispatch of all materials and items covered under the
scope of this specification shall be affected only after FAT has been completed and approval
for shipment of the system has been given in writing. It shall be in the form of dispatch
clearance/shipping release by the authorized representative of purchaser.

e. On-Site Acceptance Test (OSAT) of SYSTEM The OSAT will be conducted after system
installation on site and is intended to assure that no damage occurred to the system during
shipment, that the system is correctly installed and that the system requirements are
satisfied when connected to “live” field inputs/outputs. Test Report requirements: The
supplier shall submit of data sheets, Inspection reports and test reports based on approved
Test Procedure and QAP as per documents asked in section 12.

f. Quality Assurance Requirements: The supplier shall be responsible for conducting all the
necessary tests as required to fulfil the requirements of standards and codes for which he
will be claiming about his system compliance and as approved in QAP to ensure the quality
of their system to the level of industrial standards.

7.22 INSTALLATION, TESTING & COMMISSIONING:

a) The system shall be installed and commissioned by the vendor at HWP (Tuticorin) site
b) An activity chart detailing step-by-step activity sequence shall be submitted by vendor for
the approval of purchaser and same shall be strictly following by vendor later on at the time
of installation and commissioning activity.
c) After installation and commissioning, supplier shall extend all the necessary help in
resolving various operation and maintenance problems faced by site.
d) It is to be noted that all field instruments & associated cables up to the control room
marshalling cabinet are in the scope of purchaser. Vendor has to integrate the existing field
wiring with their new termination cabinet. Old cabinets will be dismantled as brought out in
section 3.
e) Vendor shall offer the services of the installation team which shall carry out installation of
equipment in the control room, laying the interconnecting cables inside control room, testing
and commissioning of the system.
f) All technical personnel deputed on site by vendor shall be fully conversant with the
supplied system and offered software package.
g) Vendor’s responsibility at site shall include all activities necessary to complete the job as
per specifications including following:
I. Removal of old cabinets as asked n section3 and Installation of all DCS-PLC
equipment in control room.
II. Cabling of all power/ signal & system cables between different sub-systems.
III. Safety/Electronic/Barrier Earthing of all panels to earth pits.
IV. Mounting of all hardwire instruments in various cabinets.
V. Mounting, wiring & termination of all free issue items given by purchaser.
VI. Powering up the system, loading the system configuration carrying out
internal loop checks.
VII. Loop checking simulating with field instruments.
VIII. Field tests
IX. Commissioning and on-line debugging of the system

55
X. Performance of final acceptance test
XI. Submission of “AS BUILT” drawings.
XII. Providing all skilled / non-skilled manpower required for above.

56
 Section: 8

STANDARDS & CODES

List of Standards & Codes to be followed:

S. Standards & Codes
No.
1 IEC 61131: Programmable Controllers
2 IEC 60529: Degrees of protection provided by enclosures (IP Code)
3 IEC 62138-I&C compliance to safety and software aspect for computer
based system.
4 VDE 0884/8.87 (German std.) for power supply module against electrical
shock.
5 IEC 61058 for SIL criteria
6 IEC 60079: Hazardous Area
7 IS 4237 for Insulation test

57
 SECTION: 9

RECOMMENDED QUALITY ASSURANCE PLAN (QAP)

SYSTEM CHECK OUT AND ACCEPTANCE TESTS: Inspection, testing and commissioning
System shall undergo tests in the following manner:
Factory Acceptance Test (FAT):
System testing shall be carried out in the best quality test like manner in conformity with the
international standards and other relevant specifications. If the systems are imported than vendor
to submit QAP of the manufacturer which should be equivalent to these tests. The submitted QAP
shall take care of test mentioned below.

STAGE-I (PRE-FAT TESTS)

A.
1. The system is required to comply with the tests as listed below or equivalent tests wherever
required..
2. The vendor shall submit sufficient documents and other test certificates from reputed/ govt.
approved test lab for confirming their claim for complying the tests. If the tests have been
already carried out by the original supplier (OEM) of the system, then the tests certificates
shall be submitted to the customers. If the test certificates are not available, then the tests
need to be carried out at reputed/ govt. approved test lab for confirming their claim for
complying the tests.
3. In the event that certain requirements of the following tests conflict with the requirements of
these tender specifications then, the latter shall govern.

Sr. no. Components of the Type of Testing Relevant Standards Acceptance criteria
System
1 Testing of Individual Type Tests: As per Relevant IS/ Compliance to the
cards of the system IEC/OEM standards Standard/Test .
Such as I/O modules ,
,CPU modules,
Communication modules
, power supply modules
etc.
1a --do-- Vibration As per Relevant IS/ Compliance to the
IEC/OEM standards. Standard/Test

1b --do-- Immunity to Climatic As per Relevant IS/ Compliance to the

conditions such as Dry IEC/OEM standards Standard/Test.
heat and cold with
stand tests, Cycle
damp heat withstand
test etc.
1c --do-- Immunity to H.F As per Relevant IS/ Compliance to the
interference such as IEC/OEM standards Standard/Test .
Electro static discharge
test, Radiated
electromagnetic field

58
 test ,Fast transient
burst test, Surge test
etc.
1d --do-- Electromagnetic As per Relevant IS/ Compliance to the
emission such as IEC/OEM standards Standard/Test
conducted emission
limits & Radiated
emission limits etc
1e --do-- Immunity to voltage & As per Relevant IS/ Compliance to the
frequency variations IEC/OEM standards Standard/Test
1f --do-- Insulation resistance & As per Relevant IS/ No single failure
Dielectric test IEC/OEM standards should be
reported.

B. During Pre –FAT ,the vendor shall carry out all the list of tests mentioned below in stage II FAT
Test. The vendor shall submit the test procedure followed, results with all the relevant documents for
these test and get it vetted by purchaser before start of FAT.

STAGE II : FAT TEST

The following tests shall be carried out during FAT by vendor along with HWB. The vendor shall carry
out all these tests before calling the customer. The vendor shall submit the test procedure followed,
results and all the relevant documents one week in advance before the customer is called for tests.
The vendor shall submit the filled test reports and get it vetted by purchaser after the tests are over.
All the checks shall be done 100 % by HWB

Sr. no. System Type of Tests Extent of Check Reference Acceptance criteria
Description drawings
1 Documentation of Checking of Full checking as The documents
the system such documents per the system should be complete in
as Hardware requirements all respects.
Manuals,
Software
Manuals,
Operation
Manuals ,
Drawings of the
system
components etc..
2 Complete system Dimensional 100% by by Approved GA Dimension within
checks for DCS HWB drawings specified tolerance
cubicles and limits.
marshaling
cabinets
3 Complete system General 100% by y HWB Conformance to
arrangement for approved GA
DCS drawings.
cubicles/marshali

59
 ng cabinets
4 Complete system Overall system 100% Conformance to
along wioth BOM architecture & approved drawings
checks approved BOM and BOM
5 Panel wiring Visual inspection 100% by HWB Approved Correctness of wiring,
wiring ferruling proper
drawing quality of dressing,
segregation of power
and control cables.
6 Crimping quality, 100% by HWB Approved Correctness of wiring.
color coding and wiring Filled test reports are
grounding drawing submitted by vendor
schemes and get it vetted by
purchaser.
7 Complete system Power-up/power Complete Approved Satisfactory starting
down test for system to be test of system after
system. This will switched off procedure system is switched
also include and rechecked on.
voltage output for 100%
level at all the automatic
Power supply proper start up
outputs after resuming
of power
8 Complete system Communication All Overall All system buses
tests for communication system should be healthy
integrated system buses to be architecture and hot redundancy
checked for is operational
healthiness and wherever provided.
redundancy All diagnostic
messages appear
appropriately.
9 Complete system Individual I/O 100% by HWB I/O allocation I/O operation is
simulation drawing and proper from
termination termination modules
details to its corresponding
approved display on operator
document station and vice
versa.
10 Complete system Detail software Complete Approved Complete simulation
and logic software and document of software and logic
simulation logic should be containing package to be tested
tested by I/O allocation to confirm that the
simulating I/O drawing. system meets
conditions purchaser’s
using switches requirements.
and analog
signal sources
100% by HWB

60
11 Complete system MMI All OS pages Approved Correctness of OS
Configuration to be checked screen- pages as per
checks for static and dumps/ soft purchaser’s
dynamic copies requirements.
displays 100%
by HWB
12 Complete system System I/O module As per All diagnostics
Diagnostics diagnostic specification displays & alarms/
for hardware events as purchaser’s
CPU diagnostic
and software requirements.
Power supply
diagnostic
OS diagnostic
Power supply
communication
13 Complete system Redundancy a)I/O module As per All hot redundancies
checks redundancy specification perform along with
b) CPU for hardware display/alarm/events
redundancy and software as per specifications.
c)
Communication
redundancy
d) Power supply
redundancy
14 Complete system System response checking

a) Scan time As per As per As per specification

specification specification for for hardware and
for hardware and software.
hardware software
and
software
b) Overall system As per As per As per specification
response time specification specification for for hardware and
for hardware and software.
hardware software
and
software
15 Full Panel wiring Megger & high 1. Insulation IS: 4237 Insulation resistance
for all the panels voltage test. This resistance should be greater than
will be done w/o to be 100 mega ohm and no
i/o modules in line checked at insulation break down
500VDC. occurs at 1.5kV AC
2. HV
breakdown
to be test at
1.5kVAC
16 Complete system System Hardware 100 % by As per approved

61
 configuration HWB configuration docs
checks
17 Complete Continuous Run 100% Full system be No failures should be
Integrated system test of the system kept running for reported.. If any fault
with 50 % Inputs 100 hours on is observed, the same
and outputs at continuous basis should have technical
ambient reason and should be
temperature rectified and the test
shall be repeated
again.

Test Certificates
All routine and type test certificates including test records, etc. shall be supplied after completion of
FAT.

SAT (Site acceptance test): After acceptance at the factory, all the equipment shall be packed
suitably and transported to the site. All the hardware and software tests done at the factory
shall be repeated at the site and equipment shall be considered suitable for next phase of
testing if the results of these site tests are found acceptable. The tests shall be carried out with
actual loops of the plant in line with the complete system (Site Acceptance Test). In SAT, FAT
test sl. No. 17 will not be included. All other test shall be 100% carried out by supplier along with
HWB.

During SAT, Loop checking shall be carried out by supplier to check the functional performance
of all elements comprising the loop and thereby ensuring proper configuration, functioning and
interconnection. All Analog field instruments connected to control room shall be loop checked at
0%, 25%, 50% & 100% of FS (For both increasing and decreasing signals). All observations
shall be recorded in suitable format and shall be complied before final acceptance.

After SAT, Nitrogen or water run with the systems shall be carried out for 5-7 days. After the
successful completion of Nitrogen or water run, the plant shall be taken in line with the new
system. This phase is termed as Semi Industrial run. Duration of this semi-industrial run shall be
30 days, during which time the Supplier shall be directly responsible for the of the system and
additional hand holding training of the operators. Semi- industrial run shall continue by the
supplier if any failure or mal function is observed in the part or whole system.

Commissioning: After successful completion of the semi-industrial run, the equipment shall be
considered as having been commissioned and accepted

62
 Section: 10
INFORMATION FROM VENDOR
10.1: VENDOR QUALIFICATION CRITERIA RELATED DOCUMENTS TO BE SUBMITTED ALONG
WITH BID
Sr. No Description With bid(no of
sets , Hard
copies )
1 Documentary evidence of the one similar kind of work with the system of 2
minimum 2800 I/O count or two similar job of 2100 I/O counts or three similar
job of 1400 I/O counts
2 Documentary evidence for average annual turnover of Rs. 7.45 Crores for 2
the immediate last 3 consecutive financial years
3 Average annual turnover, profit and loss statements certified by chartered 2
accountants for last 5 years shall be submitted. Annual reports can be
submitted in addition to these.
4 completion certificates from client as evidence 2
5 Address & contact nos. of the organizations where the offered system is 2
installed
6 Technical support and spares for minimum 10 years after the date of 2
obsolescence of the system. Letter in this regard from the OEM linking to the
present case of purchase shall be submitted along with the technical bid
7 Manpower and experience of Key persons: Details in the FORM-A to be 2
submitted

10.2: TECHNICAL DOCUMENTS TO BE SUBMITTED ALONG WITH BID

Sr. No Description With bid(no of
sets , Hard
copies )
1. Tender specifications duly signed & stamped by the bidder. 2

2. Deviation list to the Tender specifications 2

3. Detailed DCS & SIL-3 PLC configuration & Architecture offered 2

The Architecture should show all the components of the system viz.,
• CPU rack where hot redundant CPUs shall be mounted. It should also
show all other module such as P.S, Redundant I/O communication modules,
Ethernet module (for communications with HMI), etc. Any module used here
shall be redundant as asked in our specification.
• Interconnection of CPU with the I/O modules through redundant bus system
should be shown clearly. Similarly interconnection of CPU with HMI should
be shown clearly.
• The block diagram should show the switches, PCs used as Engg station,
Operating Station etc. and it communication link with CPU.
• I/O racks where I/O modules shall be mounted. It should also show all other
modules such as P.S, communication module etc on the rack
• All the racks used for I/O should be shown in the architecture. The

63
 redundant communication link should be shown clearly on the I/O rack.
4. Hard ware details: Details of make & model no of each type of component ( 2
CPU, I/O module, Communication module, Power supply, Ethernet switch,
servers, client, etc) , offered as per Architecture.
5. Qty against each type of modules offered as per the architecture should be 2
shown in SOR (Technical brochure along of each type of module shall be
submitted).
6. Technical brochure along of each type of module component ( CPU, I/O
module, Communication module, Power supply, Ethernet switch, servers,
client, etc) shall be submitted.
7. Test certificates for DCS & PLC of each & every module for the system
asked as per specifications ( refer section 9 of specs)
8. Test certificates & SIL 3 certificates for PLC of each & every module for the 2
system asked as per specifications
9. Technical details of CPU , I/O & other modules such as 2
• Processor speed,
• Bit size of processor
• Processor make & model
• Memory(RAM, EPROM, EEPROM, FLASH ROM) capacity details etc.,
10. The basis of arriving at the qty of I/O modules & CPU modules should also 2
be shown based on our I/O count.
11. A small write up on the DCS catering to the functional requirement of the 2
required DCS by purchaser.
12. A write up on the redundancy functioning of CPU system for both DCS & 2
PLC. The description should cover the requirement asked in the
specifications.
13. A write-up on the redundancy functioning of the I/O modules 2
14. Details of the bus system (along with driver used , speed, distance limitations 2
etc.) for CPU to HMI and CPU to I/O modules should be given as asked in
our specifications
15. Bidder to submit the details of HMI software offered. Preferably a copy of the 2
demo software to be submitted for our use. Make and model of HMI,
software, logic software , server software etc to be submitted) .
16. Bidder to submit the details of control software used. Bidder to confirm the 2
Control software used is as per IEC 61131-3 standard as asked in our
specifications. The document should contain
Details all the software blocks with their functional details. Preferably a copy
of the demo software to be submitted for our use
17. Details of the no of Panels which will be supplied along with the system. 2
18. Make, model, Specifications, Technical Brochure of the Server PC & 2
Operating/ Engg station PC.
19. Make, model, Specifications, Technical Brochure of the Ethernet switches. 2
20. Technical brochures of other components such as Power supplies, Relays, 2
Communication cables, TBs any other bought out items used by the supplier
for completion of the project
21. Make, Model, Brochure of the Galvanic Isolators/barriers used. The qty of 2
each type of Isolators offered should be specified.
22. Total power requirement for above system (with break-up for each part of the 2

64
 system.
The supplier must indicate the following in the offer:
Total electrical load.
Power supplies shall be used.
Frequency variation permissible. However, the vendor’s system either
should be capable of operating in 50 Hz ± 4% Hz frequency variations or if
required, separate frequency regulator shall be provided by the vendor.
System starting surge.
Heat generated by the control room equipment
Control room loading for civil scope.
Maximum AC downtime which shall not cause system shut down or loss of
data. Battery backup supply requirements, if any.
23. Quality Assurance Plan (QAP) for the DCS. 2
24. Vendor should submit the detailed time schedule of the Activities starting 2
from placement of Order showing the schedules for
• Detailing of the system
• Submission of Documents for approval
• Application Development
• FAT
• Delivery
• SAT
• Installation & commissioning.
25. Vendor shall guarantee that he will support all system hardware and firmware 2
with spare parts and service for a period of 10 years from the date of
obsolescence of the system. A certificate in this regard from the original
manufacturer of the system shall be submitted along with the bid.
26. Vendor shall give the name, Address of the organization, Name of the 2
contact with person with phone no. & e-mail no of the company where they
have supplied a similar system (with approx. same no of I/O count) in the last
seven years.
27. Vendor shall submit the BOM/SOR (Annexure-A) format dully filled with 2
quantities only for the system offered by them. The rates should not be filled
in the technical offer (unpriced commercial offer).
28. All the relevant documents asked in the tender and which are not brought out 2
above
29. FORM-A showing the details of personnel to be appointed by the bidder 2

65
 Section: 11
SCOPE OF SUPPLY & SUPPORT SERVICES
11.1 SCOPE OF WORK:
The requirements of DCS-PLC system are mainly covered on functional basis as brought in
previous sections. The vendor shall be responsible for providing all materials, equipment
accessories and services, to meet the requirements of functional completeness, operational and
maintainability and reliability of the system as per entire scope of work covered under this
specification within the quoted price and without any further commercial implication to the
purchaser. In the event of any conflict between the requirement of any two clauses or documents
forming a part of this specification, the decision of the purchaser will be final and binding in all
such cases.

The scope of order shall include the design, supply, Engineering , Testing ,transportation and
commissioning of the hardware and software as detailed in the functional specifications as well as
other related tools and services mentioned in this section. The scope of the vendor shall include,
but not be limited to the following

a) Design & detailed engineering of the system.

b) Procurement, Supply of necessary DCS CPU, I/O, Power supply, Communication modules,
Barriers/Isolators, Relays & other Panel hardware as per the technical specifications. The qty
& details of the components required are also brought out in SORs.
c) Procurement, Supply of necessary SIL3 PLC’s CPU, I/O, Power supply, Communication
modules, Barriers/Isolators, Relays & other Panel hardware as per the technical
specifications. The Qty & details of the components required are also brought out in SORs.
d) Fabrication & supply of I/O panels for DCS & PLC. For CPU separate panels to eb provided.
Also Test jogs to be supplied in panels separate from I/O panels.
e) Removal old relay based panels ( ground floor of CCR)approx. 18 nos and carrying out the
jobs as defined in section 3.
f) Supply of base frame for erecting DCS & PLC panel in control room. False flooring will be
provided by the purchaser.
g) Supply of necessary Licensed DCS & SIL3 PLC logic, Server, Operating station and any
other software as per the technical specifications. The Qty & details of the components
required are also brought out in SORs.
h) Supply of redundant Servers, Operating stations & Engineering Stations & other IT hardware
as per the technical specifications. The qty & details of the components required are also
brought out in SORs.
i) Supply of Cable glands and accessories for Cable termination in to new panels.
j) Supply & installation of control desk for housing operator stations, annunciators, required
push button, Ammeters etc.
k) Any other hardware / software necessary to make system complete and functionally
operative.
l) Supply & laying of Interconnecting cables between panels, Power supply cables from power
supply distribution panel to I/O panels of complete system including DCS,PLC OS, servers
etc ,( specs as per Ann D7)
m) Supply and laying of 12 pair cable & junction box for interconnection of Relay based panel
(available in ground floor of control room) to DCS panel and annunciator termination. (A
lumpsum of 1000 m of 12 pair cable will be supplied).( specs as per Ann D7).
n) Supply of FO cable for filed HMI ( specs as per Ann _D7)

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 o) Transportation of the system to site & to CCR at site.
p) Installation of complete IT hardware( Servers, OS, cables, switches, Racks etc
q) Installation of new DCS & SIL3 panels & glanding, termination of signals into the new panels.
r) Continuity check of loop from field to the marshalling cabinet shall be in the purchaser’s
scope.
s) Earthing system along with the cabling for each system (DCS & PLC Earthing system as
elaborated elsewhere in the document). New earthing pits are required to be made at site by
supplier .Supply, installation and cable termination earthing cable and accessories from panel
to earthing pit shall be in scope of supplier.
t) SOR/BOM list items give feel of quantum of work. Vender is responsible for complete supply
of items required for functional completeness of system as per the specifications without any
additional cost implication.
u) Erection, commissioning and successful operation of the system up to the stage of
acceptance to the satisfaction of purchaser.
v) Vendor shall make available the services of their engineers (min 4 engineers) till
acceptance/commissioning of the system. Subsequent to commissioning the system
engineers (2 nos.) shall be available at site for a minimum period of 2 months and after
that 1 system engineer shall be available for a period of 4 months (total 6 months after
commissioning).
w) Deputation of required manpower (Technicians/Helpers) for erection and commissioning of
system at site. Deputation of required manpower (Engineers) for erection and commissioning
of system at site during shutdown.
x) For all the supplies made by bidders, Erection & Commissioning shall be in supplier’s scope.
y) Performance testing, providing of operation and maintenance manuals, and training of client’s
personals.
z) System shall be guaranteed for 2 years after successful commissioning and acceptance of
the system by purchaser
aa) AMC shall also be offered for 3 years after completion of guarantee period.

11.2 CIVIL WORK: The scope shall include necessary civil works.
11.3 REMOVAL OF THE EXISTING SYSTEM:
The supplier shall remove the existing system as brought out on scope and section3. And this
activity will be an integral part of the installation scope of the vendor.
11.4 SYSTEM CHECKOUTS AND ACCEPTANCE TEST:
a) The acceptance criterion shall be “to meet the entire requirement set forth in these tender
specifications to the satisfaction of purchaser”.
b) All components of the system will be checked together and operated at vendor’s works.
c) This will include all sub system / inputs that form a part of the system as installed.
d) The purchaser’s representatives shall be associated for this stage of the project. The purpose
of the checkout will be to determine, as completely as possible, that the systems built and
configured to the user’s specifications. The details of tests has been brought out in section 8
& 9 of specifications.
11.5 SCOPE OF HARDWARE AND SOFTWARE:
The scope of order shall include the design, supply, testing, transportation, installation and
commissioning of the hardware and software system as defined in this tender specification. Also
refer SOR/BOM Ann-A.

11.6 SUPPLY OF BOUGHT OUT ITEMS

67
 The supply of bought out items shall be of standard make. The supplier shall take prior approval
from purchaser before deciding the make of bought out items.

11.7 DOCUMENTATION :
DOCUMENTS TO BE SUBMITTED BY THE BIDDER ALONG WITH THEIR OFFER
1.0 ACCEPTANCE OF TECHNICAL SPECIFICATIONS
Bidder has to submit signed copy of technical specifications along with the Bid as a mark of
Acceptance of the Terms & conditions, Scope of work, Technical Specification etc.
2.0 DEVIATION FROM TENDER SPECIFICATIONS
In case of any deviation from the Technical specifications or conflict between any clause of this
specification or any clause in the offer submitted by the bidder, same shall be specifically brought
out by the bidder as deviations in their offer by grouping all such details in a separate “Deviation
Sheet”. The deviation should clearly indicate
The Chapter no., clause no. and the deviation against this clause
3.0 DOCUMENTS TO BE SUBMITTED & AFTER THE PLACEMENT OF PO:
Refer section 12 for details

11.8 Manuals:
Refer section 12 for requirements.

11.9 KICK-OFF MEETING:

A kick-off meeting between vendor and HWB/HWPT for DCS-PLC will be set up in order to define
final time schedule and documents to be supplied. In addition regular project meetings shall be
performed.
11.10 Spares:
The vendor shall provide as a part of the scope of supply, necessary commissioning spares, if
any, free of charge. All spares required for commissioning may be listed separately. Unused
portion of commissioning spares can be taken back by the supplier after commissioning.
11.11 Maintenance tools and aids:
The vendor shall include in the scope of supplies the maintenance tools and aids.
1. The system shall provide suitable diagnostic procedure for troubleshooting for all system
components and equipment.
2. The vendor shall also provide maintenance tools such as the following
a. Testing jigs for trouble shooting of all types of cards if required for performing
maintenance( refer Sor/BOM).
b. Diagnostic software if required for performing maintenance.
3. Adequate maintenance/service manuals including, trouble-shooting procedures and test
points for every module and component

11.12 TRAINING
a) The training shall cover complete education of all aspects of the system. The training module
shall be divided to impart the following categories:
I. System features
II. Maintenance features
III. Operational features
I. System feature: The training shall cover, but not to be limited to, Configuration of logic
sequence & interlocks, Configuration of PID controllers, Configuration of Alarm
management, Configuration of Trend management, Configuration of safety functions,

68
 Programming, Operation, Trouble shooting, Maintenance, System configuration,
modification in the software, various hardware and software feature of the system etc.
II. Maintenance feature: This shall cover all aspects of the troubleshooting and
maintenance of various parts / units of the system up to the module / component level.
This shall also include but not to be limited to Identification of faults in CPU,
Identification of faults in I/O modules, Identification of faults in communication system,
Identification of faults in Operator Station, Alarm management for maintenance
functions, replacement of modules, Routine maintenance procedures, Routine
calibration procedures, software diagnostic etc..
III. Operational feature: This shall cover all aspects of the operation of the system and
various other features, including but not to be limited to the Operating the Plant from
Operator Station, Alarm management, History management, Trending & Recording,
Graphic operation & navigation, Report Generation etc.
b) The training shall cover complete education of all aspects of the DCS –PLC system. The
training program shall be divided to impart training to four different groups.
i. System Engineers group
ii. Process Engineers group
iii. Operation group
iv. Technician group
c) The tentative details of these are shown below.
I. System Engineers Group (6 engineers) : The training shall be for 5 working days
imparting in depth knowledge of the system features as described above. The training
shall be conducted at the supplier’s work of the vendor within 2 months of placement of
PO.( during detailed engg of the system)
System Engineers Group( after FAT for 6 engineers) : The training shall be for 5
working days imparting in depth knowledge of the system features & maintenance
features as described above. The training shall be conducted at the supplier’s work of
the vendor after FAT.

II. Process Engineers Group: The training for 4 working days imparting knowledge of
complete operation( operation feature) of the DCS-PLC system
III. Operator Group: The training for 4 working days imparting knowledge of complete
operation of the DCS-PLC system.
IV. Technician Group: The training for 4 working days imparting knowledge of routine
maintenance of the DCS-PLC system.
No. of people to be trained has been explained below :
I. System and process engineers group – 6+6.
II. Process engineers group – 5
III. Operation group _ 20
IV. Technician group _ 10.

d) Sr. no I of point no (c) training shall be done at supplier’s works whereas Sr no. II, III & IV
training shall be conducted at site.
e) Topics/syllabus to be covered for each category has to be submitted by vendor one week
before imparting training and same will be approved by purchaser.
f) Course material in the form of class notes/CD ROM has to be submitted by vendor one week
before training and same will be approved by purchaser.
g) The training shall cover complete education of various aspects required for successful
operation and maintenance of the system.

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 i) Air/rail travelling, boarding lodging and incidental charges pertaining to purchaser’s personnel
shall be borne by purchaser. Cost of all other expenditure for training and course material
deemed to be included in the scope of vendor.
j) The resident engineer posted after acceptance of system for 6 months shall impart on-the-job
training to HWPT's operation and maintenance staff.

11.13 a)SUPPORT SERVICES:

 SUPPORT CAPABILITY
I. The supplier shall be capable of providing support services of a very high order. HWPT
shall have the right to check-up the supplier's support performance from independent sources
and vendor shall submit all relevant information to check the same.
II. The supplier shall indicate the organisation, manpower and other resources of customer
support division.
III. The supplier shall produce documentary evidence of support from the principal after
obsolescence for a period of 10 years. The address of the principal may also be mentioned.

 Spares availability
I. The vendor shall ensure stocking of spares within the country and the same shall be
made available on demand within a period of 48 hours.
II. The supplier shall further ensure the availability of all spares for at least 10 years from the
date of obsolescence of the system. The supplier shall furnish a certificate to this effect from
their principal.
 Personnel Support Services:
The vendor shall make available whenever necessary, the services of the specialists at
HWPT site within 48 hrs from the time of communication, telephonic or otherwise.
 Deputation of vendor's engineer during each phase:
I. The supplier shall station one engineer at site during first six months of guarantee period
free of charge starting after the commissioning of the DCS –PLC system of the plant.
II. The engineer posted shall be the one who is involved in executing the technical aspects of
the system from the initial stage. The engineer shall assist the purchaser in maintenance and
upkeep of the system including all necessary liaisons with the vendor offices and personnel.
The resident engineer shall also impart on-the-job training to HWPT’s operation and
maintenance staff.
 Guest house /hostel shared accommodation can be provided to the Resident Engineer on
chargeable basis subject to availability

11.13b) SOFTWARE AND DOCUMENTATION UPDATES

Any changes, revisions, de-bugging etc. to the systems software shall be provided to HWPT
on a continuous basis as and when they are released/developed by the vendor or the
principal manufacturer within guarantee period.

Firmware updates
I The vendor shall undertake to keep HWPT informed about any development in the
firmware versions. This shall be obligatory on the part of the vendor. Any developments
arising out of shortcomings of the systems in the performing its designed task shall be
carried out by the vendor at HWPT's site in the form of regular engineering, free of cost
including hardware and deputation of vendor's engineer to site.

70
 II. The revisions brought out for enhancement of performance shall be made available to
HWPT.
III. The supplier / principal shall have HWPT on their mailing list for all software and
firmware updates and developments.

11.13.c) Other Software Terms & conditions

Some of the clauses for software are as follows.
a. The original software license shall be in the name of Purchaser.

b. The license in the name of Purchaser should be a perpetual license with life time validity.

c. The application software developed by Seller on the licensed software shall be the sole
property of purchaser.

d. The purchaser should be able to modify/change the application software developed by

seller any time at a later date after acceptance.

e. The application software (at the time of acceptance) shall be guaranteed for 2 years after
acceptance. Within this period any error/bug correction required shall be done free of cost by
seller.

f. Any upgrades to the licensed software shall be made freely available to the purchaser up
to guarantee period. However, if due to these upgrades, any changes in application software
are required to be done, the same shall be done free of cost within guarantee period.

g. In case the license is given in the form of hard key (Dongle), then for any hardware
problem (apart from physical damage, theft) in the dongle within the validity of license, the
dongle shall be replaced by Seller without any cost implication to HWB. For any physical
damage or theft of dongle, the same shall be replaced by seller at a nominal cost of such
hardware (Dongle hardware) in the market. No software license cost shall be charged to
purchaser.

h. If the license is in soft form (code) and subsequently after acceptance, if there is a
problem in PC on which it is installed, then the software should be installable in another PC. If
the new reactivation code is required from the OEM, the same shall be made available to the
purchaser from the seller. There should be a grace period of preferably 30 days for which the
installed software should run on a new PC without asking for new reactivation code from OEM.

11.14 GUARANTEES:
A) GUARANTEE:
The system shall be guaranteed for a period of 24 months from the date of commissioning. The
guarantee shall cover the full performance of all the modules / components / peripherals as per the
specifications. Any defective hardware shall be repaired/replaced within 48 hrs. of the failure. In case of
replacement of any requirement or subsystem or part thereof during the guarantee period, the replaced
equipment or subsystem or part shall have a further guarantee for a period of 24 months from the date
of repair / replacement. The vendor shall provide a list of spares which will be exclusively kept for this
system either at the works or at site to cater to this guarantee service. Any software problem reported
shall be rectified during the guarantee and all software shall be guaranteed against bugs for all times.
The supplier shall guarantee that all material, goods, spares and software supplied are of best design,
material, components and workmanship and that the goods are new, of the latest manufacture and free
from any defect.
If any defect or bug is found in goods or software, and the defect is attributable to the supplier, then
goods shall be supplemented, repaired or replaced by the supplier and all related expenses shall be

71
 borne by supplier. In the event of delay by the supplier, HWPT shall reserve the right to rectify the
same at risk of the supplier and the cost shall be recovered from the supplier.
Replacement of spares during the guarantee period shall be free of charge. All the services provided
under an AMC shall also be provided during the guarantee period of 2 years.
During the guarantee period, problems in software such as bugs, etc. shall be patched at no extra
charge.
The guarantee shall include the following:
a) Planned preventive calls: 4 nos per Year.
b) Preventive maintenance: Minimum 2 days per quarter in the year.
c) Shutdown maintenance: 6 working days per 4 years.
d) Emergency call: Unlimited

B) PERFORMANCE BANK GUARANTEE:

Supplier has to submit performance bank guarantee as stipulated in the DPS clause .

11.15 ANNUAL MAINTENANCE CONTRACT

The supplier shall furnish charges for comprehensive maintenance of the entire DCS-PLC System on
yearly basis for a period of three years after guarantee.
The charges shall be quoted on the basis of total comprehensive maintenance (including
replacement of defective items /systems).
During the guarantee and AMC periods, critical spares shall be kept at HWPT site by the supplier
During the guarantee period and AMC periods, problems in software such as bugs, etc. shall be
patched at no extra charge.
The AMC shall include the following:
a) Planned preventive calls: 4 per Year.
b) Preventive maintenance: Minimum 2 days per quarter in the year.
c) Shutdown maintenance: 10 days per 2 years.
d) Emergency call: Unlimited
AMC charges shall be considered for evaluation of the bids. Purchaser shall have right to award
AMC after guaranty period with the agreed terms and conditions in case required by the purchaser.

11.15 SERVICES SUPPLIED BY HWPT DURING ERECTION

11.16.1 Construction power supply:
a) The vendor shall indicate in his bid peak construction power in the tender. Free construction
power supply will be provided at one point in the unit. All extensions required should be arranged
by the vendor the electric power supply would be made available at the nominal 230 V single
phases 50 cycles that the vendor shall install his incoming mains board, duly equipped with
proper protections etc. The vendor shall also install at his own cost, required cable, meter and
other materials for tapping of and distributing power from the terminal point.
b) The vendor shall bring good tested equipment required for the job. The vendor’s failure to take
necessary action in this regard, within the period stipulated by the purchaser, the power supply is
liable to be cut off. Until such time the vendor takes remedial action in this regard or at the
discretion of the purchaser to impose penalty as a deterrent.
c) It shall be responsibility of the vendor to provide and maintain the complete installation on the
load side of the supply as well as his incoming mains board with the due regard to the safety
requirement at the site. The vendor’s installation shall comply in all respects with the appropriate
statutory requirements given in various acts, rules and regulations.
d) The purchaser would not be liable for any loss or damage to the vendor’s equipment as a result
of variations in the voltage or frequency or interruptions in the power supply. For any

72
 failure/stoppage of power supply for continuous period, the vendor will be eligible for only
reasonable extensions of time and not for any compensation on his account. While the
department would make efforts to make available reasonable continuous power supply.
e) The construction power supply would be made available by the department at a point in the
Control Room, within a radius of 200 meters from the area of construction activity, or at any other
place which may be mutually agreed upon.
f) The vendor’s temporary distribution system, including metering, shall be subjected in every
respect to the approval of the Department and shall be so arranged as to avoid any interference
with the operation of other agencies on the site.

11.16.2 Construction Water Supply: Water will be unfiltered plant water and supplied free of cost at a
point in HWPT.
11.16.3 Contractor manpower stay and transport to site: The contractor shall make his own arrangement
for providing all facilities like accommodation and transport for his employees at his own cost.
Department shall not be responsible for any risk faced by the contractor while transporting the
personnel to and fro from site. Guest House accommodation Rs.120/- per day per bed
(Non A/C).
11.16.4 MEDICAL FACILITIES:
No medical facilities will be provided to the employees of the contractor by the department.
11.16.5 INSURANCE:
While carrying out the above work, necessary insurance coverage for contractor workmen and
material should be done by the contractor. If any accident/injury occurs to the working personnel,
the contractor only has to bear all the expenses for any sort of the compensation payable to the
injured person. The department will not be responsible in any manner in this regard.
11.16.6 FOOD FOR CONTRACTOR EMPLOYEES
Contract employees can avail food from the departmental Canteen at the specified rates for the
contract employees subject to availability of food at the Canteen.
11.16.7 STORAGE
The Contractor shall arrange his own storage facility at plant site in place allotted to him by the
department at their own cost.
11.16.8 STORES & EQUIPMENT
The contractor shall be responsible for all the materials, which he is storing in the storage room
and the department will not bear any responsibility for the loss/damage to the contractors’
material by any reasons whatsoever it may be.
11.16.9 WORKING HOURS
The General Shift working hours of the plant is from 0830hrs to 1630 hrs. The contractor should
follow these working hours. If a particular job could not be completed within the stipulated period,
contractor can continue beyond the above-mentioned hours with the permission of the competent
authority.

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 Section 12

DOCUMENT SCHEDULE
Vendor shall provide the following final documents in English. In case of certificates etc. which are not in
English, Translation of the same shall accompany the certificates. All documents shall be A4 or A3 size
only.

List of documents required after the Placement of PO

Sr. Description Copies Copies Final Copies

No required required Copies Required
within one within 1& required Certified final
month of Half months within three drawings after
PO( Hard ( Hard months ( commissioning (
copies) copies) Hard 2 hard copies & 2
copies) nos. of CDs)
1 Detailed DCS & SIL-3 PLC 2
configuration & Architecture
offered .
2 Data sheets of all the 2
Hardware & Software items for
Approval of Purchaser
3 Technical Catalogues, 2
specifications s & data sheets
of each component shown in
Architecture for approval
4 Bill of Material as per 2
specification for approval
5 Controller sizing details 2

6 Power consumption and heat 2

load
7 Detailed time schedule of 2
activities starting from
Placement of PO till
commissioning
8 System Configuration Manuals 2 2 4

9 Layout drawings of all the 2 2

panels cabinets, OS,ES &
Servers
10 Internal GA drawings of all the 2 4
Cabinets & Panels
11 Dimensional drawings & test 2 4
certificates for the panels
12 SIL3 Certificates of PLC 2 2 4
13 Detailed Quality Assurance 2
Plan for the system

74
14 I/O list Database & 2 2 4
Assignments
15 Tag database for HMI, DCS & 2 2 4
PLC
16 I/O Rack loading diagram 2 2 4

17 I/O Card Terminal Board 2 2 4

Loading Diagrams
18 Power supply wiring diagram 2 2 4
for all the panels
19 System grounding Diagrams 2 2 4

20 Interconnections details of all 2 2 4

DCS & PLC Panels
21 Wiring diagrams with 2 2 4
termination details for OS,ES,
Servers, CPU Panels
22 Control program for each loop 2 2 4

23 Description of the function of 2 2 4

each program.
24 Software Schemes for Control 2 2 4
/Interlock Logic
25 Developed HMI pages & 2 2 4
Graphics
26 Final Loop diagrams showing 2 4
all terminal details
27 Interconnection Cable 2 2 4
Schedule
28 Operation, Maintenance and 2 4
service manual for the system,
sub-system and individual
units /modules
29 Manuals for bought out items 4
30 List of software’s and their 2 4
Detailed Manuals
31 Documentation of all 2 4
application software such as ,
symbol library, reports,
generated messages, basic
software , graphics etc.
32 Concise ready reference 2 4
manuals shall be provided for
operations, maintenance and
software

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33 Test certificates of the system 2 4
Hardware, intrinsic safe
certificates for barriers
34 FAT & SAT Procedure 2
35 Final graphic display (HMI) 2( after 4
drawings. FAT)
36 Test reports on the test 2( after 4
conducted during FAT FAT)
37 Test reports on the test 4
conducted during SAT
38 Final report on FAT, SAT & 4
Commissioning
39 Operation, Maintenance and 4
service manual for the system,
sub-system and individual
units /modules as per the
features mentioned in training
clause of section 11.
40 Supply of As built drawings of 2 ( after 4
all the panels FAT)
41 Supply of complete application 2 ( after 4
software backup FAT)

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 Section: 13
Conditions & Requirements of Bidding
13.1 LANGUAGE:

All correspondence and manuals / documents shall be in English language.

13.2 ACCEPTANCE OF THE SYSTEM

Purchaser shall accept the system, on compliance of the following milestones by the supplier.
a. The system with all subsystems including hardware, software, communication systems, and
auxiliaries have been supplied, installed and commissioned to the satisfaction of purchaser.
b. Training has been imparted to Purchaser's personnel as stipulated earlier in this tender
specification.
c. All the documentation as asked in previous Sections of this tender specification as well as those
required for complete comprehension of the system has been delivered.
d. All services as mentioned in this tender specification as well as those required for complete
comprehension of the system has been complied with by the vendor.
e. All other activities, whether stipulated in this tender specification or not, but which are
necessary for meeting the requirements have been completed by the vendor or by any sub-
contractor of the vendor.
.

13.3 VENDOR QUALIFICATION CRITERIA:

1. The bidder should have done one similar kind of work with the system of minimum 2800 I/O
count or two similar job of minimum 2100 I/O counts or three similar job of minimum 1400 I/O
counts (Approx.80 %, 60 % and 40 % of total field I/O count of 3500 for combined system in
the last seven years
2. Similar work:
Similar works would mean job inclusive of Supply, Engineering, procurement, Fabrication,
Software Development, Testing, Inspection, Installation, Commissioning, Performance testing,
Training, complete project management, Documentation of Distributed Control System (DCS)
or a PLC based system or a combination of DCS and PLC based system with a combination of
both Analog & Digital I/Os in a Chemical/Petrochemical/Steel/Cement/Oil & gas/ Fertilizer or
equivalent process industry.
3. Bidder should have an average annual turnover of Rs. 7.45 crores for the immediate last 3
consecutive financial years. Year in which no turnover is shown would also be considered for
working out the average. This should be duly audited and certified by chartered accountant.
4. Average annual turnover, profit and loss statements certified by chartered accountants for last
5 years shall be submitted. Annual reports can be submitted in addition to these.

13.4 TECHNICAL CRITERIA FOR THE SYSTEM TO BE SUPPLIED

a. Offers of DCS along with SIL3 PLC based systems are only acceptable.

b. For DCS based systems, the offers from OEMs or system houses /open system integrators of
the OEM systems are acceptable.

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 c. Vendor should offer the SIL3 PLC of the same make as DCS make only. Further, the DCS and
SIL3 PLC combination should be already installed and working satisfactorily at minimum one
site/locations. The references of the same shall be enclosed along with the technical offer.
d. Address & contact nos. of the organizations where system is installed is to be furnished along
with the offer.
e. Bidder must enclose completion certificates from client as evidence. This shall be certified by
an officer not below the rank of Project manager/Section head or equivalent. If desired by
employer, the bidder shall also arrange for site visit to ascertain the satisfactory working of the
system.
f. The Acceptable makes of DCS are ABB, SIEMENS, HONEYWELL, YOKOGAVA,
ROSEMOUNT, TOSHIBA, GE, FOXBORO or equivalent. SIL3 PLC shall be of the same make
as DCS.
g. DCS along with SIL3 PLC or its equivalent model offered shall be latest in the product range of
OEM.
h. The system series offered shall be field proven system (successful installation for 5 or more
years) & shall have installation in a continuous process Industry.
i. Bidder should be able to give the technical support and spares for minimum 10 years after the
obsolescence of the system. The bidder should get a letter in this regard from the OEM linking
to the present case of purchase. The same shall be submitted along with the technical bid.
j. Only Indian citizens shall be allowed to visit the HWPT site for the purpose of submitting the
quotation or for carrying out the job & execution of the project.

13.5 MANPOWER AND EXPERIENCE OF KEY PERSONS:

The bidder should have in house project department along with competent and adequate
engineering strength in the required area of DCS & SIL3 PLC Engg, Installation &
Commissioning to handle various facets of project.
For DCS & SIL3 PLC, bidder should keep minimum 5 engineers for carrying out detailed
Engineering, procurement, software development etc. with at least one graduate engineer
having minimum experience of 10 years and two graduate engineers having minimum
experience of 5 years and two graduate engineer / diploma engineer having minimum
experience of 5 years. These shall be deployed for this work. The one graduate engineer
with minimum 10 years’ experience shall also work as Project Manager. Bidder should
submit the list of these employees meeting this criterion and stating clearly how these
would be involved in this work.
Details shall be furnished in form-A given below . Apart from this, bidder has to arrange
for adequate teams for carrying out the Installation & Commissioning of the system at
site.

FORM “A”
DETAILS OF TECHNICAL AND ADMINISTRATIVE PERSONNEL TO BE EMPLOYED FOR THE WORK

Sr Name of Designati Qualification Professional How these Remarks

No the person on experience and would be
details of work involved in this
carried out work
1 2 3 4 5 6 7

78
 Signature of the Bidder(s)

13.6 PRE-BID VENDOR'S VISIT TO THE SITE

It is advisable that bidders should visit HWPT before submitting their Offers to understand the
system integration in detail for their own clarity of the site location.

HWP Tuticorin Site Visit Dates: 13/07/2017 and 14/07/2017

Contact details for visit to HWPM site

a. HWB Mumbai: Manager (I), Heavy Water Board , V floor, VIKRAM BHAVAN,
ANUSHAKTI ANAGER, MUMBAI-400094.
E-mail: swadhwa@mum.hwb.gov.in Phone 022-25487509

b. HWP, Tuticorin: HWP, Tuticorin, EIC(I&C), HWP Colony(P.O), Tuticorin, Tamilnadu-628007

Email: tkamaraj@tut.hwb.gov.on, ph: 0461-2244 580

13.7 The DCS-PLC system shall be dispatched by air/road after the system checkout tests at the
Vendor's / principal's work. The Erection, installation & commissioning of the new system shall be
completed in all manners in 60 days.

The system shall be commissioned before the start-up and shall be integrated smoothly into plant
operation during start-up and subsequent production as brought out in section 9
The vendor shall give a detailed schedule and milestone chart for the Engg, supply, erection and
commissioning of the system. The logical sequence of activities for installation of new system
during shutdown shall be clearly indicated in the schedule.

13.8 Post supply inspection by outside agency for imported items :

Post Supply inspection for by outside agency in respect of supplies made is not permitted. Any offer
containing the condition of post supply inspection by outside agency will be out-rightly rejected. It is
therefore, mandatory for the bidders, while quoting, to indicate in clear terms the requirement of post
supply inspection by any outside agency.

13.9 PRICES
The vendor shall quote for the complete system including installation & commissioning. Detailed
breakup of prices as per the SOR (Annexure-A) shall be provided. It is vendor’s responsibility to
include all the items required for completeness of the system as per specification. If the item not
mentioned as specific item , then same to be included in any other item of the SOR

13.10 PAYMENT TERMS

Payment terms shall be as per the standard practice of Directorate of Purchase & stores,
Department of Atomic Energy.

79
13.11 SUBMISSION OF BIDS

Bids shall be submitted in typewritten or printed. The bids shall be submitted in three separate parts
as follows:

a. Technical bid
This shall contain the detailed technical offer and specifications in accordance with the
requirements and specifications given in tender specification. Deviations from the stipulated
specifications shall be clearly indicated. Alternate specification/configurations, if any shall be
indicated with explanatory notes on how these would comply with the functional requirements.
Vendor shall fill up the deviation if any, along with the technical bid.
The technical bid shall also contain a technical summary in the same sequence and number/sub-
number of the sections included herein, the compliance and deviations from specifications and
requirements in summary form. Summary shall be such as to have a one-to-one correspondence
with the sections of this tender specification and shall indicate the overview of entire offer. Those
bids without the technical abstract sheet as stipulated here are liable to be rejected at the sole
discretion of the purchaser.
b. Unpriced Commercial Bid
This shall contain the Earnest Money Deposit and copies of the Unpriced commercial bid, which
shall be identical to priced commercial bid with prices left blank or duly blanked out..
c. Commercial bid with prices:
The bidder is requested to submit the priced bid separately in SOR/BOM format enclosed in
Annexure-A. .

13.12 The hardware and software supply, erection, installation and commissioning, etc. shall be the
responsibility of single vendor only. No splitting of job execution shall be allowed.

13.13 Unless otherwise stated, it shall be assumed that the system offered is in full compliance with this
specification. Any deviations from this specification or any part of the bidding material shall be
clearly stated with basis of deviation to decode on acceptance of the offer.

13.14 TENDER EVALUATION CRITERIA:

The following criteria are included for evaluation for the entire scope of work mentioned in the tender
specification.
a. Bids shall be evaluated based on the SOR documents enclosed along with the Tender
Document
b. HWB reserves the right to enter into AMC after the completion of 2 years of guarantee
period. A separate WO shall be placed for the same after the 2 years of guarantee period.
c. The AMC charges for 3 years as per Schedule of rates shall be considered for evaluation
of the bids.
d. Annual charges towards the AMC shall only be paid at the end of Year.
e. Training is to be provided as per clause no. 11.13 of the tender documents. The cost of
the training is included in SOR-G Services of the SOR.

80
 Section: 14
SECURITY RELATED SPEIFICATIONS FOR SYSTEM

14.1 Security Related Requirements

14.1.1 Operating Station / Engineering Station/ Servers Security Requirements

14.1.1.1 Removal of Unnecessary Services and Programs

During detailed Engineering, vendor shall perform the following tasks:
1. Vendor shall provide documentation detailing of all applications, utilities, system services,
scripts, configuration files, databases and all other software required for the system and the
appropriate configurations including revision and or patch levels for the same. The listing
shall include all ports and services required for normal operation as well as any other ports
and services required for emergency operation. The listing shall also include an explanation
or cross reference to justify each service is necessary for operation.
2. The vendor shall remove or disable all software components that are not required for the
operation and maintenance of the control system prior to FAT. The vendor shall provide
documentation on what is removed / disabled.

14.1.1.2 File System and operating System Permissions

During detailed Engineering, vendor shall perform the following tasks:
1. The vendor shall configure systems with least privilege file and account access and provide
documentation of the configuration.
2. The vendor shall configure for least user privilege level possible for the required services and
provide documentation of the configuration

14.1.1.3 Hardware Configuration

Before start of FAT, vendor shall perform the following tasks:
1. The vendor shall disable through software or physical disconnection all unused
communication ports, CD/DVD drives and other removable media drives and provide the
documentation of the same.
2. The vendor shall configure the system in such a way to allow the system administrator to re-
enable the devices and provide documentation of configuration.
3. The vendor shall password protect the BIOS from unauthorized changes unless it is not
technically feasible in which case the Vendor shall document this case mentioning necessary
reason for the same and provide mitigation measures.
4. The vendor shall configure the network devices to limit access to/from specific locations
where appropriate and provide documentation of the same.

14.1.1.4 Installing Operating Systems, Applications and Third Party Software Updates in
Servers, Operating Station and Engineering Station
Till the guarantee period,
1. The vendor shall provide notification of known vulnerabilities affecting vendor supplied or
required OS, application and third party software within 1 month after public disclosure. The
vendor shall provide notification of patches affecting security within 1 month. The same shall
be tested and validated on Test jig before installation on main system.

14.1.1.5 Disabling, removing or modifying Well-Known or Guest Accounts.

1. The vendor shall disable or remove all default and guest accounts prior to the FAT on the
approved recommendation of Purchaser. Once changed as per the requirement, new
accounts will not be published except that new account information and passwords will be

81
 provided by the vendor via protected media. After the SAT, vendor shall disable or remove
all Vendor-owned accounts.

14.1.1.6 Session Management

Preferably the system
1. shall provide the strongest encryption method and shall not permit the user credentials to be
transmitted in clear text.
2. shall not allow multiple concurrent logins, applications to retain login information between
sessions, provide any auto fill functionality (e.g. User Id, Password) during login or allow
anonymous logins.
3. shall provide user account based logout and timeout settings.
4. shall preferably submit procedure for changing encryption keys at reasonable intervals.

14.1.1.7 Password / Authentication Policy and Management

1. The systems shall preferably provide a configurable account password management system
that preferably allows for selection of password length, frequency of change, setting of
required password complexity, number of login attempts, inactive session logout, and screen
lock by supplication and denial of repeated or recycled use of same password. The system
shall not store passwords electronically or in vendor supplied hardcopy documentation.
2. The system shall preferably provide a mechanism for rollback of security authentication
policies during emergency system recovery or other abnormal operations where system
availability would be negatively impacted by normal security procedures.

14.1.1.8 Role Based Access Control for Control System Applications

Before start of FAT
1. The Vendor shall provide user accounts with configurable access and permissions
associated with the defined user role and shall verify that user cannot escalate privileges
under any circumstances without logging into a higher privileged role first.
2. The vendor shall provide documentation of access and security permissions, user accounts
with associated roles.
3. The vendor shall configure the system so that initiated communications start with the most
privileged application controlling the communication. Upon failed communication, the most
privileged side will restart communications. The vendor shall verify that the master network
device initiates communications.

14.1.2 Programmable Logic Controller

14.1.2.1 Programmable Logic Controllers (CPU)

1. In the offer, preferably vendor shall inform the availability of any physical and cyber security
features. These features includes authentication, encryption, access control, event and
communication logging, monitoring and alarming to protect the device and configuration
computer from unauthorized modification or use.
2. The vendor shall confirm that the addition of security features does not adversely affect
connectivity, latency, bandwidth, response time and throughput including during the SAT
when connected to existing equipment.
3. The vendor shall remove or disable all software components that are not required for the
operation and maintenance of the device prior to the FAT. The vendor shall provide
documentation on what is removed or disabled.

82
 4. Till the guarantee period, the vendor shall provide within a 1 month, appropriate software and
service updates to mitigate all vulnerabilities associated with the product and to maintain the
established level of system security.

14.1.3 Network Devices

14.1.3.1 Network Devices (Switches)

Before Start of FAT,
1. The vendor shall verify and provide documentation that the network configuration
management interface is secure.
2. The vendor shall remove or disable unused network configuration and management
functions on the network devices.
3. The vendor shall preferably provide ACLs, port security address lists and enhanced security
for the port mirroring.
4. The vendor shall preferably provide documentation on the network devices installed with
security settings.

14.1.4 General

14.1.4.1 Non-disclosure Agreement

1. After placement of Work Order, the Vendor shall provide a agreement to delineate how
Vendor employees who have sensitive knowledge of the Purchaser’s Control systems and
who leave their positions or have responsibilities changed will be prohibited from disclosing
that knowledge.
2. The vendor shall provide detailed documentation on how the control system security can be
maintained and supported in the event the Vendor leaves the business.
3. The vendor shall return to the Purchaser any sensitive data in the Vendor’s possession within
6 months of commissioning of the system.

14.1.4.2 Notification and Documentation from Vendor

1. Along with the offer, the Vendor shall preferably provide the documentation of written flaw
remediation process if any.
2. During Guarantee and AMC period,
a. When vendor become aware of or discover any flaws, the vendor shall provide notification of
such flaws affecting security of Vendor supplied software within 1 month. Notification shall
include, but is not limited to, detailed documentation describing the flaw with security impact,
root cause, corrective actions etc.
b. The Vendor shall provide appropriate software updates to mitigate all vulnerabilities
associated with the flaw within 1 month of its information in public domains.

14.1.4.3 Problem Reporting

In the offer , Vendor shall provide a process for users to submit problem reports and
remediation requests. Till the guarantee period, the vendor shall review and report their initial
action plan with 24 hrs of submitting the problem reports. The vendor shall provide auditable
history of flaws including the remediation steps taken for each.

14.1.4.4 Physical Access security of cyber Components

1. The Vendor shall provide lockable or locking enclosures for control system components (e.g.
servers, clients, and networking hardware)
2. The vendor shall verify, confirm and provide documentation that unauthorized logging
devices are not installed (e.g. key loggers, cameras and microphones).

83
14.2 Security Requirement during Testing of the System

14.2.1 FAT & SAT requirement of OS,ES & Servers

14.2.1.1 Removal of Unnecessary Services and Programs

FAT Requirement:
1. The Vendor shall verify and provide the results of cyber security scans/equivalent (as a
minimum vulnerability and active port scan, with the most current signature files) run on the
control system. Verification checks the results with an inventory of the required services,
patching status and documentation to validate the requirement.
2. The vendor shall provide for each networked device (e.g. Server, Workstation, Switch) the
following configuration documentation lists, which shall be verified:
a) Network services required for the operation of that device. Indicate the service name, protocol
and port range.
b) All the software configuration parameters required for proper system operation.
c) Certified OS, drivers and other software versions installed on the device.

SAT Requirement:
1. The vendor shall compare the results of cyber security scans run on the system as a primary
activity of the SAT, with an inventory of the required services, patching status and required
documentation after completion of FAT.
2. At the conclusion of the SAT and before commissioning, the above cyber security scans (with
the most current signature files) must be run again.

14.2.1.2 File system and Operating System Permissions

FAT & SAT Requirement:
1. The vendor shall provide, as a part of the FAT & SAT procedures, validation and
documentation of the permissions assigned.

14.2.1.3 Hardware Configuration

FAT & SAT Requirement:
1. The vendor shall provide, as a part of the FAT & SAT procedures, validation and
documentation of the disabled or locked ports and the removed drives.

14.2.1.4 Installing Operating Systems, Applications and Third Party Software Updates
FAT & SAT Requirement:
1. The vendor shall install and update all tested and validated security patches prior to the start of
the FAT & SAT.
2. The vendor shall provide documentation that all updates have been tested and installed.
3. The vendor shall install firmware updates available for the computer or network device certified
by the system manufacturer at the time of installation.
4. The vendor shall verify system functionality at the conclusion of patch updates and provide
documentation of the results.
5. The vendor shall perform security scans with the most current signature files) to verify that the
system has not been compromised during the testing phase and provide documentation of the
results of the scans.

84
14.2.1.5 Disabling, Removing or Modifying Well-Known or Guest Accounts
FAT & SAT Requirements:
1. FAT procedures include exercising this functionality, examining the log files and validating the
results. FAT & SAT procedures include written validation and documentation of the
requirements.
14.2.1.6 Session Management
FAT & SAT Requirements:
1. FAT & SAT procedures include validation and documentation of the requirements as applicable.
14.2.1.7 Password/Authentication Policy and Management
FAT & SAT Requirements:
1. FAT & SAT procedures include validation and documentation of the password and
authentication policy and management as applicable.

14.2.1.8 Role-Based Access Control for Control System Applications

FAT Requirements:
1. The Vendor shall compare the control system assessment during this period with required
documentation to validate the requirements.
SAT Requirements:
2. The Vendor shall verify that all additions to the control system, after the completion of the FAT,
have the same rigor of documentation that was necessary pre-FAT and appropriate
comparisons are required post-SAT to validate the requirement.

14.2.2 Programmable Logic Controller FAT & SAT Requirement

14.2.2.1 Programmable Logic Controllers ( CPU)
FAT Requirements:
1. As applicable ,the Vendor shall verify and provide documentation of physical and cyber security
features if available in the system including, but not limited to , authentication, encryption,
access control, event and communication logging, monitoring and alarming to protect the device
and configuration computer from unauthorized modification or use.
2. The Vendor shall verify and provide documentation that all validated security updates, firmware
updates and patches are installed and tested at the start of the FAT.
3. The Vendor shall verify and provide documentation that all unused software and services are
removed or disabled.
4. The Vendor shall verify and provide documentation that any Vendor-configured or manufacturer
default accounts, usernames, passwords, security settings, security codes and other access
methods are changed, disabled or removed at the start of the FAT.
5. As applicable, Post-FAT, the vendor shall create a baseline of the system communications and
configuration including but not limited to cyber security features, software, protocols, ports and
services and provide documentation describing each item.
6. The Vendor to provide necessary certificate /test to confirm that the addition of security features
does not adversely affect adequate connectivity, latency, bandwidth response time and
throughput.

SAT Requirements:
1. As applicable ,the Vendor shall verify and provide documentation of and changes to physical and
cyber security features if available in the system including, but not limited to authentication,
encryption, access control, event and communication logging, monitoring and alarming to protect
the device and configuration computer from unauthorized modification or use.
2. As applicable ,Post-SAT, the Vendor shall create a baseline of the system communications and
configuration including but not limited to, cyber security features, software, protocols, ports and
services and provide documentation describing any changes.

85
 3. The Vendor shall verify and provide documentation that any Vendor-configured or manufacturer
default accounts, usernames, passwords, security settings, security codes and other access
methods are changed, disabled or removed at the start of the SAT.
4. The Vendor to provide necessary certificates /test to confirm that the addition of security features
does not adversely affect adequate connectivity, latency, bandwidth response time and
throughput.

14.2.3 Network Devices FAT & SAT Requirement

14.2.3.1 Network Devices( switches)

FAT & SAT Requirements:
1. The Vendor shall validate the method of managing the network devices and changing network
addresses.
2. The Vendor shall verify security levels and provide documentation of the network configuration
management interface.
3. The vendor shall install firmware updates available for the network device certified by the system
manufacturer at the time of installation.
4. As applicable, vendor shall verify the ACLs port security address lists and describe the enhanced
security for the port mirroring.
5. As applicable, Vendor shall scan the network ports and document traffic origination and functions
for each port.

6. The vendor shall provide a summary table indicating each communication path required by the
system. Include the following information in the table a)Source device name and Mac/IP address
b)Destination Device name and Mac/IP address c)Protocol and range of ports

14.2.4 General FAT & SAT Requirements

14.2.4.1 CODING PRACTICES

FAT & SAT Requirements:
1. FAT & SAT procedures shall include validation and coding practices used as applicable.

14.2.4.2 Notification and Documentation from Vendor

FAT Requirements:
1. As applicable, vendor shall verify that flaws known by them till the completion of FAT, the
Vendor’s corrective actions follow their process and the process is effective. The Vendor shall
verify that FAT documentation of the flaws validation and remediation are provided.
2. The Vendor shall verify that any changes to the core system code, logic or configuration are
analyzed to verify new vulnerabilities are not introduced into the system as a result of the change.
SAT Requirements:
1. As applicable, flaws known by the Vendor, the Vendor’s corrective actions follow their process
and the process is effective. Vendor shall verify that SAT documentation of the flaws validation
and repair are provided.
2. The Vendor shall verify that any changes to the core system code, logic or configuration are
analyzed to verify new vulnerabilities are not introduced into the system as a result of the change.

86
14.3 Security Requirements during Installation & Commissioning of the System

14.3.1 After Verification & Validation of the COTS system at factory, vendor shall place the tamper proof
or tamper evident seals or mechanisms to ensure integrity of the system hardware during
transport and before installation.
14.3.2 Vendor shall protect the complete software including the system software and application
software by tamper proof or tamper evident mechanisms to ensure integrity of the system
software during transport and before installation.
14.3.3 Vendor shall document the system configuration, including security settings of all hardware and
software that are part of the system after FAT acceptance and the same shall be verified by
Purchaser on all hardware and software before installation and after commissioning. The security
settings like Accounts, access rights & privileges, Password settings (default / expiry etc.),
Network device settings, Update Settings, List of disabled and enabled devices, ports, services,
protocols on system etc shall be checked.
14.3.4 Vendor shall prepare and document and implement the security policy on use of tools and special
systems/softwares for commissioning that address as a minimum the following:
a) Each tool/system/software associated with the system.
b) Sanitization of tool/system/software’s (e.g. scanning by latest anti-virus) every time before
connection to System.
c) Secure storage and access control of the tools/system/software.
d) A clearly defined procedure for using and connecting/disconnecting the tool/system/software
to System which include verification after disconnection to ensure that the system is not set at
a more vulnerable state due to the use of tool/system/software.
14.3.5 An approved configuration management procedure shall be used by vendor for any change in
system, including the following:
a) Changes to fix anomalies detected during installation & commissioning
b) Patches & Updates of system or application software
c) Installation of any other software.
14.3.6 The approved configuration management procedure specified above shall include as minimum:
a) Analysis of impact of the change on functions and security of the system.
b) Verification after change implementation to ensure that system:
I. Security settings mentioned in Para3 above are unchanged
II. Has not been moved to a more vulnerable state.
c) Where feasible, software patches, updates, upgrades shell be applied only after testing them
under field conditions on a Test Jig before installation on the system.

14.3.7 To the extent possible, Vendor shall perform the offline Licensing of products. In rare case,
licensing is to be done online (i.e. requires internet connection) then vendor should ensure that
the connection is monitored using antivirus and firewall.
14.3.8 Vendor shall ensure that any authorized changes in the main system shall be reflected in the
spares also. Before spares are put in the system, the configuration settings shall be confirmed
against documented settings.

87
14.4 Security Related Documents To Be Submitted Along With The Offer

14.4.1 Programmable Logic Controllers (CPU)

1. In the offer, preferably vendor shall inform the availability of any physical and cyber security
features. These features includes authentication, encryption, access control, event and
communication logging, monitoring and alarming to protect the device and configuration computer
from unauthorized modification or use.
2. The vendor shall confirm that the addition of security features does not adversely affect
connectivity, latency, bandwidth, response time and throughput including during the SAT when
connected to existing equipment.

14.4.2 Product Security Class

1. In the offer, if available, Vendor shall specify the Security Class(EAL 1 to EAL7) of the product as
per ISO/IEC 15408 standard which determines its security strength and evaluation level. Vendor
shall produce necessary documents to show compliance of the product to the security class
specified in the requirements.

14.4.3 Security Certification

1. In the offer, if available, Vendor shall submit the security certificate of the system from computer
security certification agencies if available.

14.4.4 Coding Practices

1. Along with the offer, the Vendor shall preferably provide documentation of development practices
and standard applied to Vendor written control system software including firmware to ensure a
high level of defense against unauthorized access.
2. The vendor shall preferably provide documentation of coding practices used in developing the
delivered software.

14.4.5 Notification and Documentation from Vendor

1. Along with the offer, the Vendor shall preferably provide the documentation of written flaw
remediation process.

14.4.6 Problem Reporting

1. In the offer , Vendor shall provide a process for users to submit problem reports and remediation
request

88
 ANNEXURE-A (PRICE BID)

PRICE BID

ONLY SUPPLY IS APPLICABLE FOR ITEM NO. 1 TO 9 (SOR-A TO SOR-F).

ONLY INSTALLATION & COMMISSIONING IS APPLICABLE FOR ITEM NO. 10 (SOR-G) AND ITEM NO. 11 (SOR-H) .

Part Custom/
Packing &
No / Sub total ( Excise
Sr.
no
Item Category
Item
Description
Qty. Unit
Nature
of Price
Model
No.(If
Basic
Cost
Discount Basic Price
-Discount)
Forwarding
Charges
(in % only)
Duty
(in %
…
any) only)

I. ONLY SUPPLY &

RELATED TAXES DETAILS OF
(Installation & MATERIAL &
1 Commissioning
column not to be
QTY AS PER
ITEM SOR-A
1 Lot
…
filled for these (ENCLOSED)
items)

DETAILS OF
MATERIAL &
2 -DO- QTY AS PER
ITEM SOR-B1
1 Lot
TO BE FILLED IN COMMERCIAL BID
…
(ENCLOSED)
ONLY…
DETAILS OF
MATERIAL &
3 -DO- QTY AS PER
ITEM SOR-B2
1 Lot
…
(ENCLOSED)

DETAILS OF
MATERIAL &
4 -DO- QTY AS PER
ITEM SOR-C
1 Lot
…
(ENCLOSED)

DETAILS OF
MATERIAL & TO BE FILLED IN COMMERCIAL BID
5 -DO- QTY AS PER
ITEM SOR-D
1 Lot
ONLY… …
(ENCLOSED)
 ANNEXURE-A (PRICE BID)
DETAILS OF
MATERIAL &
6 -DO- QTY AS PER
ITEM SOR-E1
1 Lot
…
(ENCLOSED)
DETAILS OF
MATERIAL &
7 -DO- QTY AS PER
ITEM SOR-E2
1 Lot
…
(ENCLOSED)

DETAILS OF
MATERIAL &
8 -DO- QTY AS PER
ITEM SOR-F1
1 Lot
…
(ENCLOSED)

DETAILS OF
WORK AS PER
9 -DO-
ITEM SOR-F2
(ENCLOSED)
1 Lot
…
II. ONLY
INSTALLATION &
COMMISSIONING
DETAILS OF
/ SERVICES &
WORK AS PER
10 RELATED TAXES
(Supply Column &
ITEM SOR-G
(ENCLOSED)
1 Lot
…
related taxes
column to be left
blank.)

DETAILS OF
11 -DO-
WORK AS PER
ITEM SOR-H
(ENCLOSED)
1 Lot
…
BIDDER MUST ENSURE THAT BASIC COST OF EACH SOR QUOTED ABOVE MUST MATCH WITH THE TOTAL COST
OF RESPECTIVE ATTACHED SORs.IN CASE OF DISCREPANCY, COST MENTIONED IN THIS PRICE BID WILL BE
FINAL.
 ANNEXURE-A (SOR-A)

SOR-A (DCS)
VENDOR HAS TO SPECIFY THE QUANTITY IN ‘QTY’ COLUMN WHEREVER
"VENDOR TO FILL" IS MENTIONED. REMAINING CELLS WHERE QTY IS ALREADY
MENTIONED BY US,NEED NOT TO BE CHANGED BY BIDDER.
Sr. Item Item Description Qty. Unit Make Model / Unit Total
no Category Description Price Price
1 I. Software HMI Software for Engg. 1 no.
station (Development) for
both DCS and PLC

2 Software for I/O, Trend & 2 nos.

Alarm Server for DCS &
PLC (for 2 severs)

3 HMI Software for 3 no.

TO BE FILLED IN COMMERCIAL BID ONLY

Operating station (runtime
version).

4 HMI Software for 1 no.

standalone OS directly
connected to CPU

5 HMI Software for View 1 no.

client.

6 Software for Field Station 1 no.

EX Proof HMI

7 PROGRAMMING (LOGIC 1 no.

DEVELOPER) SOFTWARE
FULL DEVELOPMENT
VERSION for DCS.

8 Any other software(s) not 1 LS

included above (set)

9 II. Main CPU MODULES 2 nos.

Redundant
Controller
system (Max
Loading
50%-60%)
on set
10 COMMUNICATION Vendor nos.
MODULES / PORTS to fill
(CONTROLLER TO I/O)
(QTY AS PER 6.1.3 OF
SPECS)
11 COMMUNICATION Vendor nos.
MODULES (CONTROLLER to fill
TO OS) (QTY AS PER 6.1.3
OF SPECS)
12 POWER SUPPLY MODULE Vendor Nos.
(QTY AS PER 6.1.3 OF to fill
SPECS)
 ANNEXURE-A (SOR-A)

13 RACK (QTY AS PER 6.1.3 Vendor nos.

OF SPECS) to fill
14 MEMORY MODULE Vendor nos.
to fill

15 ANY OTHER MODULE(S) 1 LS

NOT INCLUDED ABOVE
(SET)

16 MODBUS comm module 2 nos.

TO BE FILLED IN COMMERCIAL BID ONLY

for MODBUS RTU&
MODBUS TCP/IP.

17 III. I/O Racks Vendor nos.

controller to fill
system (as
per I/O
details)
18 Analog Input modules for Vendor nos.
all analog inputs except to fill
pigtail temp AIs ( max 8
channel modules)
18a Analog input module only Vendor nos
for 80 nos. of pig tail temp to fill
AIs( max 32 channel
module)
19 Analog Output module Vendor nos.
to fill

20 Digital Input module Vendor nos.

to fill

21 Digital Output Module Vendor nos.

(shall have inbuilt relay / to fill
relay board with contact
rating 24V DC 5A 1NO
1NC)

22 Rack Power supply Vendor nos.

modules (redundant for to fill
each rack)

23 Communication modules / Vendor nos.

port (redundant for each to fill
rack)
24 Prefabricated/cables, 1 LS
Connectors/ Accessories
etc. (set)

25 Any other type of module / 1 LS

accessories not included
above (set)
 ANNEXURE-A (SOR-A)

26 Termination module for 150 nos.

redundant AO or AO
redundant interface
module 1(one) channel
module. This channel is
for redundant set (2 nos.)
of AO as input and one no
of AO as output

27 Trip Isolators( 1 analog 45 nos.

input with two DO contacts
& 1 repeat AO)

28 IV. PCs and Workstation Grade PC 7 nos.

accessories (without Monitor) for
operating station ,view
client station, engg station
as per the specification of
tender including 1 no
spare

TO BE FILLED IN COMMERCIAL BID ONLY

29 22” LED color monitor with 9 nos.
fixtures
30 Server Grade PC for I/O 3 nos.
,Trend & Alarm Server
(without Monitor) including
1 no spare
31 Firewall for view client 1 nos.

32 Black & white Laser 1 nos.

Printer.( A4 size)

33 Alarm Printer High Speed 1 nos.

Dot Matrix (132 Column)

34 Ethernet switch managed Vendor nos

( Industrial type) to fill
(minimum 6 required
35 Server Racks for servers & 1 LS
computer table for ES
(Set)

36 Armored Optical fibre 300 mtrs

cable ( 6 core) for filed
HMI
37 Zone 1 ,EX proof certified 1 no
HMI PC ( 10” – 11”) for
compressor panel in field
make, Schneider/
Siemens/STAHL/equivalent

38 Armoured & Shielded 1 LS

Ethernet cable and other
accessories. (set) for
control room
39 Any other item/component 1 LS
not included above (set)

40 V. SINGLE CHANNEL 141 nos.

ISOLATORS GALVANIC ISOLATORS
 ANNEXURE-A (SOR-A)

FOR DCS & CUM Barrier for three wire

PLC: Make & RTD to 4 -20 MA
Series : P-F ( ,programmable type
KFD2) or
MTL ( 5000 /
8000) or
equivalent
Make/Model.
Power rail
mounted.
The Qty.
includes the
spare qty.
(20%).
41 Single channel 140 nos.
GALVANIC ISOLATORS
CUM Barrier FOR
Thermocouple to 4 -20 MA
,programmable type with
internal cold junction
compensation using RTD
41a Dual channel GALVANIC 44 nos
ISOLATORS CUM Barrier
FOR Thermocouple to 4 -
20 MA ,programmable
type with internal cold
junction compensation
using RTD
42 Single channel 190 nos.
GALVANIC ISOLATORS

TO BE FILLED IN COMMERCIAL
cum Barrier FOR Analog
Input :4 to 20 MA / Loop
powered 4 to 20 MA
Output: 4 to 20 MA (1 in 1
out)
43 GALVANIC ISOLATORS 200 nos.
cum Barrier For Analog
Input : One Loop powered
AI (4 to 20 MA) Output :
two 4 to 20 MA
BID ONLY
43a Single Channel 80 Nos.
Current Converter
(0-1A to 4-20 mA)
44 GALVANIC ISOLATORS 300 nos.
cum barrier FOR DI Input :
Two , Output : Two
45 GALVANIC ISOLATORS 150 nos.
cum barrier FOR DI Input :
one , Output : Two

46 GALVANIC ISOLATORS 165 nos.

cum barrier FOR AO ( 4 to
20 MA)
 ANNEXURE-A (SOR-A)

47 24 V DC Relays and other 200 nos.

accessories (Contact rating
110 V DC 5A 2NO 2NC)

48 24 v DC relays for isolation 300 nos.

of Digital inputs (contact
rating 24 V DC 5 A 2NO
2NC)

49 Push buttons-20 nos. & 1 LS

Lamps-10 nos.

50 Any other items / 1 LS

components not included
above (set)

51 VI. Others Control Panel for 1 LS

Controller + I/O Racks +
Isolator + interface relays
cabinets for DCS (set)

52 110 V AC to 24 VDC 1 LS
redundant power supplies
with diode o ring module
with MCB for each panel
make : Siemens / GE/
Schneider P.S. Make :
Phoenix/ Siemens /
Schneider/ GE/ MTL /PF
(set)
53 Control Desk for operating 1 LS
station

54 Power distribution Panel 1 LS

for DCS as per tender

COMMERCIAL BID
TO BE FILLED IN
specs

55 Annuciators (24 channel) 6 nos.

ONLY
56 Any other item/component 1 LS
not included above (set)

TOTAL OF SOR-A
 ANNEXURE-A (SOR-B1)

SOR-B1 (PLC Main Plant)

VENDOR HAS TO SPECIFY THE QUANTITY IN ‘QTY’ COLUMN WHEREVER "VENDOR TO FILL"
IS MENTIONED . REMAINING CELLS WHERE QTY IS ALREADY MENTIONED BY US, NEED
NOT TO BE CHANGED BY BIDDER

Sr. Item Category Item Description Qty Unit Make Model/Description Unit Total
no Price Price
Software for Engg. Station for
1 I. Software 1 no.
PLC CPU

PROGRAMMING (LOGIC
DEVELOPER) SOFTWARE FULL
2 DEVELOPMENT VERSION for 1 no.
PLC

Any other software required &

3 1 LS
not included above. (set)

TO BE FILLED IN COMMERCIAL BID ONLY

II.Main
Redundant
Controller
4 CPU MODULE 2 nos.
system (Max
loading
50%-60 %)
COMMUNICATION MODULES /
PORTS
vendor
5 (CONTROLLER TO I/O) (QTY AS to fill nos.
PER 6.2.3 OF SPECS)
COMMUNICATION MODULES
6 (CONTROLLER TO OS) (QTY AS vendor nos.
PER 6.2.3 OF SPECS) to fill

7 POWER SUPPLY MODULES (QTY vendor nos.

AS PER 6.2.3 OF SPECS) to fill

8 MEMORY MODULES vendor nos.

to fill
9 RACKS (QTY AS PER 6.2.3 OF vendor nos.
SPECS) to fill
ANY OTHER MODULE(S) not
10 included above vendor LS
to fill
III. I/O
11 controller RACKS vendor nos.
system to fill
 ANNEXURE-A (SOR-B1)

12 Analog Input modules vendor nos.

to fill

13 Digital Input module vendor nos.

to fill
Digital Output module (shall
have inbuilt relay or relay
14 boards shall be provided vendor nos.
with contact rating to fill
of 24V DC 5 Amp 1NO 1NC.)

15 Rack Power supply modules vendor nos.

(Redundant for each rack) to fill

16 Communication modules / port vendor nos.

TO BE FILLED IN COMMERCIAL BID ONLY

(Redundant for each rack) to fill
MTA (Termination modules) for
17 redundant DI & DO & AI vendor LS
modules to fill

Any other type of module(s)

18 1 LS
not included above (set)
MTA (Termination modules) for
non-redundant IOs
19 1 LS
(set)
Control Panel for Controller +
I/O Racks + Isolator +
20 IV. Others interface relay cabinets for PLC 1 LS
of main plant. (set)
110 to 24 VDC redundant
power supplies with diode o
ring module and MCB for
each panel make : Siemens /
21 GE/ Schneider P.S. Make : 1 LS
Phoenix/ Siemens / Schneider/
GE/ MTL /PF (set)

Power distribution Panel for

both PLCs( main plant and
22 1 LS
compressor house) as per
tender specs
Any other item/component not
23 V. 1 LS
included above (set)
TOTAL OF SOR-B1

2 of 2
 ANNEXURE-A (SOR-B2)

SOR-B2 (PLC Comp. House)

VENDOR HAS TO SPECIFY THE QUANTITY IN ‘QTY’ COLUMN WHEREVER "VENDOR TO

FILL" IS MENTIONED . REMAINING CELLS WHERE QTY IS ALREADY MENTIONED BY
US, NEED NOT TO BE CHANGED BY SUPPLIER.

Sr. Item Category Item Description Qty Unit Make Model/Description Unit Total
no Price Price
I. Main
Redundant
Controller
1 system (Max CPU MODULE 2 nos
loading
50%-60 %)
COMMUNICATION MODULES /
PORTS
2 (CONTROLLER TO I/O) (QTY Vendor nos.
AS PER 6.2.3 OF SPECS) to fill

TO BE FILLED IN COMMERCIAL BID ONLY

COMMUNICATION MODULES
Vendor
3 (CONTROLLER TO OS) (QTY AS to fill nos.
PER 6.2.3 OF SPECS)
4 POWER SUPPLY MODULES (QTY Vendor nos.
AS PER 6.2.3 OF SPECS) to fill

5 MEMORY MODULES Vendor nos.

to fill

6 RACKS (QTY AS PER 6.2.3 OF Vendor nos.

SPECS) to fill
ANY OTHER MODULE(S) not
7 included above Vendor LS
to fill
II. I/O
9 controller RACK Vendor nos.
system to fill

10 Digital Input modules Vendor nos.

to fill
Digital Output module (shall
11 have inbuilt relay or relay board Vendor nos.
with contact rating to fill
of 24 VDC 5 Amp 1NO 1NC.)

12 Rack Power supply modules Vendor nos.

(Redundant for each rack) to fill

1 of 2
 ANNEXURE-A (SOR-B2)

13 Communication modules / port Vendor nos.

(Redundant for each rack) to fill
MTA (Termination modules) for
14 redundant DI & DO Vendor LS
modules to fill

15 Any other type of module(s) Vendor LS

not included above to fill
MTA (Termination modules) for
16 non-redundant IOs Vendor LS
to fill
Control Panel for Controller +
I/O Racks + Isolator +
17 III. Others interface relay cabinets for 1 LS
main plant.

110 to 24 VDC redundant

power supplies with Diode o
ring module with MCB for
each panel make : Siemens /
18 GE/ Schneider P.S. Make : 1 LS
Phoenix/ Siemens / Schneider/
GE/ MTL /PF (set)

Any other item/component not

19 1 LS
included above. (set)

TOTAL OF SOR-B2
 ANNEXURE-A (SOR-C)

SOR-C (Cable & Other Accessories)

Sr. Item Description Qty Unit Unit Total Price

no Price
1 12 pair Signal cable as per tender specs as per ANN D7 1000 mtr

COMMERCIAL BID ONLY

2 Power cable from ACDB panels to DCS and PLC panels as per tender 1 LS

TO BE FILLED IN
specs (set) as per ANN D7

3 Structural Steel (set) 1 LS

4 Cabling & other material etc for earth pit (set) 1 LS

JBS for termination of GB/GC compressor signals or any other

5 1 LS
compressor signals (set)
TOTAL OF SOR-C

1 of 1
 ANNEXURE-A (SOR-D)

SOR-D (Spares DCS)

1. Qty. for the items, wherever "Vendor to fill" is mentioned is to be filled by the bidder & shall be 10 %
of the qty. mentioned/offered in SOR-A to the next higher integer.

2. This 10 % spares are the loose spares.

Sr. Item Item Description Qty Unit Make Model Unit Total
no Category Price Price
I. I/O
vendor
1 controller RACK nos.
to fill
system
Analog Input modules for all analog inputs vendor
except pigtail temp AIs ( max 8 channel
2 modules) nos.
to fill

Analog input module only for 80 nos. for pig

tail temp AIs( max 32 channel module)
2a 1 Nos.
vendor
3 Analog Output module nos.
to fill

vendor

TO BE FILLED IN COMMERCIAL BID ONLY

4 Digital Input module nos.
to fill
Digital Output module vendor
(shall have inbuilt relay / relay board with
5 contact rating 24V DC 5A 1NO 1NC) nos.
to fill
Rack Power supply modules (Redundant vendor
6 nos.
for each rack) to fill
Communication modules / port (redundant vendor
7 nos.
for each rack) to fill
Any other type of module(s) not included
8 1 LS
above (set)
Termination modules for AO or AO
redundant interface module 1(one) channel
9 module. Each channel for redundant set (2 15 nos.
nos.) of AO as input and one no of AO as
output
Ethernet switch managed (Industrial type) 1
10 no.

Pre-fabricated Cables, Terminal Blocks,

11 II. Cables 1 LS
Connectors etc. (set)

110V AC to 24 V DC power supplies with

III. Power
12 Dioide o ring module used in Panels (20% of 1 LS
Supply
total qty required instead of 10 %) (set)
TOTAL OF SOR-D

1 of 1
 ANNEXURE-A (SOR-E1)

SOR-E1 (Spares for PLC Main Plant)

1. Qty. for the items, wherever "Vendor to fill" is mentioned is to be filled by the bidder & shall be 10 %
of the qty. mentioned/offered in SOR-A to the next higher integer.

2. This 10 % spares are the loose spares.

Sr. Item Unit Total

no Category Item Description Qty Unit Make Model Price Price

I. I/O
vendor
1 controller RACK nos.
to fill
system
vendor
2 Analog Input Module nos.
to fill

TO BE FILLED IN COMMERCIAL BID ONLY

Digital input module vendor
3 nos.
to fill
Digital output module (relay output vendor
4 contact rating 24 VDC 5 Amp 1NO 1NC) nos.
to fill
Rack Power Supply Modules (Redundant vendor
5 nos.
for each rack) to fill
Communication Modules / port vendor
6 nos.
(Redundant for each rack) to fill
spares for termination modules for vendor
7 LS
redundant DI, DOs, AIs to fill
Any other type of module(s) not included
8 1 LS
above. (set)
Pre-fabricated cables, terminals blocks,
9 II. Cables 1 LS
connectors etc. (set)

110V AC to 24 V DC power supplies with

III. Power
10 Dioide o ring module used in Panels (20% 1 LS
Supply
of total qty required instead of 10 %) (set)
TOTAL OF SOR-E1

1 of 1
 ANNEXURE-A (SOR-E2)

SOR-E2 (Spares for PLC Compressor House )

Sr. Item Category Item Description Qty Unit Make Model / Unit Total
no Description Price Price

1 I. Main controller CPU module 1 no.

TO BE FILLED IN COMMERCIAL BID.

system
Communication Module /
2 2 nos.
Port (controller to I/O)
Communication Module
3 2 nos.
(controller to OS)
RACK POWER SUPPLY
4 2 nos.
MODULE

5 Rack 1 no.
Any other modules not
6 1 LS
included above (set)

TOTAL OF SOR-E2

1 of 1
 ANNEXURE-A (SOR-F1)

SOR-F1 (Test Jig DCS)

Sr. Item Category Item Description Qty Unit Make Model / Unit Total
no Description Price Price
I. Main Redundant
1 CPU module 1 no.
controller system
Communication Module /
2 2 nos.
Port (controller to I/O)
Communication Module
3 2 nos.
(controller to OS)

RACK POWER SUPPLY

4 2 nos.
MODULE

TO BE FILLED IN COMMERCIAL BID ONLY

5 Rack 1 no.

Any other modules not

6 1 LS
included above (set)
Interconnection cable
between Communication
7 1 LS
modules of CPU rack and
OS. (set)

II. Rack with Power supply

module for I/O system. I/O
RACK
8 modules required for 1 no.
testing shall be taken from
spares qty.
RACK POWER SUPPLY
9 MODULE 2 no.
Interconnection cable
between Communication
10 modules of CPU rack and 1 LS
I/O rack. (set)
Any other module /
11 accessory not included 1 LS
above (set)

TOTAL OF SOR-F1

1 of 1
 ANNEXURE-A (SOR-F2)

SOR-F2 (Test Jig PLC for Main Plant)

Sr. Item Category Item Description Qty Unit Make Model / Unit Total
no Description Price Price

1 I. Main Redundant controller CPU module 1 no.

system
Communication Module /
2 2 nos.
Port (controller to I/O)
Communication Module
3 2 nos.
(controller to OS)

TO BE FILLED IN COMMERCIAL BID.

RACK POWER SUPPLY
4 2 nos.
MODULE

5 Rack 1 no.

Any other modules not

6 1 LS
included above (set)

Interconnection cable
between Communication
7 modules of CPU rack and 1 LS
OS.

II. Rack with Power supply

module for I/O system. I/O
8 modules required for testing RACK 1 no.
shall be taken from spares
qty.
RACK POWER SUPPLY
9 MODULE 2 no.

Interconnection cable
between Communication
10 modules of CPU rack and 1 Lot
I/O rack.
Any other module /
11 accessory not included 1 LS
above. (set)

TOTAL OF SOR-F2

1 of 1
 ANNEXURE-A (SOR-G)

SOR-G (Services)

Sr. Item Description Qty Unit Unit Total

no Price Price
1 Engineering, preparation of drawings, loop diagrams, development of HMI 1 LS

COMMERCIAL BID ONLY

& logics, wiring of panels, testing ( FAT) , documentation for DCS & PLC &
Cost of training as section 11.13.

TO BE FILLED IN
Minor Civil job like civil modifications required for erection of panels,
2 1 LS
structural work, Preparation of two Earth pits etc.

Charges for deputation of required manpower (Technicians/Helpers) and

3 Engineers for erection and commissioning of system at site & any other 1 LS
work required for Engineering & Installation & Commissioning of the
System.
TOTAL OF SOR-G

1 of 1
 ANNEXURE-A (SOR-H)

SOR-H (AMC Charges)

Sr. No. of
Item Description Price
no Years

AMC Charges for 1st year of operation after the completion of warranty
1 1
period of 2 years

COMMERCIAL BID
TO BE FILLED IN
AMC Charges for 2nd year of operation after the completion of warranty
2 1
period of 2 years

AMC Charges for 3rd year of operation after the completion of warranty
3 1
period of 2 years

TOTAL OF SOR-H

1 of 1
 Annexure B1

Server Specification

   Description  Requirement  

1  Make  To specify 
2  Model No.  To specify 

3  Processor type  Intel® Xeon® E5‐4600 family product 

4  Number of processors  One 
5  Chipset  Intel® C602 Chipset 

6  Memory  32 GB DDR3L, 1600 Mt/s or better, CAS CL 9 or lower 
RAID Controller (RAID 0/1/1+0/5/50/6/60) with 
7  Storage Controllers  Hardware RAID support, PCIe2.0 compatible, 6 Gb/s 
SAS, 512 MB NV, Min. 4 drive support. 
8  Internal hard disk drive  900GB x 4, 6G/s SAS, 15K RPM SFF (2.5”) 

Minimum Required – 6 
9  Network interface  4 x 1GbE (Onboard) 
2x 1GbE External NIC (Dual Port NIC) 

10  Optical Drive  SATA DVD RW Optical Drive 

Serial ‐ 1 
Graphics Video VGA ‐ 1 (Rear) 
11  External I/O ports  4 x 1GbE (Onboard) 
SD slot ‐ 1 (internal) 
USB 2.0 Ports ‐ 10 (4 front, 4 rear, 2 internal) 

Dedicated LCD Panel or iLO (Integrated Lights Out) 
12  System Monitoring 
system monitoring. 
13  Graphics  Integrated Matrox G200 video standard 
For Single Processor ‐  
PCIe 3.0 x 16 – 2 Nos. 
14  Expansion slots 
PCIe 3.0 x 8 – 1 Nos. 
PCIe 3.0 x4 – 1 Nos. 
15  Form Factor  Rack 
16  Chassis  Rack 4U 

ACPI 2.0b Compliant 
PCIe 3.0 Compliant 
WOL Support 
17  Compliance industry standards 
IPMI 2.0, SMASH CLP, DCMI 1.0 compliant 
USB 3.0 Support 
SMBIOS 2.7.1 
 Tool‐less access to all system components for easy in 
18  Serviceability 
rack serviceability. 
110/230 VAC (Interchangeable) 750 W (Min.) Hot 
19  Power Supply 
pluggable redundant power supply  

19  Cooling Unit  Hot Pluggable redundant 4 Fan System 

Windows Server 2008/2012/2016 32 BIT/64 BIT (Latest 
21  Operating System  compatible version) Standard Edition Licensed with 
Original OS Media or Better. 
All necessary power cables (Indian standard) required 
22  Cables 
for the servers. 

23  LCD  22” LED Backlit Monitor  

24  K/B and Mouse  OK 

25  Other Software  Microsoft Office 2013 Basic Licensed 
26  Antivirus  Symantec Antivirus Latest Version 2 year license  
 Annexure B2

Workstation Specification

Description Requirement
1. Make Bidder to specify
2. Model Bidder to specify
3. Grade of System Workstation Grade
4. Processor Intel Core i5-7400T or better
5. Chipset Intel C612 Chipset
6. Main Memory 8GB DDR3L Memory extendable Upto 16GB of
DDR3L Dual
Channel 1600 Mhz RAM with support on 2 DIMMs
7. I/O Ports Front
- 1 USB 3.0
- 3 USB 2.0

Rear
- 2 PS2
- Serial Communication Port
- 2 x 1GbE Ports

8. Gigabite Ethernet Minimum 2 on board Gigabit Ethernet RJ45 ports

9. I/O Expansion One PCI Express x 16 slot
Two PCI Express x 1 slot
One PCI slots
10. HDD Controller Built In mother board
11. Power supply 250W / 300W (300W option for MT/V chassis only)
400 watts Power supply wide-ranging, active
Support for Voltage 110/230 VAC
12. Keyboard & Mouse Multimedia Keyboard and Optical Scroll Mouse
13. DVD drive DVD Writer
14. Hard disk 1 TB SATA
15. Cabinet ATX cabinet with adequate cooling
16. Operating systems Windows 10 Professional 32bit/64Bit Licenses with
online -Validation with
OS Recovery Media
17. Accessories Mouse pad with palm rest.
18. Spike Buster MX 4 OUTLET.(CPU, MONITOR,PRINTER,
SPEAKER)
19. Speakers Minimum 800 Watts or more Multimedia Stereo
Speakers
20. Other Software Microsoft Office 2013 Home & Business Original
Licensed
21. Antivirus Latest antivirus with 2 years license license
 Annexure B3

Alarm Annunciator Specification

Sr. Description Requirement

No.
1. Supply Voltage 20-60 V AC/DC, 90-270 V AC/DC, 50-60 Hz (
power supply to be arranged by supplier)
2. Windows 24/12
3. Window Sizes Preferably 30 x 65 mm
4. Display Device Super bright high efficiency low power consuming
LED's
5. Facia Type Individual windows lens Front Replaceable
6. Window/LED Color RED, Yellow, Green, White & Blue
7. Flash Rate Fast - 60 flashes/min. Slow - 30 flashes/min.
8. Response Time 40 msec.
9. Input Signal Potential free contacts (NO or NC site selectable)
10. Grouping site selectable (Trip / Non Trip)
11. Interrogation Voltage + 12 V DC
12. Output Contacts 1 NO + 1 NO + 1 NO
13. Architecture Integrated
14. Operational Seq. ISA Standards sequences - Auto/Manual/First-
up/Ringback OR
any other sequence on request
15. Operational Temp. 0 0C to 50 0C
16. Power Consumption 1.5 Watts per Window (Max.)
17. Serial 485 Port
communication
 Annexure C
Approved vendors' list for major bought out items
S.No Item discription Approved vendors
1 workstation grade PC HP DELL
2 Color Monitros HP DELL Samsung
3 Server Grade PC HP DELL
4 Laser Pinters HP DELL
5 Dot matrix Printers EPSON HP WIPRO
6 Industrial Ethernet Switches CISCO MOXA siemens
7 FO cable Uniflex Cables Krone Amp., AT&T
8 Signal & Power Cables CCI Associate cables UniFlex cables
9 Relays OMRON OEN SIEMENS/SCHNEIDER/PHEONIX
10 Panel Rittal
AO /AI/DI/DO selection
11 module/trip isolators Pheonix WAGO P&F /UL
12 Terminals Pheonix WAGO Wied mullar
13 Furnitures Godrej
14 Control Desk Pyrotech Rittal
14 currect to 4-20 mA Pheonix RISHAB P&F
Relay modules/AO redundant
16 seletion module UL Pheonix
Note : Any other make of IT/ oather hard ware shall be subject to review and approval by HWB during technical evaluation
 D3  
  EXISTING PUMP AND COMPRESSOR RELAY PANEL SYSTEM 
FIRST  FLOOR 
 

  ANNUNCIATION/SEMI GRAPHIC RELAY BOX/RECEIVER SWITCH

 

 
PLC PANELS GROUND FLOOR 
 

  REAR
11

17

15

14
16

12

11

12

13
   

ATION
SUBST
RICAL
ELECT
    

 
11

17

16

15

14

12

11

12

13
  FRONT

 
FIELD 
   
SWITCHES 
     
  FRONT
01

02

04

05
03

06

07

08

09
 

ELECT

ATION
RICAL
SUBST
 
01

02

03

04

05

06

07

08

09
  REAR
 
 
FIELD 
SWITCHES   
 
 D4 
Existing Relay Logic Panel Details
Panel
Present Panel Front Proposed Panel Front Present Panel Rear Proposed Panel Rear
Number
1. Control logic power Removed
distribution .
01 2. Program matrix-1 Removed Control logic power distribution Removed 
3. Program matrix-2 Removed
1. Alarm Annunciation cards Removed
02 2. SPIC (Compressor)Trouble 11th Unit Drier interlocks Removed 
Removed
interlock for GB Shut down
1. 11th unit Drier interlocks Removed
03 for Motor Operated valves Test Setup for relays and timers Removed 
2. Alarm Annunciation cards Removed
1. 12th unit control logic
Removed
04 supply 12th unit interlocks Removed 
2. 12T1/T2 Level relays Removed
05 12th unit interlocks Removed 12th unit interlocks Removed
12th unit Alarm Annunciation
06 Removed  12th unit interlocks Removed 
cards and interlocks
12th unit Alarm Annunciation
07 Removed  12th unit interlocks Removed 
cards and interlocks
12th unit Alarm Annunciation
08 Removed  12th unit interlocks Removed 
cards and interlocks
09 12th unit pumps interlocks Removed 12th unit interlocks Removed
14th unit alarm cards and
10 Removed  14th and 16th Unit interlocks Removed 
interlocks
16th unit alarm cards and
11 Removed  17th unit alarm cards and interlocks Removed 
interlocks
 D4 
1. Program matrix-3 (17th
Removed 
unit)
12 19K3 Interlocks Removed 
2. 17th unit alarm cards and
Removed 
interlocks
19K3 & 20K41 interlocks and
13 Removed  20K41/42 Interlocks Removed 
Alarm cards

Removed 
1. 20K41/42 Control logic power distribution.
14 20K42 & 20K5 interlocks Removed 
2. 22P41/42/43 interlocks
Removed 

22P41/42/43 interlocks and 1. 22P43 interlocks Removed 

15 Removed 
Alarm cards 2. 26P81/82 interlocks Removed 
27K01/02 interlocks and
16 Removed  27K11/12 interlocks and alarm cards Removed 
alarm cards
1. 30 and 31 unit control logic supply
Removed 
distribution
27K02&13 interlocks and
17 Removed  2. 30K03/04 interlocks Removed 
alarm cards

3. 38th unit pump interlocks Removed 

1. 37th and 38th unit control logic supply

31,32,33&37 unit Interlocks Removed 
distribution
18 and Control logic power Removed
distribution 2. 27K2 Interlocks Removed 
 Annexure – D5 
20K41/42 
                                                        Field 
                                          Local Panel                                           RELAY PANEL ROOM                                    CONTROL ROOM 
                 Control Room Ground Floor  First Floor 
 

 
Annunciation
 
Relay Panel
 

Field  Selector Switch

 
Switches Terminal Box  

   

  Circuit
Interlock
Solenoid Valves
(EV)
 
Alarms
Multi Core
 
Air Header
Alarm Card

Service Loop
Selector Switch

HIC
HIC

 
 
FIELD 
ANALOG PARAMETERS 
GC & GB Annexure‐ D6 

CONTROL ROOM (I FLOOR) 
 
FRCA112
  Indicator/Recorder & Alarms
FIC113
  (Receiver Switch)
FICA114 etc.
 

 
FIELD PNEUMATIC
    Indicator/Recorder & Alarms
 
SIGNALS  
(Receiver Switch)
PT/DPT/FT etc.
 

 
CONTROL ROOM (I FLOOR)
  Annunciation Relay
FIELD  Box
DIGITAL PARAMETERS   CONTROL ROOM (GR. FLOOR)
 

  Alarm Relays – 8 nos. Annunciation & Semi

  Lamp Test Relay – 4 nos. Interlock graphic Relay Box
  TB Circuit
MULTI CORE 
  (Relay)
Annunciation & Semi
 
TERMINAL BOX graphic Relay Box
 

                                           
Annunciation & Semi
 
graphic Relay Box
            FIELD SWITCHES (2 – CORE)  Electrical Substation 

              (LOCAL Panel)                              CONTROL ROOL (REAR) 
 
 
 ANNNEXURE- D7 SPECIFICATIONS OF CABLES

DETAILED TECHNICAL SPECIFICATIONS OF SIGNAL , POWER

CABLE & optical fiber cable
 ANNNEXURE- D7 SPECIFICATIONS OF CABLES

1. SIGNAL CABLES SPECS 

12 pair 
S.  DESCRIPTION  UNIT  12pair  x 0.75 sq mm 
No. 
1.  NAME OF THE MANUFACTURER     
2  CABLE TYPE    PVC insulated, Individual & Overall screened , PVC inner sheathed, Galvanised Steel Round 
Wire/flat Strip Armoured and overall FRLS PVC sheathed screened cable  
3  APPLICABLE STANDARDS    BS 5308‐2/86, BS 50288‐7 , IS:8130/84, IS:5831/84, IS:3975, IS: 1554‐1/88, ASTM‐D‐2863, 
ASTMD‐D‐2843, IEC: 754‐1, IS:10810, IEC:332‐1 & this data sheet 
4  Voltage Grade  V  500 V 
5  No. of Pairs  No.  12 pair x 0.75 sq mm 
6  CONDUCTOR     
a)  Matieral    Electrolytic Annealed Tinned Copper as per Class‐2 of IS:8130 
b)  Size  Sq.mm  0.75
c)  No. of strands   No.  7  
d)  Shape of Conductor    Stranded & circular 
7  INSULATION     
a)  Material    PVC Type‐C compound as per IS:5831/84, EN 50290 
b)  Type    Extruded 
c)  Thickness (min)  mm  0.44
d)  core   identification    All Pairs shall be white & blue. Also cores of each pair shall be numbered for identification   
e)  Min. Number of Twists of cores  No.  Min. 10 Twists/meter 
in a Pair 
  INDIVIDUAL PAIR SHIELD     
a)  Material     Aluminum Mylar Tape 
b)  Type    Helical 
c)  Thickness (min)  mm  0.024 mm
d)  Overlap/coverage  %  25/100
8  OVERALL SHIELDING     
a)  Material     Aluminum Mylar Tape 
b)  Type    Helical 
c)  Thickness (min)  Min  0.040 mm
d)  Overlap/ Coverage  %  25/100
 ANNNEXURE- D7 SPECIFICATIONS OF CABLES

9  DRAIN WIRE (for individual pair     
& overall shield as applicable) 
a)  Material     Annealed  tinned copper 
b)  Size  Sq.mm  0.5
c)  No. of strands  No./mm  7
10  INNER SHEATH     
a)  Material     PVC, Type‐ST‐2 as per IS:5831/84, EN 50288 with FRLS property
b)  Type    Extruded 
c)  Thickness (min)  mm  1.5
d)  Colour     Black 
11  ARMOUR     
a)  Material     Galvanized steel round wire/flat strip conforming to IS 3975 
b)  Type    Single layer 
C)  Dia of Wire armour (Nom.)  mm  1.6 or 4X0.8
12  OUTER SHEATH     
a)  Material    FRLS  PVC, Type‐ST‐2 as per IS:5831/84 
b)  Type    Extruded 
c)  Thickness (Min.)  mm  1.8
d)  Colour of outer sheath    Blue  
e)  Overall diameter (approx.)  mm  Bidder to specify 
f)  Tolerance on overall diameter  mm  Bidder to specify 
h)  Marking on outer sheath    Manufacturer’s name, year of manufacture, voltage grade (i.e. 500 V), no. of cores/pairs, 
cross sectional area of conductor, FRLS stamping, sequential length marking shall be provided 
on outer sheath of cables at every 1mtrs interval 
13  Total qty required   mts  1000 
14  Packaging  In drums  In drum of 1000mtr ±5%
15  ELECTRICAL PARAMETERS     
a)  Max. DC resistance of conductor  Ohm/km  24.5 
at 20 deg. C of completed cable 
b)  Min. insulation resistance of  MOhm/km 10
conductor at 27 Deg.  C of 
completed cable 
c)  Max. Mutual capacitance at  nf/km  250 
1KHz 
 ANNNEXURE- D7 SPECIFICATIONS OF CABLES

d)  Max. capacitance between core  pf/mtr  400

& screen at 1 KHz 
e)  Max. inductance between  mH/km  1 
conductors 
f)  Max. L/R ratio  MicroH/Ohm  25 
g)  Max. drain wire resistance  Ohm/km  30 
including shield at 20 deg C 
h)  Min Electrostatic noise  dB  ˃ 76 dB 
reduction ratio 
i)  High voltage test     
  Core to core   KV rms  1 KV rms for 1 min 
  Core to shield  KV rms  1 KV rms for 1 min 
16  FRLS Properties     
a)  Min. Oxygen index as per ASTM‐ %  29 
D‐2863 
b)  Min. Temp  index as per ASTM‐ Deg C  250 
D‐2863 
c)  Max. HCL emission as per IEC‐ %  20 by weight 
754‐1 
d)  Max. smoke density rating as  %   60 
per ASTM‐D2843 
e)  Flammability test As per IEC ‐   Cable shall meet the test requirement of IEC‐332‐1, Flame extinguish time shall be 1 sec
332‐1 

2. Power & earthing cable specs. Will be same as per the IS standards which are referred above. Conductor rating will
depend upon the current rating requirement. Cable need to be armored, FRLS type with the above testing requirements.
 ANNNEXURE- D7 SPECIFICATIONS OF CABLES

3. TESTS AND INPECTION TO BE CARRIED OUT AT SUPLLIER WORKS

5.1 Vendor shall offer all types of cables to be supplied for inspection at their works before
dispatch. 15 days advance notice informing readiness of the item at their works for final
inspection shall be provided to HWB.
5.2 Cables shall be inspected to determine conformance with the specification & approved
QAP.
5.3 For tests given at a, b & c of sr.no 4 below, tests of samples from each drum shall be
done as per the relevant standard and specification. For tests given at d, e & f of sr.no
6 below one drum of each type of cable shall be taken for testing.

4. DOCUMENTS & TEST CERTIFICATES TO BE SUBMITTED ALONG WITH DISPATCH

The supplier shall show the test Certificate of following tests in English language in 3 sets
at the time of Pre dispatch Inspection for 100% qty of all cables ( i.e for all drums to be
supplied) and submit the same at the time of delivery.

Sr. no. TESTS Bidder’s remark

a. ELECTRICAL TESTS:
a.1 high voltage test
core to core
core to screen
a.2 max. conductor resistance at 20 C
a.3 max. drain wire resistance at 20 C
a.4 min. Insulation resistance at 20 C
a.5 max. Capacitance
core to core
core to screen
a.6 max Inductance
b. PHYSICAL DIMENSIONS
b.1 number of strands
b.2 min. thickness of outer sheath
b.3 min thickness of inner sheath
b.4 nom. Thickness of insulation
b.5 colour of core
b.6 dimension of armour wire
b.7 colour of outer sheath
b.8 overall diameter
c. SCREEN(Individual & OVERALL)
c.1 min. thickness of Al-Mylar Tape
c.2 coverage/overlap (min)
c.3 Nos/size of drain wire approx
d. All PVC sheath
d.1 min. tensile strength
d.2 min. elongation at break
e. TESTS ON ARMOUR
e.1 Tensile strength
e.2 elongation (min)
f. FRLS TESTS (OUTER SHEATH)
f.1 min. oxygen index: ASTMD-2863
f.2 min. temp index: ASTMD-2863
f.3 Max. smoke density rating : ASTMD-
2843
 ANNNEXURE- D7 SPECIFICATIONS OF CABLES

f.4 Max. HCL gas emission : IEC 754-1

f.5 FLAMMABILITY as per IEC-332-1

Fiber Optic Cable Specifications:  
 

Sr. 
Specification  Value 
No. 

1  Mode  Multimode 

2  Tube  Central Tube (Unitube) 

3  Fibers/Core  6

6  Bend Radius  20 x OD 

Operating 
7  ‐30 to 70 °C 
Temperature 
8  Max Attenuation  3.0 dB/km or better 
9  Tensile Strength  1000 N or better 
Water Proof taping along with 
  Taping 
Corrugated Steel taping 
Polymer coating on the corrugated steel 
  Coating 
taping 
  Armored   Yes , cable should be armored 
PE outer sheath, preferably FRLS outer 
  Outer Sheath 
sheath