Refueller Fabrication Manual

SPECIFICATION MANUAL
FOR
REFUELLER FABRICATION
BHARAT PETROLEUM CORPORATION LIMITED

AVIATION TECHNICAL DEPARTMENT
NOIDA
BPCL – REFUELLER SPECIFICATION MANUAL

MANUAL DISTRIBUTION LIST
No. HOLDER OF CONTROLLED COPY

1. HEAD, AVIATION BUSINESS.
2. MARKETING MANAGER (AVIATION)
3. CHIEF MANAGER AVIATION OPERATIONS
4. TEAM LEADER (TECH. SERV.) AVIATION
5. AVIATION MGR. (NORTH)
6. AVIATION MGR. (EAST )
7. AVIATION MGR. ( SOUTH)
7. AVIATION MGR. ( WEST )
8. ENGINEERING & PROJECT (H.Q.)
9. ENGINEERING & PROJECT (NORTH)
10. STATION MANAGERS / INCHARGES
MANUAL DISTRIBUTION LIST ISSUE: 02 DATE: 01.10.2013

SECTION : 00 REV NO. : REV DATE:
ISSUED BY : AVIATION TECHNICAL DEPT. PAGE NO. : PAGE 1 OF 1
The following is the summary of Revisions in the Refueller Specification Manual,
Issue No.1.
Revised Document Details Updation Record
S.NO. Brief Details of Revision
Sec No. Page No Rev. No. Date Date Sign.



ABBREVIATION FULL FORM
AFS Aviation Fuelling Station
A/G Above Ground
AOM Aviation Operations Manual
AQCAM Aviation Quality Control & Assurance Manual
API American Petroleum Institute
APU Auxiliary Power Unit
ASTM American Society for Testing Material
ATF Aviation Turbine Fuel
ANSI American National Standards Institute
BPCL Bharat Petroleum Corporation Limited
BSI British Standards Institution
CCOE Chief Controller of Explosives
DCP Dry Chemical Powder
DGCA Directorate General of Civil Aviation
DMC Dead Man Control
DP Gauge Differential Pressure Gauge
FDF Fuel Defuel Valve
F.E. Fire Extinguisher
FM Fuel Monitor
FWS Filter Water Separator
GCW Gross Combination Weight
GPU Ground Power Unit
HEPCV Hose End Pressure Control Valve
HFC Head Fuelling Crewman
IATA International Air Transport Association
IP Institute of Petroleum
Jet A -1 A Grade of Aviation Turbine Fuel
MF Micro Filter
OISD Oil Industry Safety Directorate
PD Pressure Differential
PPE Personal Protective Equipment
PESO Petroleum & Explosive Safety Organization
PSI Pounds Per Square Inch
QC Quality Control
QRV Quick Release Valve
SAV Shell Aviation Ltd
SPCV Secondary Pressure Control Valve
TLTS Team Leader Technical Services.
U/G Underground
USG U S Gallons
ABBREVIATIONS ISSUE: 02 DATE: 01.10.2013

LIST OF SECTIONS
SECTION – 1 GENERAL REQUIREMENTS
SECTION – 2 CHASSIS SELECTION – BASIS AND FEATURES
SECTION – 3 FUNCTIONALITY AND CONSTRUCTION OF AVIATION MODULE
SECTION – 4 PAINT SPECIFICATIONS, PAINTING PROCEDURES & VM
SECTION – 5 STATUTORY REQUIREMENTS INSPECTION / TESTING /

COMMISSIONING
SECTION – 6 INSTRUCTION MANUAL
SECTION – 7 MAKE / SPECIFICATION DETAILS OF MAJOR COMPONENTS
SECTION – 8 CHECKS OF CHASSIS & REFUELLER AFTER FABRICATION
SECTION – 9 TECHNICAL INFORMATION OF CRITICAL COMPONENTS
SECTION – 10 DIAGRAM OF GENERAL ARRANGEMENT/ FUEL FLOW

ELECTRICAL/ PNEUMATIC SYSTEM
LIST OF SECTIONS ISSUE: 02 DATE: 01.10.2013

SECTION – 01
GENERAL REQUIREMENTS
SECTION – 1 GENERAL REQUIREMENT
1.1 STATUS
1.2 ENQUIRIES AND OFFERS
1.3 PURCHASE AND MANUFACTURE
1.4 TESTING AND HANDING OVER
1.5 STANDARDS AND SPECIFICATIONS
GENERAL REQUIREMENTS ISSUE: 02 DATE: 01.10.2013

GENERAL REQUIREMENTS
1.1 STATUS
1.1.1 This document describes the basic requirements to be taken into account while planning
procurement of chassis and fabrication of a Refueller. The specific requirements, if any,
based on user’s experience need to be considered & incorporated in the tender.
1.1.2 The specifications meet the requirement of design, construction and testing of the refueller.
It may be modified by raising amendments to fabricate refuellers at par with the
international norms, local statutory norms and business specific requirements. Any changes
or amendments in this manual shall be brought with full justification and need of change in
the notice of Aviation Technical Department thru Line Managers for evaluation and
approval by Technical Services department.
1.1.3 The vehicle is to be normally used in and around airports at limited speed except while on
transfer to another location. However the vehicle design must meet all the regulatory
requirements of MVA, RTA, MOST, PESO, DGCA, Petroleum Rules, AAI guideline etc.
like permitted axle load, length, width, height, permitted safety fittings etc.
1.2 ENQUIRIES AND OFFERS
1.2.1 When submitting a quotation to BPCL, the fabricator should provide sufficient technical &
descriptive details to demonstrate that all aspects of the specification as well as the
applicable regulatory requirements, have been complied with in the proposed design offer.
1.2.2 General arrangement drawing shall be submitted to BPCL within 30 days from the date of
LOI & should include the following details as a minimum.
Minimum clearances, maximum overall dimension, dimension of tank cross section incl.
radii of top, sides and corners, net weight & axle weight of the complete unit incl. tank &
chassis plus the other data deemed to be relevant. One copy of the drawing, duly approved
by Aviation Technical Dept. and Engineering & Projects Dept. would be returned to the
fabricator.

Detailed construction drawings of tank fabrication, piping layout and components layout,
would be submitted in duplicate to BPCL within 30 days after approval of weight and
dimension of drawings.
Drawing approval by BPCL would mean General Agreement and flow circuit diagram with
the layout, dimensions and the weight of the unit, but will not necessarily imply that BPCL
has verified the design parameters like stress calculations, construction details, compliance
with all / any of the applicable rules and regulations etc. All these would still remain as the
responsibility of the fabricator.
1.3 PURCHASE AND MANUFACTURE
The chassis is normally purchased by BPCL and issued to the successful fabricator as a
free issue item. In case, BPCL wants the fabricator to procure the chassis, the fabricator
would check the suitability of the chassis for the capacity of the refueller under fabrication
and present all the technical data in support of procurement of the suggested chassis and
would seek BPCL’s approval prior to the procurement.
Where this specification omits specific details of equipment or design, the manufacturer
would be required to use his experience, skill & knowledge of industry norms & the best
practices in respect of the vehicles being fabricated.
Some of the standards are to be followed during fabrication are provided in the later part of
this section. However there are other recognized International or equivalent national
standards which may be applied in whole or part of it to meet the regulatory requirement &
also to get the best possible product.
1.4 TESTING AND HANDING OVER
The fabricator would arrange to carry out full fledged testing of the vehicle with the
product as per terms and conditions mentioned in the tender and the same would be
witnessed by BPCL representative (Aviation / Engineering & Projects). A joint test report
as per Section 8, Sr. No. 8.2 & 8.4 would be prepared & signed by BPCL (Aviation /
Engineering & Projects) & the fabricator’s representatives.
Final acceptance of the vehicle by BPCL would not relieve the supplier of his obligation to
comply with the specifications and any amendment or modification which may be required
to be carried out by the fabricator to ensure that the vehicle meets all the applicable
regulations as well as fit for use / purpose.

1.5 STANDARDS AND SPECIFICATIONS
The following standards would be followed during fabrication.
ISO 1825: 2010, Third/latest Edition Aviation fuelling hose & hose assembly
API / IP 1583 (latest Issue) Aviation Fuel Monitors
IS 5986 Fe Grade 360 or better M.S. Storage tank
DOT 406 A.L. Storage tank
S 304 ERW Schd.10 Pipelines
ANSI B of 150 class Other pipeline fittings & flanges
CC0E Approved Spark arrestor
CCOE Approved Fusible plug
CCOE Approved Master switch
Car Series H Fuel identification markings
Petroleum Rules Hazchem Chart
Sa 2 ½ Sand blasting
API / IP 1584 (latest Issue) Delivery couplings
OISD 110 Control of undesirable static electricity
BPCL Colour Scheme Painting, Logo & Signage’s

SECTION – 02
CHASSIS SELECTION
- BASIS AND FEATURES
SECTION – 2 CHASSIS SELECTION – BASIS AND FEATURES
2.1 CHASSIS SPECIFICATIONS FOR 15KL
2.4 MODIFICATIONS BY THE REFUELLER FABRICATOR
2.5 ELECTRICAL REQUIREMENTS
2.6 MISCELLANEOUS REQUIREMENTS
2.7 GENERAL DESIGN
2.8 CIRCUIT PROTECTION
2.9 BRAKES INTERLOCKS – PNEUMATIC / ELECTRICAL

REQUIREMENTS
GENECHASSIS SELECTION – BASIC AND FEATURES ISSUE: 02 DATE: 01.10.2013

CHASSIS SELECTION – BASIS AND FEATURES
2.1 CHASSIS SPECIFICATIONS FOR 15 KL
2.1.1 CABIN & CHASSIS
i) The chassis should be FULL FORWARD CONTROL TYPE

ii) Cabin should be ergonomic tiltable/fixed FACTORY BUILT CABIN with wiper
etc.
iii) The chassis frame shall be heavy duty pressed channel section carbon
steel cross members.
iv) Suitable towing arrangement shall be provided in front of the chassis.
v) Cabin should be designed with large size windows on all the sides i.e. front,
sides and rear for unobstructed visibility. The front windshield shall be of
large size of single piece design, door windows shall be of sliding/winding
type and rear window shall be full size fixed type (wind screen type) with SS
wire mesh required as per Petroleum Rules. Glass of all the windows shall
be of high quality toughened safety glass.
vi) Interior of the cabin should be designed for best comfort with molded
interiors and heat insulation padding of good quality material. The engine
hood and other heat radiating equipment’s shall be insulated with molded
casing of ergonomic design. The floor area will be fully lined with approved
quality matting with padding etc.
vii) Driver seat shall be adjustable type cushioned seat with retractable
safety belt confirming to JID D 4604 or the latest approved standard.
viii) Cabin should have comfortable foot step and handles located inside the
cabin on both sides of the door for easy entry. If any additional foot step is
required, same shall be fitted on BPCL instruction.
ix) In addition to normal panel / dashboard instruments, an engine revolution

counter, low air pressure indicator and engine hour meter are required.
x) The chassis frame shall be LADDER TYPE HEAVY-DUTY FRAME with RIVETTED /
BOLTED CROSS MEMBERS.
xi) Arrangement for washing / cleaning of windscreen to be provided

xii) Electric wiper motor (Heavy duty) will be provided with a long wiper blade to
cover full wind screen.
2.1.2 The braking system shall be either of pneumatic type or air assisted hydraulic
ype. Coiled air hose of sufficient length shall be provided with ISO Palm coupling
and locking arrangement with auto brake interlock fail safe system at low
pressure.
2.1.3 The connection of break system for tractor & trailer shall be through palm
coupling conforming to ISO 1728 / SAE J318 standard.
2.1.4 Break action is to be spring loaded on air pressure off (hand break).
2.1.5 The heavy duty nylon tyres of suitable size and “anti static“ type with resistance
of earth not less than 10,000 ohms unused and not more than 1X106 ohms shall
be provided. An additional spare tyre to be supplied along with the chassis.
2.1.6 The minimum possible turning circle / radius is required. Turning radius to be
mentioned by the party in their technical offer.
2.1.7 The electrical system shall be of heavy duty preferably (100 Ah or more) battery
of 12/24 V shall be provided. Electrical current is to be supplied by a heavy duty
alternator preferably (55 Amps). Power rating of Battery of 100 Ah is indicative
However vendor has to quote the rating based on their model
2.1.8 All the electrical circuits should be protected with fuses and circuit breakers in the
feed of each circuit.
2.1.9 A mechanical PTO shall be provided by the chassis supplier. The successful
bidder and supplier of the chassis will need to provide details of the Gearbox
PTO and confirm acceptability of the propeller shaft layout and Pump mounting
on the chassis to our refueller fabricator. Following are the specifications of PTO
for selection for chassis supplier.
a) Flange type clutch dependent Power Take Off should be provided.

b) PTO should be side/rear mounted suitable for fitting of ATF pump for
refueller.
c) This power take off will be used to drive the ATF Pump.
d) The power take off should be able to deliver at least 38 HP or more @ 1000
RPM (approx) for continuous operation.
e) Pneumatically operated PTO switch should be provided in the driver cabin.
f) The PTO ratio should be more than 1:1. In case PTO ratio is not possible,
additional gearbox to be provided.

2.1.10 Front and rear directional signals, normal hazard rotating warning (flash light),
reverse light with audio alarm and break lighting are required.
2.1.11 Battery shall be placed in enclosed battery box with proper insulation and
protection at appropriate place. The battery box shall be made of good quality
anti acid type to avoid corrosion due to acid and longer life. Battery cut off
switch (Master switch) provision to be made inside the cabin.
2.1.12 The Chassis supplier should provide the electrical/electronic output for remote
control of engine throttle from Auxiliary panel installed outside(panel not in scope
of chassis supplier). Output control to remotely stop the engine is also to be
provided. The engine throttle output is required to control the ATF pump
operating through engine.
2.1.13 Clutch operation should be easy to operate and the clutch should be single plate
dry friction type.
2.1.14 HYDRAULIC POWER ASSISTED STEERING for added driving comfort.
2.1.15 Chassis will go to the fabricator for the fabrication of the equipment and is likely
to take approx 6 month’s time and the free servicing will have to be done at the
fabricator’s works on request from our fabricator.
2.1.16 Chassis detailed drawing to be provided to fabricator on demand for installation

of refueling module efficiently.
2.1.17 Each chassis shall be supplied with one copy of Operation & maintenance
Manual / CD along with spare parts catalogue / CD. Additional copy of manual /
CD to be supplied to BPCL Aviation H.Q. – NOIDA.
2.1.18 The engine should be designed to meet Euro-III / Euro-IV Emission Norms
accordingly by an approved certifying testing agency.
2.1.19 Vendor to comply with the requirements of CMVR/RTO/Statutory agencies. Any

limitation in getting registration in particular states shall be clearly brought out in
technical bid.
2.1.20 The exhaust pipe of the vehicle should be re-routed to the co-driver side of the
vehicle in the front of the cabin.
2.1.21 CCOE approved spark arrestor shall be provided. In case any exemption have
been granted on the chassis by a regulatory agency on meeting the safety
requirements, the exemption documents shall be enclosed along with the
technical bid & documentary evidence would be submitted at the time of delivery
of chassis.

2.1.22 Chassis shall be latest, commercially successful and spots services available for
such models. Model approval shall be furnished along with technical bid and
supplier to extend all necessary support to BPCL in registering the vehicle at the
offices mentioned in the document.
Kindly note that Chassis required is for the following locations:
1
2
3
The chassis offered should be ensured for their registration in above mentioned
states. However in future, if BPCL wants to register these chassis in other states,
necessary documents shall be provided by the vendor at the time of registration
of vehicles, at no extra cost to BPCL.
Vendor has to confirm, the spare parts for the model offered should be made
available for 10years.Vendor has to submit the list of spares.
2.1.23 Chassis details for 15 KL refueller
The chassis shall be rigid type with the following requirements:
a. Drive - 6X2, Right Hand

b. Wheel Base - Should not be more than 5,200 mm, Minimum wheel
base required is 4880 mm
c. Over all length - Should not be more than 10,000 mm, Minimum 9010
mm.
d. 6 T on the front axle
e. 19 T on the rear axle of the chassis
f. Gross Combination Weight (GCW) 25,000 Kg (approx.), limited by
manufacturer of GCW.
g. Engine HP : 154 HP or more @ 2400 rpm (approx)
2.1.24 Designed load on the front / rear axle to be indicated. Your technical approval
for maximum loading of these vehicles to be clearly mentioned under following
conditions.
2.1.25 Chassis will be subjected to a continuous loading i.e. the fuel in the storage tank will be
kept always full while in operations. It is therefore desirable to have suspension system
duly strengthened.
2.1.26 The chassis should have 150 ltrs. to 180 ltrs. fuel tank and should be mounted on left
side of the chassis.

2.1.27 If chassis modification is necessary, it will be done by fabricator in consultation with
chassis supplier. All necessary assistance shall be extended to them without any delay
and hesitation and without any charges.

i) The tractor chassis should be FULL FORWARD CONTROL TYPE
ii) Cabin should be ergonomic tiltable/fixed type FACTORY BUILT CABIN with
wiper etc.
iii) The chassis frame shall be heavy duty pressed channel section carbon
iv) Suitable towing arrangement shall be provided in front & rear of the chassis.
v) Cabin should be designed with large size windows on all the sides i.e. front,
sides and rear for unobstructed visibility. The front windshield shall be of
large size of single piece design, door windows shall be of sliding/winding
type and rear window shall be full size fixed type (wind screen type) with SS
wire mesh required as per Petroleum Rules. Glass of all the windows shall
be of high quality toughened safety glass.
vi) Interior of the cabin should be designed for best comfort with molded
hood and other heat radiating equipment’s shall be insulated with molded
casing of ergonomic design. The floor area will be fully lined with approved
quality matting with padding etc.
vii) Driver seat shall be adjustable type cushioned seat with retractable
viii)Cabin should have comfortable foot step and handles located inside the
cabin on both sides of the door for easy entry. If any additional foot step is
required, same shall be fitted on BPCL instruction.
ix) In addition to normal panel / dashboard instruments, an engine revolution

counter, low air pressure indicator and engine hour meter are required.
x) The chassis frame shall be LADDER TYPE HEAVY-DUTY FRAME with RIVETTED /
BOLTED CROSS MEMBERS.
xi) Arrangement for washing / cleaning of windscreen to be provided

xii) Electric wiper motor (Heavy duty) will be provided with a long wiper blade to
cover full wind screen.
type. Coiled air hose of sufficient length shall be provided with ISO Palm
coupling and locking arrangement with auto brake interlock fail safe system at
low pressure.
2.2.5 The heavy duty nylon tyres of suitable size and “anti static“ type with resistance
of earth not less than 10,000 ohms unused and not more than 1X106 ohms
shall be provided. An additional spare tyre to be supplied along with the
chassis
2.2.7 The electrical system shall be of heavy duty preferably (110 Ah) battery of
12/24 V shall be provided. Electrical current is to be supplied by a heavy duty
alternator preferably (55 Amps). Power rating of Battery of 100 Ah is indicative
However vendor has to quote the rating based on their model
2.2.8 The electrical connection between tractor & trailer should be of 7 pin socket
type 24N and should meet relevant ISO standards.
2.2.9 All the electrical circuits should be protected with fuses and circuit breakers in
the feed of each circuit.
PTO and confirm acceptability of the propeller shaft layout and Pump mounting
on the chassis to our refueller fabricator. Following are the specifications of
PTO for selection for chassis supplier.

refueller.
d) The power take off should be able to deliver at least 60 HP or more @ 1800
RPM (approx) for continuous operation.
e) Pneumatically operated PTO switch should be provided in the driver cabin.

f) The PTO ratio should be more than 1:1. In case PTO ratio is not possible,
additional gearbox to be provided.
2.2.11 Front and rear directional signals, normal hazard rotating warning (flash light)
reverse light with audio alarm and break lighting are required.
control of engine throttle from Auxiliary panel installed outside(panel not in
scope of chassis supplier). Output control to remotely stop the engine is also to
be provided. The engine throttle output is required to control the ATF pump
2.2.14 Clutch operation should be easy to operate and the clutch should be single
plate dry friction type.
2.2.16 Chassis will go to the fabricator for the fabrication of the equipment and is likely
to take approx 6 month’s time and the free servicing will have to be done at the
fabricator’s works on request from our fabricator.
2.2.17 Chassis detailed drawing to be provided to fabricator on demand for installation

of refueling module efficiently.
Manual / CD along with spare parts catalogue / CD. Additional copy of manual
/ CD to be supplied to BPCL Aviation H.Q. – NOIDA.
2.2.19 The engine should be designed to meet Euro-III / Euro-IV Emission Norms
2.2.20 Vendor to comply with the requirements of CMVR/RTO/Statutory agencies. Any

limitation in getting registration in particular states shall be clearly brought out
in technical bid.
2.2.21 The exhaust pipe of the vehicle should be re-routed to the co-driver side of the
vehicle in the front of the cabin.
2.2.22 CCOE approved spark arrestor shall be provided. In case any exemption have
been granted on the chassis by a regulatory agency on meeting the safety

requirements, the exemption documents shall be enclosed along with the
technical bid & documentary evidence would be submitted at the time of
delivery of chassis.
2.2.23 Chassis shall be latest, commercially successful and spots services available
for such models. Model approval shall be furnished along with technical bid
and supplier to extend all necessary support to BPCL in registering the vehicle
at the offices mentioned in the document.

1
2
3
The chassis offered should be ensured for their registration in above mentioned
states. However in future, if BPCL wants to register these chassis in other
states, necessary documents shall be provided by the vendor at the time of
registration of vehicles, at no extra cost to BPCL.
The chassis shall be tractor trailor combination type with the following
requirements:
a) Drive - 4X2, Right Hand

b) Wheel Base - Should not be more than 3700 mm, Minimum wheel base
required is 3300 mm
c) Over all length - Should not be more than 7,000 mm, Minimum 5880 mm
d) 6 T on the front axle
e) 10.2 T on the rear axle of the chassis
f) 19 T on 2 axle running gear (R.G.) without the self weight of R.G.
g) Gross Combination Weight (GCW) 35,200 Kg (approx.), limited by chassis
manufacturer of GCW.
h) Engine HP : 175 HP @ 2400 rpm (approx)
Designed load on the front / rear axle to be indicated. Your technical approval
for maximum loading of these vehicles to be clearly mentioned under following
conditions.

2.2.25 Chassis will be subjected to a continuous loading i.e. the fuel in the storage
tank will be kept always full while in operations. It is therefore desirable to
have suspension system duly strengthened.
2.2.26 The chassis should have 150 ltrs or more capacity fuel tank and should be
mounted on left side of the chassis.
2.2.27 If chassis modification is necessary, it will be done by fabricator in consultation

with chassis supplier. All necessary assistance shall be extended to them
without any delay and hesitation and without any charges.

i. The tractor chassis should be full forward control type
ii. Cabin should be ergonomic tiltable/fixed type factory built cabin with
wiper etc..
iii. The chassis frame shall be heavy duty pressed channel section carbon
iv. Suitable towing arrangement shall be provided in front & rear of the
chassis.
v. Cabin should be designed with large size windows on all the sides i.e.
front, sides and rear for unobstructed visibility. The front windshield shall
be of large size of single piece design, door windows shall be of
sliding/winding type and rear window shall be full size fixed type (wind
screen type) with SS wire mesh required as per Petroleum Rules. Glass
of all the windows shall be of high quality toughened safety glass.
vi. Interior of the cabin should be designed for best comfort with molded
hood and other heat radiating equipment’s shall be insulated with
molded casing of ergonomic design. The floor area will be fully lined with
approved quality matting with padding etc.
vii. Driver seat shall be adjustable type cushioned seat with retractable
viii. Cabin should have comfortable foot step and handles located inside the
cabin on both sides of the door for easy entry. If any additional foot step
is required, same shall be fitted on BPCL instruction.

ix. In addition to normal panel / dashboard instruments, an engine
revolution counter, low air pressure indicator and engine hour meter are
required.
x. The chassis frame shall be LADDER TYPE HEAVY-DUTY FRAME with

RIVETTED / BOLTED CROSS MEMBERS.
xi. Arrangement for washing / cleaning of windscreen to be provided
xii. Electric wiper motor (Heavy duty) will be provided with a long wiper
blade to cover full wind screen.
ype. Coiled air hose of sufficient length shall be provided with ISO Palm
coupling and locking arrangement with auto brake interlock fail safe system at
low pressure.
2.3.5 The heavy duty nylon tyres of suitable size and “anti static“ type with
resistance of earth not less than 10,000 ohms unused and not more than
1X106 ohms shall be provided. An additional spare tyre to be supplied along
with the chassis.
2.3.7 The electrical system shall be of heavy duty preferably (110 Ah) battery of
12/24 V shall be provided. Electrical current is to be supplied by a heavy duty
alternator preferably (55 Amps). Power rating of Battery of 100Ah is indicative
.However vendor has to quote the rating based on their mode
2.3.8 The electrical connection between tractor & trailer should be of 7 pin socket
type 24N and should meet relevant ISO standards.
2.3.9 All the electrical circuits should be protected with fuses and circuit breakers in
the feed of each circuit.
PTO and confirm acceptability of the propeller shaft layout and Pump
mounting on the chassis to our refueller fabricator. Following are the
specifications of PTO for selection for chassis supplier.

refuller.
d) The power take off should be able to deliver at least 100 HP or more
@ 1800 RPM (approx) for continuous operation.
e) Pneumatically operated PTO switch should be provided in the driver
cabin.
f) The PTO ratio should be more than 1:1. In case PTO ratio is not
possible, additional gearbox to be provided.
2.3.11 Front and rear directional signals, normal hazard rotating warning (flash
light), reverse light with audio alarm and break lighting are required.
control of engine throttle from Auxiliary panel installed outside(panel not in
scope of chassis supplier). Output control to remotely stop the engine is also
to be provided. The engine throttle output is required to control the ATF pump
2.3.14 Clutch operation should be easy to operate and the clutch should be single
plate dry friction type.
2.3.16 Chassis will go to the fabricator for the fabrication of the equipment and is
likely to take approx 6 month’s time and the free servicing will have to be
done at the fabricator’s works on request from our fabricator.
2.3.17 Chassis detailed drawing to be provided to fabricator on demand for

installation of refueling module efficiently.
Manual / CD along with spare parts catalogue / CD. Additional copy of
manual / CD to be supplied to BPCL Aviation H.Q. – NOIDA.
2.3.19 The engine should be designed to meet Euro-III/ Euro- IV Emission Norms

2.3.20 Vendor to comply with the requirements of CMVR/RTO/Statutory agencies.
Any limitation in getting registration in particular states/ place shall be clearly
brought out in technical bid.
2.3.21 The exhaust pipe of the vehicle should be re-routed to the co-driver side of
the vehicle in the front of the cabin.
2.3.22 CCOE approved spark arrestor shall be provided. In case any exemption
have been granted on the chassis by a regulatory agency on meeting the
safety requirements, the exemption documents shall be enclosed along with
the technical bid & documentary evidence would be submitted at the time of
delivery of chassis.
2.3.23 Chassis shall be latest, commercially successful and spots services available
for such models. Model approval shall be furnished along with technical bid
and supplier to extend all necessary support to BPCL in registering the
vehicle at the offices mentioned in the document.

1
2
3
The chassis offered should be ensured for their registration in above

mentioned states. However in future, if BPCL wants to register these chassis
in other states, necessary documents shall be provided by the vendor at the
time of registration of vehicles, at no extra cost to BPCL.
Aircraft Refuelling module along with a MS cargo tank of 45000 lts. Capacity
along with module (not to be supplied by chassis vendor) will be mounted on
the chassis which will have following load distribution ( approx.) :
a) 6 T on the front axle

b) 19 T on the rear axle of the chassis
c) 36 T on 3 axle running gear (R.G.) without the self weight of R.G.
d) Engine HP : 200 HP or more @ 2700 rpm (min.)
e) Overall length : 6800mm (min.)
f) Wheel base : 3800mm (min.)

g) Technically chassis should be suitable for gross trail weight(GTW) of
61 tons.
h) Drive shall be 6x4
Designed load on the front / rear axle to be indicated. Your technical approval
for maximum loading of these vehicles to be clearly mentioned under above
conditions.
2.3.25 Chassis will be subjected to a continuous loading i.e. the fuel in the storage
tank will be kept always full while in operations. It is therefore desirable to have
suspension system duly strengthened.
2.3.26 The chassis should have 150 ltrs. to 180 ltrs. fuel tank and should be mounted
on left side of the chassis.
2.3.27 If chassis modification is necessary, it will be done by fabricator in consultation

with chassis supplier. All necessary assistance shall be extended to them
without any delay and hesitation and without any charges.
2.4 MODIFICATIONS BY THE REFUELLER FABRICATOR
Following modifications are normally required to be done by refueller fabricator.
2.4.1 Modification of drive shaft / flanges to suit the Gorman Rupp split shaft pump.
Part of this process requires that the intermediate bearing support be removed.
The pump itself then acts as this bearing and there is no need to reinstall the
original elsewhere.
2.4.2 Installing an automatic device to increase engine idling speed when pump drive
is selected. This reduces pump gearbox chatter.
2.4.3 Repositioning of the battery housing.
2.4.4 Possibly extending or reducing the chassis length.
2.4.5 Rear bumper with reflective stickers shall be provided to protect the tank and
piping in the event of rear end collision and minimize the possibility of
any part of colliding vehicle striking the tank.
2.4.6 Fire screen at the rear cab, to extend up to 300mm from ground level. Fire
screen will be made by sandwiching asbestos sheets between steel plates.

To allow the cabin to tilt forward, the fire screen is in two parts. One section
attaches to the back of the cabin extending almost the whole of its width, and
this overlaps, by 50 mm minimum, measured as a vertical dimension, another
attached to the chassis frame.
The gap between the two parts should be as small as practicable but in any
case not more than ¼ of the vertical overlap.
Additional screening should be attached to the front wheel mud flap or the side
of the chassis frame to screen the exhaust pipes, if necessary.
2.4.7 The chassis should be provided with window in the rear cabin wall. A metal grill
to be fitted to prevent the window falling out in case of fire / accident.
2.4.8 A system must be provided to stop engine from pumping. The engine shut off
knob should be of push / pull type and having sealing arrangement to be
provided on auxiliary panel.
2.4.9 A running gear is to be fitted of rating sufficient to pull a trailer of higher

capacity under airfield conditions.
2.4.10 Additional mudguards and mud flaps should be provided.
2.4.11 Additional wheel chokes should be provided (hard rubber chokes).
2.4.12 Specific orders may require an auxiliary/ external connection to be provided for
use with a separate / emergency battery pack.
2.5 ELECTRICAL REQUIREMENTS
2.5.1 The following requirements mention that electrical equipments should comply
with particular BS, EN, OISD and IS standards. There are many other
acceptable standards also available and wherever the practice for adopting the
same is common among fabricators, the same shall be used wherever
applicable.
2.5.2 The useful guidelines available in Petroleum Rule shall be followed in

connection with installation of electrical equipments, fittings and maintenance.
2.5.3 In addition to above guidelines the following OISD standards which are base
guidelines for oil industry to be followed wherever applicable.
a) OISD - 110 - Recommended Practices on Static Electricity

b) OISD - 137 - Inspection of Electrical Equipments

c) OISD - 147 - Inspection and Safe Practices During Electrical Installations
d) OISD - 148 - Inspection and Safe Practices During Overhauling Electrical
Equipment
e) OISD - 149 - Design Aspects For Safety in Electrical System
f) OISD - 148 - Recommended Practices for Transportation of Bulk
Petroleum Products
g) OISD - 167 - POL Tank Lorry Design & Safety
2.5.4 While certification / approval of any equipment by any statutory agency would
be useful, but that is not a specific or absolute requirement, any equipment
different than the standard can be shown to BPCL and prior written approval
shall be obtained for fitting it.
2.5.5 Such equipments would be acceptable provided the manufacturer can

demonstrate that all due notice has been taken of the principles set forth in
recognized standards and specifications.
2.6 MISCELLANEOUS REQUIREMENTS
2.6.1 A flame proof type lighting arrangement is to be provided on flow meter to read
meter register in night operations. This light can be controlled from refueller
cabin.
2.6.2 An adjustable flame proof type deck light is to be provided to illuminate the
aircraft panel. It should not be of such high intensity that it does not cause a
dazzling effect but of sufficient brightness to enable, by adjusting its position, to
give adequate illumination.
2.6.3 Aircraft obstruction / marker warning lights should be fitted, 2 at the front of the
cabin, 2 at the rear of the tank and additional 2 at the front of tank in higher
capacity refueller. A large flashing amber beacon light of speed 60 – 90 per
minutes should be provided in the front-centre of the cabin roof.
2.6.4 Flashing light should have following specifications.
a) Capacity – 5 W
b) Voltage – 12 V / 24 V
c) Diameter – 4”
d) Length – 10”
2.6.5 The entire electrical wiring shall be secured with clamps and arrange in stream
lined manner. Electrical cabling should be through suitable rubber conduits
only.

2.6.6 Electric wiring shall be numbered with unique numbers at both the end and
same numbers should be marked in electrical circuit diagram for easy
identification. Cable trays for electrical lines wherever possible shall be
provided.
2.6.7 Following electrical systems to be provided as safety feature for refueller.
2.6.2.1 An audio alarm is to be provided on chassis while reversing the

refueller.
2.6.2.2 Push button on higher capacity refueller rear for another operator to
give warning to the driver.
2.6.8 An electrical connection is required at the rear of the refueller for use with a
trailer. The electrical connection between tractor & trailer should be of 7 pin
socket type 24N and should meet relevant ISO standards.
Normally it is better if the chassis supplier installs such a connection, even if it

is different type, otherwise it should be in the scope of fabricator.
Any addition, if required should be via 7 pin socket type 24S and should meet
relevant ISO standards.
Electrical circuit diagram is given in Section 10.

Electrical wiring and connections should confirm to CCOE guidelines or IS
2465/95.
2.7 GENERAL DESIGN
2.7.1 The electrical system should be designed and installed to minimize the risk of
sparking and electrical fires. In particular the system should conform to the
following requirements:-
a) There should be electrical continuity between the chassis, the tank and
sub frame and all fuelling components. Electrical resistance should not
exceed 10 ohms.
b) The above does not apply to fuelling hoses or couplings which are covered
by provisions for conducting static electricity and are semi-conductive.
c) The storage tank of refueller should be bonded to the chassis by copper
jumpers.
2.7.2 Cable, cables joints and junction boxes shall be of approved make. Suitable
circuit breakers, fuses and isolators for DC motors, Dead man handle and lights
shall be provided for protection. It should ensure that the current is regulated
by means of relays beyond the cabin and all the junction boxes as far as

possible will be located inside the cabin so that the amperage conforms to the
intrinsically safe requirements.
2.7.2 The normal system voltage on the circuit should not exceed 12 / 24 volts.
2.7.3 Behind the rear of the cabin, all wire conductors should confirm to IS 2465/95
or equivalent to ensure that they are adequately insulated and are able to carry
more than the designed circuit current without causing an unsafe rise in wire
temperature.
2.7.4 The conductors should also be adequately fixed and protected so as to

minimize the risk of damage or deterioration.
a) The suitable rubber conduit should be resistant to degradation by UV light.

b) Where conduit is used for added protection and durability at a particular
location, it must be corrosion resistant.
c) The conduits will be of adequate size to accommodate number of wires
passing through it, without any damage to insulation.
d) Conduit must not be routed where it might provide a tempting hand hold or
be easily stood upon.
2.7.5 Battery compartment in cabin will be of safe and suitable design. It will be
fabricated out of SS Plates and lined with thick hard rubber. Battery terminal
should be protected by proper sized rubber caps.
2.7.6 No screw-in or cap less bulbs should be used.
2.7.7 An insulated double pole wiring must be used behind the cabin and should not
have more than 300 milliamps leakage between either polarity circuit or the
chassis.
2.7.8 A double master switch should be provided on the rear wall of the cabin and
should be easily approachable by driver to enable all electrical circuit to be
isolated. An indication to be provided near master switch when it is in the “ON”
position.
a) A suitable master switch, meeting CCOE requirement of LUCAS or

equivalent make to be provided.
b) Switching off of the main contacts is done in sequence to ensure that those
for the alternator field are broken before those for the battery.
2.8 CIRCUIT PROTECTION
The following steps should also be taken to ensure protection of electrical

circuits:-

2.8.1 All circuits, with the exception of the main battery supply and the starter and
generator circuits should be protected with fuses or circuit breakers in the feed
side of each circuit.
2.8.2 Exposed fuse wire or links should be avoided, but if used should be fitted within
a sealed unit.
2.8.3 The number of circuits connected to any single circuit protection device should
not exceed four and the rating of the device should be compatible with the
smallest conductor in any of these circuits.
2.8.4 The total current consumption of any circuit or group of circuits should not
exceed 80% of the rating of a fuse type circuit protection device. Thermal circuit
breakers can be safely designed to carry 100% of their rating continuously but
this rating should be limited to a level which gives a temperature rise within the
performance specification of the cable insulation.
2.8.5 Any fuse type circuit protection device should be so arranged that the failure of
a minor circuit should not render a major or obligatory circuit inoperative.
2.9 BRAKE INTERLOCKS – PNEUMATIC / ELECTRICAL REQUIREMENTS
2.9.1 The pneumatic system, is to be fitted with Auxiliary Air tank of 30 litres capacity
with drain cock, unloader valve and pressure gauge, Audco IN 123 valve,
direction control valves, copper tubing, hoses, pressure regulator gauges, air
purifier, air dryer etc.
2.9.2 A brake interlock system, with switches in series, is to be fitted, so that when
any of the fuelling couplings is not secured in the coupling housing or loading
hose is connected to the loading adaptor or the pump is engaged or a power
take off is engaged, then the refueller brake is applied on parking brake system.
2.9.3 With the split shaft pump specified in this document, selection of ‘pump drive’
means that ‘road drive’ is engaged, and a warning light and written message
should be displayed. It should not be possible to drive the refueller with the
PTO engage.
2.9.4 In the event that an interlock is inadvertently activated and the brakes applied
while the vehicle is moving, the application should be slow enough to bring the
vehicle to a controlled halt without endangering the driver or co-driver.
2.9.5 This specification does not require that the chassis rear brake warning lights be
illuminated when the interlock system is activated. These lights may be
activated:-

i) When the vehicle is moving and brakes are applied.
or
j) When the vehicle is moving e.g. mid ship type of transmission for the ATF
pump.
2.9.6 Whether the interlock switches are pneumatic or of electrical; reed switch /
magnetic proximity type, the system should be designed to exhaust air from the
refueller brake actuating pilot. Systems which require a positive air pressure
signal to cause the vehicle brakes to be applied should not be used.
2.9.7 The use of shuttle, check or non-return valves should be minimized.
2.9.8 All switches and related devices should be designed, arranged and protected to
withstand external fuel contact and environmental conditions – bright sunlight,
high and low humidity, dust, rain etc.
2.9.9 Whenever overwing delivery nozzle is fitted on reel hose, the brake interlock
system must be fitted.
2.9.10 A push-pull type brake interlock override master switch should be provided in
the cabin and on the control panel. This interlock override switch is to be clearly
marked and wire sealed in the position when it is non-operative.
The override switch system should be arranged to by-pass and isolate the
interlock switches (and in the case of electrical switches, the solenoid operated
pilot valve) and to apply directly to the pilot valve controlling air supply to the
chassis and trailer spring brake actuators.
2.9.11 Four large (50 mm dia.) warning lights, protruding 30 to 40 mm, should be
provided at prominent place (preferably on dash board) in the cabin with
shielding as necessary from bright sunlight and to avoid wind screen reflection
at night.
a) One flashing red, to indicate that the over ride system is in operation.
b) One flashing amber, to indicate if any interlock has been operated.
c) One flashing blue, to indicate PTO is engaged.
d) One flashing green, to indicate DMC is “ON”.
2.9.12 Two adjustable throttle actuators shall be mounted on the engine to

automatically select engine RPM at preset levels for high & low fueling rates

and de-fueling rates. Selected RPM setting shall be actuated by the deadman
control.
2.9.13 Signals for indicating the pump gearbox engagement position can be taken
from switches or sensors actuated by a device attached to the exposed selector
shaft – monitoring selection by the presence or absence of air pressure to the
gearbox is not sufficient to give clear indication of engagement / dis-
engagement.
2.9.13.1 Provision should be made for automatically operating both the chassis
and refueller braking system if an interlock on the trailer has been
actuated (e.g.: bottom loading coupling still connected).
2.9.13.2 Trailer brakes must not be able to act independently of the refueller
brakes except when the units are separated and air is exhausted for
parking purposes.
2.9.13.3 Unless otherwise specified, the arrangement would be such that a

positive air signal from the trailer would cause the refueller brakes to
be applied. In this case, absence of an air signal would allow the
refueller system to operate normally.
2.9.13.4 The trailer interlock connection on the refueller should be a ¼” BSP,

plugged bulkhead fitted located on the right hand side rear.
2.9.13.5 When specified, the refueller should be fitted with additional

connections (electric or pneumatic, in series or parallel, power on or
off) to suit trailers with particular types of interlock system.

SECTION – 03
FUNCTIONALITY
AND CONSTRUCTION
SECTION – 3 FUNCTIONALITY AND CONSTRUCTION OF
15KL, 25KL & 45KL AVIATION MODULE
3.1 TANK FITTINGS
3.2 REFUELLING MODULE
3.3 WEB CAMERA AND MONITOR
3.4 PNEUMATIC SYSTEM
3.5 ELETRICAL SYSTEM AND CONTROLS
3.6 PROTECTIVE AND SAFETY DEVICES
FUNCTIONALITY AND CONSTRUCTION ISSUE: 02 DATE: 01.10.2013

TECHNICAL SPECIFICATIONS FOR 15 KL REFUELLER
3.1 TANK FITTINGS
3.1.1 The tank shall be designed and fabricated in accordance with the latest Petroleum
Rules for transporting aviation turbine fuel. Actual detailed fabrication drawing is to
be prepared by the vendor and will have to be approved by BPCL before
commencing fabrication.
3.1.2 The design of the refueller to meet the following flow rates:
No. of Hoses Size of Hose 15 kl

(Dia x L)
1 Deck Hose 2 ” x 12’ 800 lpm
2 Reel Hoses 2” x 60’ 1200 lpm
1 Reel Hose 2” x 60’ 800 lpm
Typical design of 15KL Refueller:

3.1.3 Fabrication of tank should meet the following specification:
Material for shell / dish ends : Mild steel IS 5986 Fe Grade 410
Yield Strength : 23.5 KG/SQ.MM (Minimum)
UTS : 36.0 KG/SQ.MM (Minimum)
Minimum Elongation : 21%
Impact Strength : 40 Joules at 40 Deg C
Bend Test : 3 times the thickness

(Mandrel Dia)
Thickness : 3.5 mm
Z channel : IS 2062
Product Capacity : 15,000 Ltrs. net for 15 KL Ref
Vapour Space : 5% of Tank Volume (min)
No. of baffles : 2 for 15 KL Refueller (Minimum)
No. of compartments : 3 for 15 KL Refueller (Minimum)
No. of Manholes : 3 for 15 KL refueller (Minimum)
No. of Manholes with all : 2 Nos. Emco Std., balance 1No. Fixed,
Standard fittings on each for 15 KL Refueller
Pressure/Vacuum valve : 3 for 15 KL refueller (Minimum)

Pr. 0.14 kg/cm2 setting Vac.25 mm
gauge
Tank Outlet : 100 mm (1 No.)

Tank drain : 25 mm
Circulation Point : 100 mm (2 Nos.)
Sampling Point : 25 mm
Pipe line : ANSI 304, Schedule 10

(all SS pipe lines in use should be kept to
glossy finish through buffing)
Plate flanges : AISI B.16.5, class 150
3.1.4 DIMENSIONS
Capacity: 15 KL
Width : Should not be more than width of the cabin. Also

no Fittings should protrude outside cab width.
Height of completed : Chassis cab height 2743 mm (108”) maximum

Vehicle with dead stock Fueller tank height 2667mm (105”) maximum
Length : 10,100 mm(400’’) maximum, including drawbar

Coupling.
Notes:-
♦ The heights specified above for refuellers are based on Road Transport
Department permissible limit & IATA recommendations for minimum
clearance of 250 mm between the vehicle and potential collision points
under the aircraft wing. The minimum would apply when the aircraft is fully
loaded to the maximum permitted weight including a full fuel load, at critical
centre of gravity, with tyres and oleos in the normal serviced conditions, and
the refueller empty except for dead stock.
♦ The length is based on our past experience of accommodating the various

components in the refueller with a reasonable clearance to carry out the
maintenance. Other aspects relate to weight distribution, maneuverability,
space requirements when towing a trailer will also be considered by the
fabricator. Distance between the rear wheels and drawbar coupling is also
important since if excessive, there is a detrimental effect on trailer stability,
towing characteristics and follow pattern.

3.1.5 Tank will be made of mild steel of approved make as per following
specifications :
a. It will be structurally strong and designed to carry ATF of 15000 Ltrs on a

moving chassis to withstand all the stresses generated by the swaying
product and thermal expansion. Complete tank trailer to be designed for 3g
forces. Tank will be fabricated with all the necessary standard fittings
specified above.
b. Tank dimensions should be such that stability ratio is not more than 0.9
and does not violate RTO regulations.
c. Emco type manholes with GI dome covers painted internally and the safe
dip height shall be painted inside the dome cover. The provision for easily
opening and closing of dome cover shall be provided. Each will have a 25
mm PV relief valve suitable for fueling / defuelling rates 1800/800 LPM.
Each will also have a fusible plug of 50 mm size with melting temperature of
93 degree C, design approved by CCOE.
Typical Emco type manhole cover:
d. End baffle plates will be dished type end of suitable curvature. Each baffle will
have at least an area as great as 80% of the cross-sectional area of tank. Baffle
plates should be affixed to the tank shell by welding 3 mm thick M.S.angles

curved. These reinforcements shall be circumferentially welded to shell tank
completely all round. Baffle plates will have openings of adequate size at top
middle and bottom for interconnecting all the compartments. Each opening in
baffle plate will be adequately strengthened.
e. No tack welding will be done inside tank in any manner and no gaps left inside
tank that cannot be sand blasted / epicoated. All welding inside/outside tank will
be ground smooth prior to sand blasting / painting.
f. Tank will have following connections:
i. Tank outlets 100 mm dia.

ii. Tank drains 25 mm dia.
iii. Tank circulation point to suit 100 mm pipe.
iv. Tank sampling connection of 25 mm.
v. one no. inlet / outlet for 1 No. deck hose at suitable location.
vi. One No. 100 mm circulation point for deck hoses on top.
vii. One No. ¾ " (20 mm) opening for return ATF line from Air eliminator of
filter
viii. 10” Dial type content gauge.
3.1.6 The welding of any appurtenances to a shell or head must be made by attachment
to a mounting pad. The thickness of a mounting pad must not be less than that of
shell or head to which it is attached. A pad must extend at least 50 mm in each
direction from any point of attachment of an appurtenance. Pad must have
rounded corners or otherwise be shaped in a manner precludes stress
concentrations on shell / head. The mounting pad must be attached by
continuous weld around pad and riser ring will be welded onto all the openings
at bottom surface which come in the path of water drain. The size and locations
or rings will be indicated in drawing of tank submitted with Technical bid.
3.1.7 Bottom loading shall be via the tank internal valve. Two ground half shall be
provided, one on each side of the unit. They shall be connected together via a 3
inch cross manifold which connects into the internal valve. A pressure gauge shall
be installed downstream of each adapter to read bottom load manifold pressure
should be provided with butterfly type isolation valve & a non return valve.
3.1.8 Tank outlet i.e. connection to pump suction will have 100 mm dia emergency
bottom valve. A shear section located outboard of each emergency valve seat &
within 100 mm of the vessel to be provided. The shear section shall be
mechanical in such a manner as to abruptly reduce wall thickness of the adjacent
pipe (or valve) material by at least 20%.

3.1.9 The tank should be provided with a dial type float operated level indicator of
10“diameter. The gauge should be recess fitted in the tank.
Typical tank content Gauge:
3.1.10 A pre -check valve shall be provided adjacent to each bottom load adapter and
shall act to bleed product from the bottom load manifold to fill a can around the
jet sensor and simulate a full tank. The tank can be drained at a controlled rate
via tubing to the tank bottom to avoid splashing.
3.1.11 A continuous MS section channel will be welded underneath the tank on all along
the length of tank pad plate of 6 mm thick and adequate width. No. of joints in `Z'
channel will be minimum and these joints will be strengthened by welding 6 mm
thick patch plate complying to IS: 2062.
3.1.12 Pneumatically operated emergency valves 4" size with fusible link will also be
provided on Gauge panel.
3.1.13 A pneumatically operated collapsible railing shall be provided on the top of the
storage tank of the refueller on both the sides. 2 nos. of pneumatically operated
cylinders with all accessories and safety arrangements shall be provided with
operating switch close to the lowest point of the ladder for opening / closing of
hand railing.
3.1.14 Ladder with hand rail and additional steps from bumper to ground for comfortable
climbing deck platform will be provided. Ladder will be fabricated of M.S. flat /
angles and duly painted.

3.1.15 An electro pneumatic interlocking with the brakes when the hand rails are in
open position shall be provided at the entry of the ladder to restrict movement of
the refueller.
3.1.16 The hand rail and bottom step of the ladder will extend sufficiently above and
below the tank to provide good support for mounting & leaving the tank.
Typical collapsible railing arrangement:
3.1.12 Deck platform of heavy duty Aluminum grating shall be provided across full width
of the tank and length of deck hose. Suitable opening for manholes covers, deck
pipes & circulation pipes will be provided in the platform.
3.1.13 One no of additional aluminum ladder of 6ft. height suitable for refueling of A320
aircrafts shall be supplied along with the Refueller. There should be provision of
keeping ladder with sliding arrangement on the rear of the Refueller.
3.1.14 One air operated vent of suitable size with a fabricated rain hood should be
installed adjacent to the centre man way and operate in conjunction with the
internal valve during fueling, defueling and bottom loading. Venting capacity must
be at least 150% of the maximum fueling rate.
3.1.15 One internal valve of suitable capacity should be installed centrally on the tank
bottom centre line & discharge directly to the pump suction / bottom load
manifold. A 1” high wire shall be installed around the valve to break suction when
1” of the product remains in the tank. A vortex breaker / anti splash plate shall be
installed above the internal valve.

3.1.16 One No. dip assembly with hatch and 19 mm square rod graduated in cm & mm
will be provided - with ring on top.
3.1.17 The tank should be calibrated & a Aluminum metric dip stick on platform with
locking arrangement would be provided. The dip hatch should be provided with a
4” SS pipe ending 35 mm from the bottom of the tank. A calibration certificate to
be provided with each refueller at the time of delivery.
3.1.18 Provision for safe keeping of dip rod with locking arrangement shall be made at
suitable location on the tank top.
3.1.19 Rear bumper will be provided to protect the tank and piping in the event of
rear end collision and minimize the possibility of any part of colliding vehicle
striking the tank. The bumper shall be located at least 150 mm to rear of
refueller component. Structurally the bumper shall be designed to successfully
absorb (No damage which will cause leakage of product) the impact of the
vehicle with rated payload, with deceleration of 2 g using a factor of safety of
two based on UTS of bumper material.
3.1.20 Tower with locking arrangement of suitable strength shall be provided on the
front & rear bumper.
3.1.21 Deck hose circulation points should be located suitably away from the swivel
joint so as to avoid kink in hose while circulation test. Height of deck hose
circulation point should be as low as possible.
3.1.22 All sample points should be covered with canopy arrangement (covering of top &
four sides) to draw samples easily during heavy rains on refueling operations.
3.1.23 DETAILS OF SLOP TANK - The detail of slop tank is as follows:
Capacity : 100 Lts
Material : SS
Thickness : 10 G

Typical slop tank with float operated overfilling arrangement:
3.1.24 The slop tank should be constructed of SS with a heavy duty large size funnel, a
250 mm (minimum) hinge type lockable cap and having 60 mesh gauze filter with
sufficient support. The tank is to be totally weather proof and sealed against
ingress of contaminants. The tank is to be given a 20-mm drain with a spring
loaded ball valve in line. The slop tank shall have the following additional fittings:
a. Inspection window of toughened glass sealed with ‘O’ ring.

b. A float operated limit switch to provide signal for overfilling.
c. An audio alarm along with light indication on Auxiliary panel shall be
provided in the slop tank when the level of product reaches 75% of the
capacity.
d. A free vent with an inverted “U” opening to prevent ingress of water.
e. A 10’’ flanged type manhole cover with a neoprene gasket.
An alarm should be raised as soon as the level in the slop tank reaches 75
% of the capacity.

3.1.25 Tamper proof covers or locking devices are required on the following controls to
prevent inadvertent alteration:-
a. Air Pressure regulator

b. Master override switch (in cabin)
c. Interlock override switch
d. DMC override switch
Typical DMC with flexible cable:
3.2.1 All necessary equipment required to complete refueling module will be supplied
by the bidder.
3.2.2 Each module of 15 KL will consist of following components:
a. 100 mm bottom valve fitted with fusible plugs.
b. 100 mm slim seal butterfly valve.
c. 3”x 3" centrifugal pump with gear box.
d. 50 mm ATF pump by-pass valve.
e. 80 mm SS Swivel joints (self-lubricating type) – 1 no. for deck.

f. 80mm Pressure Control valve.
g. 75mm high performance ball valve.
h. 50 mm Aluminium swing check valve.
i. Catherine wheel type motorized hose reel with swivel suitable for 2" x 60' long
hose. All moving parts to be provided with safety guards.
j. Hoses should conform to specification ISO 1825: 2010 Third edition, Type-C.
End fittings of SPANNLOC coupling fittings both ends (As per ISO 1825:2010
stds), male to male NPT thread.
Reel hoses (2 nos.) – 2.0” dia ID and 60’ length.
Deck hose (1 no.) – 2.0” dia ID and 12’ length.
k. Hose reel should be provided with flame proof / CCOE approved rewinding
motor.
l. Power of winding / unwinding of reel hose drum with speed control is to be

derived from DC motor actuated by 24V / 12V battery of the vehicle.
m. Hose rewinding motor specification:
Capacity : 0.5 HP
Voltage : 12 V / 24 V DC
Current : 53 amps
Type : Class B
RPM : 650 Heavy Duty
Max. winding speed : 0.72 m/second ( DC motor is fixed and
variations in speed to be achieved thru
gear/chain mechanism)
n. 2.5" under wing pressure coupling.
o. 2 ½" 3-lug adaptors
p. 25mm spring loaded valve
q. Integral type cable operated drain valve and sampling valve
r. 100mm pneumatically operated emergency valve

Typical Catherine wheel type reel hose drum:
3.2.3 In defueling of 15 kl refueller, the refueller pump is used to create suction up to the
delivery couplings with FDF valve in defueling mode. The defueled product passes
through the refueller pump via delivery couplings, flow meter, fuel monitor and FDF
valve. The delivery of defueled product from the pump outlet is again through FDF
valve and Jet sensor to the tank.
3.2.4 Bidder shall supply 100mm size bottom loading internal valve, jet level sensor with
pre-check testing arrangement. Water preventing ring 12 mm wide will be provided
around this valve.
3.2.5 The product entering the tank goes through the bottom loading system and hence
is subjected to the high level shut off control system.
3.2.6 Bidder shall arrange to supply & install ATF pump. The ATF pump assembly will
be mounted on framework with sufficient padding to minimize vibrations.
3.2.7 The product pump should be of self – priming centrifugal type, mounted rigidly and
PTO driven. PTO shall be provided with suitable Chassis & with suitable running
gear.

Typical product pump of Gorman rupp make:
Make : Gorman Rupp
Model : 03H1-GR
Short Description : Suitable for operation through power take off.

To supply aviation fuel at required pressure &
flow rate.
3.2.8 A pressure limiting pump by- pass valve ( size 2 “ ) shall be installed to limit pump
output pressure in a range 75 psi to 150 psi, the valve shall also function as an
on/off valve actuated by an air reference signal from the dead man control.
3.2.9 Material of construction for pump by-pass valve would be as per the following:
a) Body / Cover ASTM A216/A216M-04
b) All trim materials ASTM A351/A351M-06
c) Elastomers BUNA N
d) Ò' Rings BUNA N
e) Internals AISI 316
f) Nuts/Studs ASTM A193

3.2.10 Above by-pass valve will be installed as per manufacturers’ recommendation,
preferably in horizontal position. The pilot shall be located at convenient
place for easy access. Bidder will arrange to set the valve as per BPCL
requirement.
3.2.11 The design of the system ensures that when fuelling, product cannot by-pass the
filter or be circulated or returned to storage from downstream of the meter.
Interlocked systems which are intended to achieve this are not acceptable i.e. the
meter must be downstream of all other branches connected back to the tank or
pump inlet.
3.2.12 400 US GPM capacity fuel monitor with air eliminator, of S S construction fitted
with SS check valves in division plates with air eliminator will be used. The
monitor will be of size 2”x25 or 2”x30”. 2 Nos. 19 mm spring loaded valves with
SS elbow will be fitted for drain and 19 mm sampling lines in such a way that
access becomes easy. Each valve will SS braided cable with polyethylene cover
fitted with crocodile clip. Sampling lines shall end in elbow, and fitted with
Camlock type SS cap & chain. Tank bottom sample point should be covered
with four sides with canopy arrangement to draw samples easily during heavy
rains on refueling operations.
Typical Filter Monitor:

3.2.13 The following instruments and controls are required and are to be neatly located
at the pumping control station. A typical panel layout is shown as Fig.
A. Main Gauge Panel
♦ Pump speed control / throttle (on auxiliary panel). A movement limit stop
should be fitted and adjusted to prevent over speeding the pump.
♦ Pump RPM indicator shall be provided on auxiliary panel. On a mechanical

indicator, a red line is to be marked on the gauge face showing the
maximum speed recommended for pump operation. In case of an electronic
indicator, a sticker reading the maximum recommended pump RPM should
be affixed on or near indicator.
♦ Pump discharge pressure gauge (SS body), 63mm, glycerin damped,

Maximum range should be approx. 0 to 150 psi with LC of 2 psi.
♦ Filter monitor differential pressure gauge, direct reading piston type 0-30
psi, with low pressure side drain test and isolating valves. Also see item
3.5.9 concerning tubing and fittings.
♦ Fuel sense point pressure gauge (SS body), 63 mm, glycerin damped, for
the secondary pressure control. The range should be 0 to 150 psi with LC
of 2 psi.
♦ Air reference pressure gauge for the SPCV, 63 mm, range 0 to 150 psi with
LC of 2 psi.
♦ Quick disconnect fittings (male halves) with isolating valves to permit the
pump pressure, PCV reference pressure, compensator pressure RHS &
LHS, and air pressure gauges to be tested in situ.
♦ Air pressure regulator (on or easily accessible just behind the panel) for
setting the secondary pressure control valve. The regulator must be stable
and of the self relieving, rapid response type with capacity of 15 bar.
♦ Depressurizing control
♦ Fuel / defuel selector level control (or adjacent push / pull type with
indicator)
♦ Outlet / foot valve control

B. Auxiliary Panel
♦ Engine Stop
♦ Deadman Light
♦ Deadman Override Light
♦ PTO Light
♦ Hand Brake Light
♦ High Level Light (Slop Tank)
♦ Deadman Override Switch
♦ Fuel Defuel Push Button
♦ Millipore Point
♦ Air Adapter Point
Typical Main Gauge panel arrangement:

3.2.14 The ¾ " return line from air eliminator will be of SS and will have visi-flow gauge,
swing check valve.
3.2.15 ¾ ” x 1” pressure relief valve set at 150 psi of approved make will be supplied
and installed on filter monitor. The discharge of PRV will be connected to return
line of air eliminator of filter monitor.
3.2.16 The filter monitor shall be rated at 110% of design flow rate & meet the
performance requirements of the API / IP 1583 code (latest edition) for fuel
monitor. The vessel shall be of stainless steel. The vessel shall be configured for
and supplied with elements of size 2”x25” or 2”x30” only. One set of new filter
elements to be provided with filter monitor and in addition the successful bidder
shall supply one set of spare new filter elements in a properly sealed box &
should be delivered along with the refueller. (Total 2 sets of filter elements ).
Butterfly valve on inlet and outlet of the filter vessel shall be provided.
3.2.17 Filter monitor sample points are to be clearly marked – Filter inlet, filter outlet &
filter drain. A label stating size and no. of fuel monitors to be fixed using
engraved laminated SS plate.
3.2.18 The filter vessel shall be fitted with an automatic air eliminator. The air eliminator
discharge line shall be connected to the main tank via a “visi-flow” indicator and a
wire – sealed open ball valve located at the tank. Discharge pipe shall be
nominally ¾ “ diameter. Drain points shall be provided for the clean and dirty
sample of the filter vessel to facilitate emptying it and for taking fuel samples. The
sample points should be provided with spring loaded normally closed ball valves.
Typical Visi-flow, Air eliminator & pressure relief valve arrangement on Filter vessel
Visi- flow
Air eliminator Pressure relief

3.2.19 Millipore points at the inlet and at the outlet of the filter should be provided by use
of proper sampling probes. The probes should have provision for sampling as
well as tapping off pressure for differential pressure gauge. A quick coupler of
male adapter along with aluminum cap attached with chain should be provided
on auxiliary panel.
3.2.20 A direct reading piston – type gauge with auto check push button to be provided
to check its performance, shall be installed with panel to measure the differential
pressure across the filter vessel.
3.2.21 A proper spring loaded normally closed pressure release valve should be
installed on the filter vessel.
3.2.22 Bidder shall install 80mm size Pressure Control valve with air bias, air set pilot
control and dead man control will be installed as per manufacturer's
instructions. The SS fuel sensing line from venturi will be connected to the pilot
of the PCV and pressure gauge on panel. The opening/closing time of PCV will
be adjusted to BPCL’s requirement.
3.2.23 Primary pressure control (HECV) shall be set to control the down stream
pressure at 45 psi.
3.2.24 In Line Pressure Control Valve (ILPCV) shall be capable of regulating the
downstream pressured at the aircraft coupling to 55 ± 2 psi. Regulating pressure
as measured above shall be adjustable with in the range 45 to 75 psi by
application of an air reference signal. The operating time of the valve by dead
man control shall be adjustable within the range of 5 to 10 seconds and closing
time adjustable within the range 2 to 5 seconds.
Typical Pressure control valve of Whittaker make:
3” flanged type inlet & outlet. Make – Whittaker, Model – F376

3.2.25 Opening time shall be measured from dead man actuation until maximum flow is
obtained. Closing time shall be measured from the time of dead man deactivation
until flow completely ceases.
3.2.26 Flow / pressure compensation to the ILPCV by means of a venturi device

(Compensator) shall be capable of providing between 15 & 35 psi compensation
in order to maintain a flow rate of between 70% & 100 % of maximum flow. The
venturi (Compensator) shall be used to stimulate nozzle pressure for the purpose
of pressure control feed back to the ILPCV.
3.2.27 3" X 2” fuel-defuel valve will be installed preferably in vertical place. Pneumatic
system will be provided for operation at a convenient place near panel with Fuel /
Defuelling indication.
Typical Fuel/Defuel Valve:
Fuel/Defuel Valve 3” x 2”, Make-Gorman Rupp, Model - 9119
3.2.28 A push pulls fuel/ defuel knob with sealing arrangement to be provided on
auxiliary panel.
3.2.29 Bulk meters with mechanical counter, fitted with suitable pulsar & reset switch
shall be installed as per recommendations of bulkmeters manufacturer. One
4" butterfly valve shall be installed on outlet, for the bulkmeters supplied without
faucet valve.

3.2.30 The bulk meter should be approved by the Legal Metrology dept. and approval
copy is to be provided to location for stamping purpose after delivery. The
supplied bulk meter should be of latest model and the bulk supplier should have
wide sales & services network across India.
3.2.31 The vehicle should be provided with a one positive displacement meter of
adequate capacity.
The details of the meter are as under:
a. Application: Delivery to Aircraft

b. Product to be measured: Aviation Turbine Fuel
c. Specific Gravity: 0.775 to 0.830
d. Operating Pressure: 150 psi
e. Measurement units: Litres
f. Flow Direction: Bi- directional
g. Connections: Flanged ends
Typical Flow meter of LC make, Model M-30-A-2:
3.2.32 The specification of Pulsar & Reset Switch to be fitted on bulk meter as under:
Pulsars: Make Veeder-Root, Series 7671

PART NO. 767163—303
• Diameter of the pulsar outer body – 3.565 #

• Total diameter including cap – 4.00 #

• Width of the pulsar body – 2.25 #
• Shaft dia. 0.250 #
• Shaft length – 16.5 mm
• Length between center of pulsar body & gland end point – 2.72 #
• Pulsar installation kit for 7887 meter register
TECHNICAL
Technical Description Dimensions

a) Input Supply 10 # 15 VDC
b) Current 50 mA at max 10 - 15 VDC
c) Switching Times
• Rise Time 2 micro seconds max with 10 mA resistive load to ground
• Fall Time 4 micro seconds max
d) Rotation Bidirectional
e) Input Shaft Speed 600 rpm max
f) Output Pulse Dual channel at 50 ppr
g) Operating Temperature: 42°C to 82°C
h) Storage Temperature: 55°C to 125°C
i) Housing Explosion Proof
j) Mounting Three ¼ - 20 UNC # 2B blind tapped holes, spaced 120° apart on
a 2.5# diameter bolt circle
k) Cable Gland BASEEFA (UK) or equivalent approved with Group IIA, IIB or
IIC enclosures
l) Cable Type 2, 3, 4, 5 or 6 core tinned copper conductors with metallic
screen
m) Cable Length 10 # 15 meters
n) Approval BASEEFA (UK) or equivalent
RE-SET SWITCH AND RESET SWITCH BRACKET
Make: STAHL (Germany)

Model: 8064/21
Physical Description Dimensions

a) AC Current 11 # 2.5 amp
b) AC voltage 400 V
c) DC Current 11 # 6 amps
d) DC Voltage 250 V
e) Compliance IP # 66
Description:
a) 8064 with flexible lead, single micro switch, with snap action contact,
plunger with plastic roller. 1 c/o contact with 3 core cable, 3 mtrs. in length.
b) Mounting bracket to mount reset switch.

3.2.33 In case fabricator is not in position to supply pulsars & reset switch as per above
specification along with mechanical meter, they will be required to purchase the
same from BPCL’s authorized suppler and the same would be fitted with his help.
In this case model approval for bulk meter along with pulsars & reset switch is
with the fabricator before dispatch of refueller.
3.2.34 Suitable compensator, separate for reel hoses & deck hose shall be installed
with needle valves, pressure gauges, shuttle check valve etc.
3.2.35 3" aluminum wafer type swing check valve will be supplied on defuelling line and
4” size on the self loading point.
3.2.36 100 mm size pneumatically operated emergency valve with fusible link approved
by CCOE will be provided at tank discharge line.
3.2.37 The loading / circulation point will have 2 Nos. 2½" ground half unit adaptors
with 2 Nos. 3” butterfly valves. One No. 3" butterfly valve and ground half unit
will be provided for self loading point. All the 2½” adaptors should have :
Lugs 6.147 - 6.274 mm thick

Slots 6.35 - 6.604 mm wide with 0.992 mm chamfer.
Typical loading / circulation point with interlock arrangement:
3.2.38 Similarly 1 no. ground half unit will be supplied and installed for deck hose
circulation with a butterfly valve for HEPC testing.
3.2.39 2.5 " Reel hose Catherene type with swivel suitable for 2" x 60 ft long Aviation
hose will be installed with manual rewind & DC motor rewind mechanism and

HEPCV testing arrangement . The hose should have protection beads every 2
feet upto 20 ft to avoid abrasion. End fitting with easy locking nut adaptor to be
provided on reel & Deck hoses for easy unlocking of hose for pressure testing,
also yellow color band at end of reel & deck hoses should be provided.
3.2.40 The deck hoses shall be connected to the piping through proper swivels and
isolation valves.
Typical deck hose arrangement with ground half couplings:
3.2.41 SS material of > 300 psi rating swivel joint shall be used on deck hose to carry
out IN – SITU hose testing.
3.2.42 Complete pipeline shall be of SS 304 ERW Schd.10. And the flanges and other
pipeline fitting will be as per ANSI B of 150 class. Pipe layout should be neat and
clean. Fabricated bends should not be used as far as possible.
3.2.43 Provision for IN – SITU hose testing arrangement along with 5 mts. long
additional rubber pipe with SS quick connector to be provided.
3.2.44 Victaulic joints will be restricted only to the components, which cannot be
connected with flange or only with OEM recommendation, otherwise at all other
pipeline connection only , flange joints to be used.
3.2.45 Complete pipeline with fittings will be tested to 300 psi and witnessed by BPCL
representative / third party representative. Material test certificate for pipeline
and fittings will be submitted.
3.2.46 All the flanged joints will be provided with copper strip jumper of 25 mm
wide x 0.93 mm thick. These jumpers should not be coated with the paints.
The pipeline and components will be adequately supported.

3.2.47 The Xomox Sanmar make high performance ball valve shall be used as per
following specifications :
Body : ASTM A 351 CF8
Seating : ST1 (PTFE)
Disk : ASTM A 351 CF8
Shaft : ASTM A 351 CF8
Lever : Operator type HPBV Handle
Drilling / Ends : ANSI 300 WAFER
Pressure Class : 300 psi
Valve Type : 803
3.2.48 The Audco make ball valve shall be used as per following specifications.
Class : 150
Body : Stainless Steel
Body connector : Stainless Steel
Ball : AISI 316
Seat : PTFE
Stem : AISI 316
Ends : Screwed BSP or as required.
3.2.49 All the ATF sensing line for venturis, PCV, FM, PD gauges shall be of
SS with SS connectors
3.2.50 Provision to be made for fitting online sampler in future.
3.2.51 All pressure gauge will have 3/8" double shut off unthreaded quick
coupling as per following specifications:
Valving type : Double shut off

Metal : SS 304
Seals : Resilient BUNA N
End fittings : To suit adaptor
Operating pressure : 150 psi
Least Count : 2 psi
Range : 0 – 150 psi
3.2.52 All pressure gauges to have IN – SITU testing arrangement on gauge panel.

3.2.53 Vendor will install male quick coupling onto panel. Party will make necessary
connection in the sensing line to enable testing of gauges with respect to a
gauge comparator.
3.2.54 The module frame will have a minimum road clearance of 300mm, when loaded,
between the ground and vulnerable fittings such as sample point and drain line
outlets. This distance allows easy access for a bucket, sample jar or small bore
hose connection. However, sample points should not be too high off the ground
to prevent splashing and spillage. Tank bottom sample point should be covered
with canopy arrangement (covering of top & four sides) to draw samples easily
during heavy rains on refueling operations.
3.2.55 A SS engraved plate for fuelling circuit and operating instruction to be provided
on the gauge panel.
3.2.56 An instruction plate should be attached near the pump selector / gear lever or on
the dashboard giving clear instructions for :-
♦ Minimum air pressure requirement

♦ Disengaging road drive /engaging pump drive / gear selection
♦ Disengaging pump drive / engaging road drive
♦ Waiting times to avoid gear baulking
♦ Which gear to engage (normally the highest numbered gear 6 or 7 / ration
1:1)
3.2.57 Labels for tyre inflation pressure should be affixed to the wheel arches /
mudguards.
3.2.58 The quantity of product in the sampling pipe line should be mentioned near the
sampling point with the following instruction.
“Drain line qty._______ lts. before taking the sample”.
3.2.59 Any recess on top of the tank which could collect rain water should be provided
with a braided drain tube of minimum dia 25 mm in the front and rear.
3.2.60 SAMPLE BOX: Sampling box (L – 25”, B – 16.5”, D – 16”) with compartments,
fabricated out of stainless steel of suitable size, to accommodate various
quality control equipment and soak-mat will be provided at rear side of refueller.
The exact location and size will be approved by BPCL.
3.2.61 QC Kit Box: One QC kit box of SS (of size 380mm X 240mm X 160mm) should
also be provided by the bidder. Drawing enclosed.

3.3 WEB CAMERA:
3.3.1 Features of Rearview Camera (reversing operations)
High Resolution Digital Image Sensor, Waterproof Module, Superior low light
Performance, Super wide view angle, IP66 Grade
Specification:
Signal System :PAL/NTSC
Image Device : 1/3.7” High resolution digital
image sensor
Effective pixel : 648(H) x 488(V)
Horizontal Resolution : 520 TVL
Lens Furnished : 1.7 mm in Built, Optional: 2.8mm,
3.6 mm
Shutter Speed : 1/50~1/100,000 Sec
Min Illumination : 0.5 Lux / F1.2,
White Balance/ Back Light Compensation : Yes
Exposure Control/AGC/ Color Correction : Auto
Synchronization: Internal synchronization
Video Output Signal: 1V p-p Composite video
Operating Temp: 0°C ~ 50°C , Humidity 85% or less (non-condensing)
Power:
Power Supply: DC 12V ±10%
Current Drawn: 5W (max)
3.3.2 Features of outdoor Camera (fuelling operations)
1/3” Sony Super HAD-II CCD, Superior Low Light Performance, Waterproof,
Automatic White Balance, IP66 Grade
Specification:
Image Device: 1/3” Sony Super HAD-II CCD
Camera Pixels: PAL: 500(H) x 582(V) ; NTSC: 510(H) x 494(V)
Resolution: 480 TVL
Min Illumination: 0.05 Lux / F2.0
Electronic Shutter: NTSC: 1/60~1/10,000 PAL: 1/50~1/10,000
IR: 24 IR LED, Ø5 mm, 850nm, IR distance- 20 Mtr.
White Balance: Auto Tracking White Balance
Backlight Compensation/ Gain Control: Auto
Lens Furnished: Built in: 3.6mm , optional: 2.8mm/6mm/8mm
Video Output: 1V p-p Composite, 75 Ω
Operating Temperature: 0°C to +50

Power:
Operating Voltage: DC 12V ±10%
Power Consumption: 5W (max)
3.3.3 HI-Tech Desktop switcher IDT:
Features of Camera selection switcher

Full Function Remote Control, Random Camera Selection through Numeric Keys
on the Remote Handset, Individual Dwell Time Setting for each Camera from 01 to
99 Seconds in AUTO Mode, Changeover from AUTO to MANUAL or Vice-versa
through Single Key, Memory Retention in case of Power failure
Specification:
Particulars : Video with 2Way Audio
Camera Inputs (n) : Min two
Display : Min two
Camera Input : 5 Pin Din
Monitor Output : RCA
Video Input : 1 V p-p Composite, 75 Ω
Video Output : 1 V p-p Comp., 75 Ω
Audio Output : 2 V p-p, 50 Ω
Operating Temperature : 0°C to 50°C
Power:
Operating Voltage : DC 12V ±10%
Current Drawn 1Amp (4 Channel)
3.3.4 7” LCD Monitor
Features
3 auto triggers
Mirror / Normal switching from menu
On-screen distance markers
Audio
Sun shield
Auto dimmer
Plug and play to accept DVD, sat NAV or other add ons
Remote control
Multi-lingual menus
Auto switching PAL/NTSC

Picture Quality
Anti-glare screen
Resolution : 480 x 3 x 234
Contrast ratio : 400.1
Brightness : 350 cd/m2
Viewing angles
Side 65 x Top 45 x Bottom 65 degree
Power
Power consumption: 10 Watts
Current: 0.8 Amps
3.4 PNEUMATIC SYSTEM: SPECIFICATION
3.4.1 The pneumatic system consists of dead man control of pressure control valve and
brake interlock system.
The main components of pneumatic system are as under:
a) Pressure regulator with panel mounted pressure gauge

b) Audco IN 123 valve
c) Palm couplings
d) BSP 4 way adapted to 3 way push button operated valve with spring return
and SS metal knob.
e) 3/8" BSP 4 way adapted to 3 way push button operated valve without spring
return and SS metal knob, sub base type.
f) Sundaram Clayton make shuttle check valve
g) 1no. 30 liter air tank with drain cock, pressure gauge, unloader valve.
h) Micronic air filter with automatic drain (M/s. Shavo Norgen or Schrader
make)
i) Electro-pneumatic lights.
3.4.2 Air tapping for the pneumatic system will be taken just on outlet of air tanks. Cab
mounted master emergency override valve will be provided. 1 No direction control
valve to be provided in cab for engaging ATF pump along with pressure regulator
and gauge. The pneumatic interconnections will be done through Dunlop
make RI series pneumatic hose, palm couplings and Audco IN 123 valve.
Additional 30 liter air tank with drain cock, Audco IN 123 valve, pressure gauge,
unloader valve will be provided.
Air filter with manual drain (threaded type) only will be provided.
3.4.3 Panel mounted brake interlock override direction control valve will be provided in
panel. Brake interlock system should be such that when one or more delivery

couplings are lifted from coupling holder trailer brakes should be applied. Brakes
should also be applied when ATF pump is engaged or the refueller is connected
for topping up operation.
3.4.4 The material of fuel sense lines should be of stainless steel. Pneumatic lines
should be of legris make PU type which has found to be of good quality with proper
weather proof conduiting for protection. No copper lines should be used in the
system.
3.4.5 The nozzle holders in conjunction with proximity switches will be installed for
Hose reels and deck nozzles at approved location.
Typical Pressure coupling with nozzle holder: Nozzle model: Carter-64348
3.4.6 One No. electric light ‘ Red Indication ‘ will be provided in cab and on control
panel each for brake interlock indication and manual override actuation.
Additionally one Amber light indication to be provided in the cabin which will glow
in the event of Brake Interlock override.
3.4.7 Brake interlock override switch should be provided on control panel and master
switch in cabin with sealing arrangement in consultation with BPCL. Brake
interlock override switch should be provided on control panel and master switch in
cabin with sealing arrangement.
3.4.8 Two adjustable throttle actuators shall be mounted on the engine to automatically
select engine RPM at preset levels for high & low fueling rates and defueling rates.
Selected RPM setting shall be actuated by the deadman control.
3.4.9 Pneumatic line shall be numbered with unique number at both ends for easy
identification; same should be marked in pneumatic line diagram also. Tray for
pneumatic line shall be provided.

3.4.10 The fuel sensing and pneumatic lines should be painted with yellow and blue
colours respectively for easy identification.3.Brake interlock on PTO to be
provided.
3.4.11 written warning in addition with light indication shall be displayed on control panel
as “BRAKE INTERLOCK ON”.
3.4.12 In addition with written warning an additional light indicator shall be displayed on
control panel as “BRAKE INTERLOCK OVERRIDE”.
3.4.13 Green light for “DMC ON” indicator on auxiliary panel shall be provided.
3.4.14 Brake interlock shall be provided on hand brake. Brake interlock override valve on
control panel shall be push pull type with sealing arrangement. Master brake
interlock override shall be provided in cabin dash board with proper sealing
arrangement.
3.4.15 Audio Alarm during reversing of vehicle shall be provided.
3.4.16 Deadman override should be provided using electro pneumatic system so that
refueling can be done when electrical deadman switch fails. Deadman switch
should be located away from fuelling panel so that it is not used by the operator on
routine basis. Provide proper sealing arrangement for deadman override switch.
3.4.17 Air reference pressure gauge for SPCV, 63 mm, range 0 – 150 psi with LC 2 psi
shall be provided.
3.4.18 SAFETY RAILING – A structurally strong & pneumatically operated collapsible

lifting railing on the top of the storage tank of refueller on both sides at deck to be
provided. 2 nos. of pneumatically operated cylinders with all accessories and
safety arrangements shall be provided with operating switch close to ladder. The
height of fully elevated deck should not be more than 1.0 m. A free – standing area
immediately outside the ladder is required. The railing shall be connected with
electro – pneumatic interlock to protect air craft from any potential damage and
prevent refueller to move without closing the collapsible railing.

3.4.19 Indicator LED lights (50 mm dia flashing type) inside refueller cabin should be as
under:
Amber - Brake interlock ON
Red - Brake interlock override ON
3.4.20 Following indicators (50 mm dia.) to be provided on refueller auxiliary panel.
White - PTO ON
Green - DMC ON
Blue - Hand brake ON (to prevent driving the vehicle with Hand Brake
engaged)
Red - DMC override
Yellow - Slop Tank Overflow
In case non availability of any of the colour as mentioned above same is to bring in
to the notice of BPCL for approval.
3.5 ELECTRICAL SYSTEM & CONTROL PANEL

All double pole wiring will be done to conform to latest applicable petroleum rules
also along with CCOE regulations and will pass through heavy duty conduits. The
conduits will be of adequate size to accommodate number of wires passing through
it, without any damage to insulation. Electrical wires will be of `Finolex' make or
equivalent.
3.5.1 Refueller will be supplied complete with following lights (apart from the lights
supplied by chassis manufacturer) :
i) Brake lights
ii) Turning lights

iii) Cabin lights - 2 Nos.
iv) Instrument panel lights
v) Adjustable spot-lights / flood lights for night operations near the deck
hoses.
vi) A large flashing amber beacon light of Lumax make with speed 60 – 90 per
minutes should be provided in the front-centre of the cabin roof. The beacon
light fitting arrangement is shown in Fig 10.20 of Sec-10. In addition to this,
2 Nos. red lights on front cab corners of approved make.
vii) Four numbers, red lights on top of tank - 2 at the front and 2 at the rear end
of high lumens of approved make.
The tail lights / parking / brake lights of approved make and model suitable to
connected chassis and also readily available in the market.
All lights and switches in module compartments of shall be weather-proof CCOE

approved.
3.5.2 Cable, cable’s joints and junction boxes shall be of approved make. Suitable
circuit breakers, fuses and isolators for DC motors, Deadman handle and lights
shall be provided for protection. It should ensure that the current is regulated by
means of relays beyond the cabin and all the junction boxes as far as possible will
be located inside the cabin so that the amperage conforms to the intrinsically safe
requirements. Two spare connectors to be provided in junction box. Electric wiring
shall be numbered with unique number at both ends and same should be marked
in electrical circuit diagram for easy identification. Cable tray for electrical lines
shall be provided. Electrical cabling should be through metal braided rubber
conduits only. The entire electrical wiring shall be secured with clamps and
arranged in stream lined manner.
3.5.3 DMC handle should have coiled cable length which can be kept back in a suitable
housing after use. No need to have self rewinding type reel drum.
3.5.4 The vehicle batteries will be supplied along with the chassis. It will be fabricator's
responsibility to maintain batteries in properly charged condition and store in dry
place. In case fabricator observes battery condition is not good, it shall be
fabricator responsibility to inform BPCL to take up with chassis supplier well in
advance, otherwise at time of final inspection, if condition of battery found in bad
condition, it will be fabricator responsibility to replace battery on his own cost. No
extra cost will be reimbursed on account battery replacement.
3.5.5 Battery compartment in cab will be of safe and suitable design. It will be
fabricated out of SS Plates and lined with thick hard rubber. Lid will be provided

under co-driver seat/suitable place. Also made provision to take out battery for
charging without tilting of cabin.
3.5.6 Fabricator will prepare ÀS BUILT' electrical layout drawing giving complete details
of equipment / controls used in the circuit. This set of drawings will be submitted
along with the final bill.
3.5.7 1 No. Control panel of size 615mm X 560mm X 3mm thick of the refueller shall be
located on driver’s side of vehicle. The panel should be of SS with glossy finish
through buffing and the scheme of gauges to be followed as suggested by BPCL.
Panel will have following features :
Control panel as per BPCL standard located at the driver’s side, shall be as
per the drawing enclosed.

a. PD gauge (Gammon) 0 - 30 psi range with auto check facility.
b. Inlet pressure gauge
c. Pressure gauges for venturi - 2 Nos.
d. PCV air reference gauge
e. Air tank pressure regulator valve

Note: All gauges (Waree / Waika, back fitting type) to be provided as per following
specification.
i). Material - SS body
ii). Range - 0-150 psi
iii). Size/ type-65 mm dia, back connection of thread size ¼ BSP
iv). LC - 2 psi
v). Glycerin filled
f. Interlock on (red), Interlock override knob, Emergency shut off knob (As shown
in Fig.) PCV air regulator knob, Flow diagram.
g. Brake interlock indication for each interlocks (1 deck hose coupling, 2 reel
hoses couplings, one at loading point & one at rear on ladder point).
h. Pump throttle arrangement. – Pump throttle could be brought on to the main panel
with suitable gradual control arrangement.
i. All the gauges for ATF & pneumatic will have testing with SS quick acting
coupling assembly and necessary needle valve to enable testing of gauges
with a gauge comparator. Provide in-situ gauge testing provision as per BPCL
standard.

j. Protective roof / canopy shall be provided on top of panel, bulkmeters and all
sampling points. It will be painted white from inside.
k. Two Nos. CCOE approved Weather proof lights shall be provided and
connected in the canopy. Controls will be provided suitably located.
Illumination should be adequate to read gauges/counters of bulkmeters. At
times difficulty is experienced by the operating staff while noting down the
totaliser reading. To overcome this problem we would like to provide a
focussing lamp with a flexible shaft for better focussing.
l. Panel to have emergency fuelling stop knob painted in Red colour.
m. Sketch of ATF pipeline circuit with all valves and equipment etched on an steel
or a suitable material will be also fixed near the control panel, along with
operating instructions. All the valves and equipment will be clearly labeled for
easy identification.
n. Emergency Shut off knob shall be provided on control panel as per BPCL
standard.
o. In addition to control panel an auxiliary panel would be also provided as per

drawing.
p. A written warning in addition with light indication shall be displayed on control

panel and in cabin as” BRAKE INTERLOCK ON”.
q. A written warning in addition with light indication shall be displayed on control

panel and in cabin as” BRAKE INTERLOCK OVERRIDE”.
Typical interlock override arrangement:

r. Green light for DMC “ON” , red light for ’DMC OVERRIDE ON” white light for
“PTO ON” , yellow light for “SLOPE TANK OVERFLOW” , and blue light for
“HAND BRAKE ON” indication on auxiliary panel.
3. 6 PROTECTIVE/SAFETY DEVICES
3.6.1 Two nos IS approved make 9 KG DCP type fire extinguisher (IS -15683) will be
provided with suitable mounting brackets at approved locations.
3.6.2 Two vertical type fire extinguisher brackets / holders to be provided on either
side of the vehicle at the rear end on single chassis at height not more than 18”
from ground level. To remove the F.E. easily, two semicircular 2” strip having
hinge at one end & locking pin at the other as shown in the photograph. The
strips when secured with locking pin should not hold F.E. loosely. Canvas
padding of appropriate thickness is to be provided on the inner layer of the strips
to hold F.E. tight and also to avoid scratches on F.E.
3.6.3 F.E. bracket must be easy to use with water drain holes at the bottom plate. For
ease of handling and help prevent the hose from being squashed or damaged,
wooden / rubber plugs at one side of the lower centre line shall be provided.
3.6.4 A 1 or 2 kg DCP ( IS -15683) fire extinguisher should be fixed in an accessible

position in the cabin.
3.6.5 Two Nos. suitable earthing bonding reel of SS material shall be supplied with
each refueller. One bonding reel to be fitted near to control panel & another on
the opposite side of the control panel. Exact position of the bonding reels will be
confirmed by BPCL representative.
3.6.6 Reel will be supplied and fitted with 30 m long SS cable and crocodile clip. The
bonding reel will be tested for electrical continuity between base plate and
crocodile clip.

3.6.7 A bonding wire connection should be installed at each bottom loading point, the
tank & filter drains, and the product recovery (dump) tank and at the drain panel.
Typical SS make bonding reel:
3.6.8 Each refueller will have aluminium earthing plate 3” x 6" with 10’ long 1/8" dia
woven steel bonding wire. Suitable bracket/pocket will be provided for keeping
earthing plate on the refueller.
3.6.9 Fuel dispensing system will be bonded for electrical continuity by providing
copper strips at all flanged joints.
3.6.10 For each refueller, following fire-proofing will be provided.

a) Fire screen at the rear cab, to extend upto 300mm from ground level.
Fire screen will be made by sandwiching asbestos sheets between
steel plates.
b) Exhaust pipe of engine will be modified to be on front of cab on

the co-driver's side and will be fitted with CCOE approved flame
arrestor. This flame arrestor will be suitable for all model chassis.
3.6.11 Diesel tank will be provided on co-driver side with locking arrangement. The
arrangement should be such that when tank overturns, product does not spill.

3.6.12 Aluminium square dip-rod with calibrations in centimeter of least count of 1 mm.
3.6.13 6 mm x 10 mt. long flexible rubber hose will be provided for tyre inflation and
fitted with suitable tyre valve at the free end. An air charging pin with 1/4" ball
valve will be provided on panel on tractor and connected to air tank.
3.6.14 Relocation of air tank and diesel tank on tractor chassis will be carried, if
necessary.
3.6.15 Sturdy Mudguards, for all the wheels, made of MS sheets and fixed with suitable
angle framework. Rubber flaps also to be provided.
3.6.16 All the sampling, drain, Millipore ports will have SS cable with crocodile clip fitted
for bonding. All sampling drains (Picture is enclosed), Millipore & Gauge testing
ports will have aluminum caps with chain (QDC type).
3.6.17 The driver’s cabin shall be fitted with sturdy battery box, approved First Aid Box,
Document box (at least 300mmx 150mmx 150mm) & tool box.
3.6.18 Engine exhaust pipe will be diverted opposite to panel side & its mouth pointing
towards ground. This modification to be undertaken in consultation with the
chassis supplier.
3.6.19 Suitable tool box to be provided with felt lining and locking arrangement.
3.6.20 4 nos. of chokes (hard rubber type, more user friendly, applicable at Apron use)
to be provided including making provision for holding chokes.
3.6.21 Suitable board to be designed & supplied (PUC type with acrylic cover) for the
purpose of consolidation and display of important dates e.g. fitter changed
on/due on/inspected on tank cleaned on/due on, gauge tested on / due on etc.
3.6.22 Successful bidder has to arrange & provide CCOE approved spark arrestor at the
end of exhaust pipe. A CCOE approval shall be provided along with other
documents before dispatch.

3.1 TANK FITTINGS
Rules for transporting Aviation Turbine Fuel. Actual detailed fabrication drawing is
to be prepared by the vendor and will have to be approved by BPCL before
No. of Hoses Size of Hose Flow Rate

(Dia x L)
1 Deck Hose 2 ½ ” x 12’ 1400 lpm
Yield Strength : 23.5 KG/SQ.MM (MINIMUM)
UTS : 36.0 KG/SQ.MM (MINIMUM)


(Mandrel Dia)
Thickness : 3.5 mm
Z channel : IS 2062
Product Capacity : 25,000 Ltrs.
No. of baffles : 5 (Minimum)
No. of compartments : 6 (Minimum)
No. of Manholes : 4 (Minimum)
No. of Manholes with all : 2 Nos. Emco Std., balance 2 Nos. Fixed,
Standard fittings on each
Pressure/Vacuum valve : 4 (Minimum)

Gauge
Tank Outlet : 150 mm (3 Nos.)
Tank drain : 25 mm

(all SS pipe lines in use should be kept to
glossy finish through buffing)

DIMENSIONS
Capacity: 25 KL
Width : Should not be more than width of the cabin. Also

no Fittings should protrude outside cab width.


Coupling.
Notes:-

3.1.4 Tank will be made of mild steel of approved make as per following specifications:
a) It will be structurally strong and designed to carry ATF of 25000 Ltrs on a

specified above.

b) Tank dimensions should be such that stability ratio is not more than 0.9 and
does not violate RTO regulations.
c) Emco type manholes with GI dome covers painted internally and the safe
Each will also have a fusible plug of 50 mm size with melting temperature
of 93 degree C, design approved by CCOE.
d) End baffle plates will be dished type end of suitable curvature. Each baffle
will have at least an area as great as 80% of the cross-sectional area of
tank. Baffle plates should be affixed to the tank shell by welding 3 mm thick
M.S.angles curved. These reinforcements shall be circumferentially
welded to shell tank completely all round. Baffle plates will have openings
of adequate size at top middle and bottom for interconnecting all the
compartments. Each opening in baffle plate will be adequately
strengthened.
e) No tack welding will be done inside tank in any manner and no gaps left
inside tank that cannot be sand blasted / epicoated. All welding
inside/outside tank will be ground smooth prior to sand blasting / painting.

f) Tank will have following connections:
i. Tank outlets 150 mm dia.

ii. Tank drain 25 mm dia.
iii. Tank circulation point to suit 100 mm pipe.
iv. Tank sampling connection of 25 mm.
v. One no. inlet / outlet for 1 No. deck hose at suitable location.
vi. One No. 80 mm circulation point for deck hoses on top.
vii. One No. ¾ “(20 mm) opening for return ATF line from Air eliminator
of filter.
viii. 10” Dial type content gauge.
at bottom surface which come in the path of water drain. The size and
locations or rings will be indicated in drawing of tank submitted with Technical bid.
3.1.6 Bottom loading shall be via the 6”(150mm) tank internal valve. Two ground half
shall be provided, one on each side of the unit. They shall be connected together
via a 3 inch cross manifold which connects into the internal valve. A pressure
gauge shall be installed downstream of each adapter to read bottom load manifold
pressure should be provided with butterfly type isolation valve & a non return
valve.

shall act to bleed product from the bottom load manifold to fill a can around the
jet sensor and simulate a full tank. The tank can be drained at a controlled rate
via tubing to the tank bottom to avoid splashing.
3.1.10 A continuous MS section channel will be welded underneath the tank on all
along the length of tank pad plate of 6 mm thick and adequate width. No. of
joints in `Z' channel will be minimum and these joints will be strengthened by
welding 6 mm thick patch plate complying to IS: 2062.
3.1.11 Pneumatically operated emergency valves 6" (150mm) size with fusible link will
also be provided on Gauge panel.
hand railing.
3.1.13 Ladder with hand rail and additional steps from bumper to ground for
comfortable climbing deck platform would be provided on the rear. Ladder will
be fabricated of M.S. flat / angles and duly painted. The position of the ladder
should not so adjust so as not to cover BPCL logo.
3.1.14 An electro pneumatic interlocking with the brakes when the hand rails are in
open position shall be provided at the entry of the ladder to restrict movement
of the refueller.

3.1.16 Check platform of heavy duty Aluminum grating shall be provided across full
width of the tank and length of deck hose. Suitable opening for manholes
covers, deck pipes & circulation pipes will be provided in the platform.
3.1.17 The tractor chassis shall be strengthened to raise the height of liquid fifth
wheel and take load of complete trailer assembly. The centre line of liquid
fifth wheel assembly would be at offset recommended by tractor chassis
manufacturer.
3.1.18 Bidder shall arrange to install Dual Liquid Fifth Wheel assembly ( suitable for 25
KL refueller) matching the loading , along with 150mm swing joint assy.,
flexible hose. And it will be installed strictly as per manufacturer’s
recommendations, after providing mounting plates on the tank bottom and
tractor. These mounting plates will be adequately strengthened.
3.1.19 The Liquid Fifth Wheel Assembly shall be at a suitable height considering the
space required for module and to prevent fouling of tank bottom with tractor
chassis at rear end.
3.1.20 Liquid fifth wheel (Dual type) should made of composite fabricated steel and
comprises of:
a. Steel upper mounting plate.
b. High strength alloy steel, ball type ring bearing with the inner bearing
race secured to the upper mounting plate.

c. Steel lower mounting plate secured to the outer bearing race.
d. Structural steel sub-frame welded to the lower mounting plate.
e. Two lowering bearing brackets with sock bushing & securing pins.
f. 6” size liquid tight rotating Al swing joint.
g. Flexible rubber joint 6” size
installed adjacent to the centre manway and operate in conjunction with the
internal valve during fueling, defueling and bottom loading. Venting capacity
must be at least 150% of the maximum fueling rate.
3.1.22 One internal valve of 150mm should be installed centrally on the tank bottom
centre line & discharge directly to the pump suction / bottom load manifold. A 1”
high wire shall be installed around the valve to break suction when 1” of the
product remains in the tank. A vortex breaker / anti splash plate shall be
installed above the internal valve.
locking arrangement would be provided. The dip hatch should be provided with
a 1.5” SS pipe ending 35 mm from the bottom of the tank. A calibration
certificate to be provided with each refueller at the time of delivery.
3.1.26 Rear bumper will be provided to protect the tank and piping in the event of
rear end collision and minimize the possibility of any part of colliding
vehicle striking the tank. The bumper shall be located at least 150 mm to
rear of refueller component. Structurally the bumper shall be designed to
successfully absorb (No damage which will cause leakage of product) the
impact of the vehicle with rated payload, with deceleration of 2 g using a
factor of safety of two based on UTS of bumper material.
3.1.27 Tower with locking arrangement of suitable strength shall be provided on the
front & rear bumper.

3.1.28 Deck hose circulation points should be located suitably away from the swivel
joint so as to avoid kink in hose while circulation test. Height of deck hose
circulation point should be as low as possible.
3.1.29 All sample points should be covered with canopy arrangement (covering top &
Capacity : 200 Lts
Material : SS
Thickness : 10 G
3.1.31 The slop tank should be constructed of SS with a heavy duty large size funnel,
a 250 mm (minimum) hinge type lockable cap and having 60 mesh gauze filter
with sufficient support. The tank is to be totally weather proof and sealed
against ingress of contaminants. The tank is to be given a 20-mm drain with a
spring loaded ball valve in line. The slop tank shall have the following additional
fittings:

c. An audio alarm along with light indication on Auxiliary panel shall be

provided in the slop tank when the level of product reaches 75% of
the capacity.
d. A free vent with an inverted “U” opening to prevent ingress of water.
e. A 10 “flanged type manhole cover with a neoprene gasket.
An alarm should be raised as soon as the level in the slop tank reaches 75 % of
the capacity.
3.1.32 Tamper proof covers or locking devices are required on the following controls to
prevent inadvertent alteration:-
a) Air Pressure regulator

b) Master override switch
c) Interlock override switch
d) DMC override switch

REFUELLING MODULE
by the bidder.
c) Running Gear 19 MT capacity with two speed / suitable landing gear
d) Liquid Fifth Wheel assembly (Dual).
e) 6” bottom valve fitted with fusible plugs.
f) 6” slim seal butterfly valve.
g) 6”x 4" centrifugal pump with gear box.
h) ATF pump by-pass valve.
i) 4” slim seal butterfly valve.
j) 3” SS Swivel joints (self-lubricating type).
k) 100mm Pressure Control valve.
l) 75mm high performance butterfly valve.
m) 50 mm Aluminium swing check valve.
n) 10” Content Gauge
o) Bobbin type motorized hose reel with swivel suitable for 2" x 60' long hose.
All moving parts to be provided with safety guards.
p) Hoses should conform to specification ISO 1825: 2010 Third editions, Type-
C. End fittings of SPANNLOC coupling fittings both ends (As per ISO
1825:2010 stds), male to male NPT thread..

q) Hose reel should be provided with flame proof / CCOE approved rewinding
motor.
r) Power of winding / unwinding of reel hose drum with speed control is to be


s) Hose rewinding motor specification:
Capacity : 0.5 HP
Current : 53 amps
Type : Class B
Max. winding speed : 0.72 m/second (DC motor is fixed

and variations in speed to be
achieved thru gear/chain
mechanism)
t) 2.5" under wing pressure coupling.
u) 2 ½" 3-lug adaptors
v) 25mm spring loaded valve Integral type cable operated drain valve
Typical Bobbin type reel hose drum:

3.2.3 In defueling of 25 kl refueller, the refueller pump is used to create suction up to
the delivery couplings by using Eductor in defueling mode. Defuelled product
should not passes thru Filter monitors.
3.2.4 Bidder shall supply 150mm size bottom loading internal valve, jet level sensor
with pre-check testing arrangement. Water preventing ring 12 mm wide will be
provided around this valve.
3.2.5 The product entering the tank goes through the bottom loading system and
hence is subjected to the high level shut off control system.
3.2.7 The product pump should be of self – priming centrifugal type, mounted rigidly
and PTO driven. PTO shall be provided with suitable Chassis & with suitable
running gear
Make : Gorman Rupp

flow rate.

3.2.8 A pressure limiting pump by- pass valve ( size 3 “ ) shall be installed to limit
pump output pressure in a range 75 psi to 150 psi, the valve shall also function
as an on/off valve actuated by an air reference signal from the dead man control.
a) Body / Cover : ASTM A216/A216M-04
b) All trim materials : ASTM A351/A351M-06
c) Elastomers : BUNA N
d) Ò' Rings : BUNA N
e) Internals : AISI 316
f) Nuts/Studs : ASTM A193

preferably in horizontal position. The pilot shall be located at convenient
place for easy access. Bidder will arrange to set the valve as per BPCL
requirement.
pump inlet.
3.2.12 600 USGPM capacity fuel monitor with air eliminator, of S S construction fitted
monitor will be of size 2”x25 or 2”x30” only. 2 Nos. 25 mm spring loaded valves
with SS elbow will be fitted for drain and 25 mm sampling lines in such a way that
fitted with crocodile clip. Sampling lines shall end in elbow, and fitted with
Camlock type SS cap & chain. Tank bottom sample point should be covered with
four sides with canopy arrangement to draw samples easily during heavy rains
on refueling operations.

3.2.13 The following instruments and controls are required and are to be neatly located
at the pumping control station. A typical panel layout is shown in attached
drawing.
A. Main Gauge Panel



of 2 psi.
LC of 2 psi.
indicator)
B. Auxiliary Panel
♦ Engine Stop
♦ Deadman Light
♦ PTO Light
♦ Millipore Point

swing check valve.
shall supply one set of spare new filter elements in a properly sealed box &
should be delivered along with the refueller. (Total 2 sets of filter elements).
Butterfly valve on inlet and outlet of the filter vessel shall be provided.
filter drain. A label stating size and no. of fuel monitors to be fixed using
engraved laminated SS plate.

Visi- flow Air eliminator Pressure relief
of proper sampling probes. The probes should have provision for sampling as
well as tapping off pressure for differential pressure gauge. A quick coupler of
male adapter along with aluminum cap attached with chain should be provided
on auxiliary panel.
3.2.20 A direct reading piston – type gauge with auto check push button to be provided
to check its performance, shall be installed with panel to measure the differential
3.2.21 A proper spring loaded normally closed pressure release valve should be
installed on the filter vessel.
control and dead man control will be installed as per manufacturer's
instructions. The SS fuel sensing line from venturi will be connected to the pilot
of the PCV and pressure gauge on panel. The opening/closing time of PCV will
be adjusted to BPCL’s requirement.

3.2.23 Primary pressure control (HECV) shall be set to control the down stream
pressure at 45 psi.
application of an air reference signal. The operating time of the valve by dead
man control shall be adjustable within the range of 5 to 10 seconds and closing
time adjustable within the range 2 to 5 seconds.
4” flanged type inlet & outlet. Make – Whittaker,

(Compensator) shall be capable of providing between 15 & 35 psi compensation
in order to maintain a flow rate of between 70% & 100 % of maximum flow. The
3.2.27 4" x 3" fuel-defuel valve will be installed preferably in vertical place. Pneumatic

Fuel/Defuel Valve 4” x3”, Make-Gorman Rupp
3.2.28 A push pull fuel/ defuel knob with sealing arrangement to be provided on
auxiliary panel.
3.2.29 Bulk meters with mechanical counter, fitted with suitable pulsar & reset switch
shall be installed as per recommendations of bulkmeters manufacturer. One
4" butterfly valve shall be installed on outlet, for the bulkmeters supplied without
faucet valve.
copy is to be provided to location for stamping purpose after delivery. The
supplied bulk meter should be of latest model and the bulk supplier should have
wide sales & services network across India.
adequate capacity.
a) Application: Delivery to Aircraft
b) Product to be measured: Aviation Turbine Fuel
c) Specific Gravity: 0.775 to 0.830
d) Operating Pressure: 150 psi

e) Measurement units: Litres
f) Flow Direction: Bi- directional
g) Connections: Flanged ends
Typical Flow meter of Avery Hardoll, Model CM-2500:

PART NO. 767163—303

TECHNICAL

a) Input Supply 10 # 15 VDC
b) Current 50 mA at max 10 - 15 VDC
c) Switching Times

e) Rotation Bidirectional
f) Input Shaft Speed 600 rpm max
g) Output Pulse Dual channel at 50 ppr
h) Operating Temperature: 42°C to 82°C
i) Storage Temperature: 55°C to 125°C
j) Housing Explosion Proof
k) Mounting Three ¼ - 20 UNC # 2B blind tapped holes, spaced 120° apart on
l) 2.5# diameter bolt circle
m) Cable Gland BASEEFA (UK) or equivalent approved with Group IIA, IIB
or II Cenclosures
n) Cable Type 2, 3, 4, 5 or 6 core tinned copper conductors with metallic

screen
o) Cable Length 10 # 15 meters
p) Approval BASEEFA (UK) or equivalent

Model: 8064/21

1. AC Current 11 # 2.5 amp
2. AC voltage 400 V
3. DC Current 11 # 6 amps
4. DC Voltage 250 V
5. Compliance IP # 66
Description:
a) 8064 with flexible lead, single micro switch, with snap action contact,
plunger with plastic roller. 1 c/o contact with 3 core cable, 3 mtrs. in length.

In this case model approval for bulk meter along with pulsars & reset switch is
with the fabricator before dispatch of refueller.
3.2.34 Suitable compensator, separate for reel hoses & deck hose shall be installed with
needle valves, pressure gauges, shuttle check valve etc.
3.2.35 3" x 3½" x 2" Eductor unit of aluminium construction with victaulic connection will
be supplied and installed.
3.2.36 3" aluminum wafer type swing check valve will be supplied on defuelling line and
3” size on the self loading point.
3.2.38 The loading / circulation point will have 2 Nos. 2½" ground half unit adaptors
with 2 Nos. 3” butterfly valves. One No. 3" butterfly valve and ground half unit
will be provided for self loading point. All the 2½” adaptors should have :

Similarly 1 no. ground half unit will be supplied and installed for deck hose
circulation with a butterfly valve for HEPC testing. 2.5 " Reel hose BOBBIN type
with swivel suitable for 2" x 60 ft long Aviation hose will be installed with manual

rewind & DC motor rewind mechanism and HEPCV testing arrangement . The
hose should have protection beads every 2 feet upto 20 ft to avoid abrasion. End
fitting with easy locking nut adaptor to be provided on reel & Deck hoses for easy
unlocking of hose for pressure testing, also yellow color band at end of reel &
deck hoses should be provided.
isolation valves. Provision for IN – SITU hose testing arrangement along with 5
mts. long additional rubber pipe with SS quick connector to be provided.
3.2.40 SS material of > 300 psi rating swivel joint shall be used on deck hose to carry
out IN – SITU hose testing.
pipeline connection only, flange joints to be used.

3.2.44 All the flanged joints will be provided with copper strip jumper of 25 mm wide
x 0.93 mm thick. These jumpers should not be coated with the paints. The
pipeline and components will be adequately supported.
Valve Type : 803
Class : 300
Ball : AISI 316
Seat : PTFE
Stem : AISI 316
3.2.47 All the ATF sensing line for compensators, PCV, FWS, PD gauges shall be of

Metal : SS 304
Least Count : 2 psi
connection in the sensing line to enable testing of gauges with respect to a
gauge comparator.
hose connection. However, sample points should not be too high off the ground
to prevent splashing and spillage. Tank bottom sample point should be covered
with canopy arrangement (covering of top & four sides) to draw samples easily
during heavy rains on refueling operations.
3.2.52 A SS engraved plate for fuelling circuit and operating instruction to be provided
on the gauge panel.

1:1)
mudguards.

3.2.56 One no. of structurally strong step ladder of Aluminum to be provided along with
all refuellers of 6’ height suitable for refueling of A320 aircrafts shall be supplied
along with the Refueller. There should be provision of keeping ladder with sliding
arrangement on the rear of the Refueller. Suitable locking arrangement also to be
provided, so that latter does not slide or move during refueller movement.
3.3 WEB CAMERA:
Specification:
Signal System: PAL/NTSC
Image Device: 1/3.7” High resolution digital image sensor
Effective pixel: 648(H) x 488(V)
Horizontal Resolution: 520 TVL
Lens Furnished: 1.7 mm in Built, Optional: 2.8mm, 3.6 mm
Shutter Speed: 1/50~1/100,000 Sec
Min Illumination: 0.5 Lux / F1.2,
White Balance/ Back Light Compensation: Yes
Exposure Control/AGC/ Color Correction: Auto
Synchronization: Internal synchronization
Video Output Signal: 1V p-p Composite video

Power:
Specification:
Camera Pixels: PAL: 500(H) x 582(V) ; NTSC: 510(H) x 494(V)
Resolution: 480 TVL
Min Illumination: 0.05 Lux / F2.0
Electronic Shutter: NTSC: 1/60~1/10,000 PAL: 1/50~1/10,000
IR: 24 IR LED, Ø5 mm, 850nm, IR distance- 20 Mtr.
White Balance: Auto Tracking White Balance
Lens Furnished: Built in: 3.6mm , optional: 2.8mm/6mm/8mm
Video Output: 1V p-p Composite, 75 Ω
Power:
Full Function Remote Control, Random Camera Selection through Numeric Keys
on the Remote Handset, Individual Dwell Time Setting for each Camera from 01 to
99 Seconds in AUTO Mode, Changeover from AUTO to MANUAL or Vice-versa
through Single Key, Memory Retention in case of Power failure
Specification:
Particulars: Video with 2Way Audio
Camera Inputs (n): Min two
Display: Min two
Camera Input: 5 Pin Din
Monitor Output: RCA
Video Input: 1 V p-p Composite, 75 Ω
Video Output: 1 V p-p Comp., 75 Ω
Audio Output: 2 V p-p, 50 Ω

Operating Temperature: 0°C to 50°C
Power:
Features
3 auto triggers
Audio
Sun shield
Auto dimmer
Remote control
Multi-lingual menus
Picture Quality
Anti-glare screen
Resolution: 480 x 3 x 234
Contrast ratio: 400.1
Brightness: 350 cd/m2
Viewing angles
Power

Current: 0.8 Amps

RUNNING GEAR ASSEMBLY
Running gear shall be designed for the actual loading.

Running gear assembly:
The running gear assembly shall consist of an under carriage with twin axles,
wheels and tyres, tandem suspension, brake assembly, with a landing gear
assembly but without king pin assembly.
Axles:
All the axles shall be made of EN 16 or equivalent alloy steel, suitably heat treated
with precision finished bearing journals & fitted with taper roller bearings. The axles
should be designed for rough driving conditions.
Running gear of 25 KL shall have 2 axle with 8 tyres of 10 X 2000 X 16 PR tyres
Suspension:
Tandem suspension assembly shall have adequate leaf springs. The spring shall
be made of En 45 spring steel material.
Brake System:
The foundation brakes shall be of design approved by manufacturer of chassis.
Twin air line brake system shall be provided with all fittings like RE valve etc. of
Sundaram Clayton make. The manually operated braking system shall also be
provided.
Wheels and tyres:

The wheels shall be of standard size matching with chassis. A spare wheel will be
also be provided with suitable bracket for fixing. The tyres shall be of same make
as that of chassis tyres.
Capacity:
Design load: To be designed
Axle Load: 19 MT for 25 KL Refueller

Dimensions:
Wheel track: 1900mm
Over all width: 2500mm

Landing gear assembly: A suitably designed landing gear assembly consisting
of two legs will be installed on tank bottom side near liquid fifth wheel assembly at
a location so selected that the tank will remain stable on disconnecting from
tractor. Two speed Jost make landing gear should be hand operated.
3.4 PNEUMATIC SYSTEM: SPECIFICATIONS
3.4.1 The pneumatic system consists of dead man control of pressure control valve
and brake interlock system.
c) Palm couplings
and SS metal knob.
e) 3/8" BSP 4 way adapted to 3 way push button operated valve without spring
return and SS metal knob, sub base type.
make)
mounted master emergency override valve will be provided. 1 No direction
control valve to be provided in cab for engaging ATF pump along with pressure
regulator and gauge. The pneumatic interconnections will be done
through Dunlop make RI series pneumatic hose, palm couplings and Audco IN
123 valve. Additional 30 liter air tank with drain cock, Audco IN 123 valve,
pressure gauge, unloader valve will be provided.

couplings are lifted from coupling holder trailer brakes should be applied.
Brakes should also be applied when ATF pump is engaged or the refueller is
connected for topping up operation.
should be of legris make PU type which has found to be of good quality with
proper weather proof conduiting for protection. No copper lines should be used in
the system
interlock override switch should be provided on control panel and master switch
in cabin with sealing arrangement.
select engine RPM at preset levels for high & low fueling rates and defueling
rates. Selected RPM setting shall be actuated by the deadman control.
colours respectively for easy identification
3.4.11 Brake interlock on PTO to be provided.
3.4.12 A written warning in addition with light indication shall be displayed on control
panel as “BRAKE INTERLOCK ON”.
3.4.15 Brake interlock shall be provided on hand brake. Brake interlock override valve
on control panel shall be push pull type with sealing arrangement. Master brake
arrangement.

should be located away from fuelling panel so that it is not used by the operator
on routine basis. Provide proper sealing arrangement for deadman override
switch.
shall be provided.

height of fully elevated deck should not be more than 1.0 m. A free – standing
area immediately outside the ladder is required. The railing shall be connected
with electro – pneumatic interlock to protect air craft from any potential damage
and prevent refueller to move without closing the collapsible railing.
under:

Typical Brake interlock light arrangement:
White - PTO ON
Green - DMC ON
engaged)

Red - DMC override
conduits will be of adequate size to accommodate number of wires passing
through it, without any damage to insulation. Electrical wires will be of `Finolex'
make or equivalent.
a) Brake lights
b) Turning lights
c) Cabin lights - 2 Nos.
d) Instrument panel lights
e) Adjustable spot-lights / flood lights for night operations near the deck
hoses.
f) A large flashing amber beacon light of Lumax make with speed 60 – 90 per
light fitting arrangement is shown in Fig. In addition to this, 2 Nos. red lights
on front cab corners of approved make.

g) Four numbers, red lights on top of tank - 2 at the front and 2 at the rear end of
high lumens of approved make.
All lights and switches in module compartments of shall be weather-proof

CCOE approved.

3.5.5 Battery compartment in cab will be of safe and suitable design. It will be
fabricated out of SS Plates and lined with thick hard rubber. Lid will be provided
under co-driver seat/suitable place. Also made provision to take out battery for
charging without tilting of cabin.
3.5.7 FLP heavy duty pin plug of Sudhir Switch Gears or equivalent make approved will
be provided for interconnecting tractor and trailer

a) PD gauge (Gammon) 0 - 30 psi range with auto check facility.
b) Inlet pressure gauge

c) Pressure gauges for venturi - 2 Nos.
d) PCV air reference gauge
e) Air tank pressure regulator valve
specification.

iv). LC - 2 psi
v). Glycerin filled
f) Interlock on (red), Interlock override knob, Emergency shut off knob (As
shown in Fig.), PCV air regulator knob, Flow diagram.
g) Brake interlock indication for each interlocks (1 deck hose coupling, 2 reel
hoses couplings, one at loading point and one at rear on ladder point).
h) Pump throttle arrangement. – Pump throttle could be brought on to the main

panel with gradual control arrangement.
i) All the gauges for ATF & pneumatic will have testing with SS quick acting
with a gauge comparator. Provide in-situ gauge testing provision as per
BPCL standard.
j) Protective roof / canopy shall be provided on top of panel and bulkmeters

and all sampling points. It will be painted white from inside.
k) Two Nos. CCOE approved Weather proof lights shall be provided and
l) Panel to have emergency fuelling stop knob painted in Red colour.

m) Sketch of ATF pipeline circuit with all valves and equipment etched on an
steel or a suitable material will be also fixed near the control panel, along
with operating instructions. All the valves and equipment will be clearly
labeled for easy identification.
n) Emergency Shut off knob shall be provided on control panel as per

enclosed BPCL standard drawing.
o) In addition to control panel an auxiliary panel would be also provided as per

drawing.
p) A written warning in addition with light indication shall be displayed on

control panel and in cabin as” BRAKE INTERLOCK ON”.
q) A written warning in addition with light indication shall be displayed on

control panel and in cabin as” BRAKE INTERLOCK OVERRIDE”.
r) Green light for DMC “ON” , red light for ’DMC OVERRIDE ON” white light
for “PTO ON” , yellow light for “SLOPE TANK OVERFLOW” , and blue light
for “HAND BRAKE ON” indication on auxiliary panel.
3.6 PROTECTIVE/SAFETY DEVICES
3.6.1 Two nos IS approved make 9 KG DCP type fire extinguisher(IS -15683) will be
3.6.2 Two vertical type fire extinguisher brackets / holders to be provided on either side
of the vehicle at the rear end on single chassis at height not more than 18” from

ground level. To remove the F.E. easily, two semicircular 2” strip having hinge at
one end & locking pin at the other as shown in the photograph. The strips when
secured with locking pin should not hold F.E. loosely. Canvas padding of
appropriate thickness is to be provided on the inner layer of the strips to hold F.E.
tight and also to avoid scratches on F.E.
Typical DCP FE bracket/holder arrangement:

3.6.5 Two Nos. suitable earthing bonding reel of SS material shall be supplied with each
refueller. One bonding reel to be fitted near to control panel & another on the
opposite side of the control panel. Exact position of the bonding reels will be
crocodile clip.

3.6.9 Fuel dispensing system will be bonded for electrical continuity by providing
copper strips at all flanged joints.
3.6.11 Fire screen at the rear cab, to extend upto 300mm from ground level. Fire
3.6.12 Exhaust pipe of engine will be modified to be on front of cab on the co-driver's
side and will be fitted with CCOE approved flame arrestor. This flame
arrestor will be suitable for tractor chassis.
3.6.13 Diesel tank will be provided with locking arrangement. The arrangement should
be such that when tank overturns, product does not spill.

3.6.15 6 mm x 10 mt. long flexible rubber hose will be provided for tyre inflation and
fitted with suitable tyre valve at the free end. An air charging pin with 1/4" ball
valve will be provided on panel on tractor and connected to air tank.
necessary.
for bonding. All sampling drains (Picture is enclosed ), Millipore & Gauge testing
ports will have aluminum caps with chain (QDC type ).
chassis supplier.
3.6.22 2 nos. of chokes (hard rubber type, more user friendly, applicable at Apron use)to
be provided including making provision for holding chokes.
purpose of consolidation and display of important dates e.g. fitter changed on/due
on/inspected on tank cleaned on/due on, gauge tested on / due on etc.

SECTION – 3 FUNCTIONALITY AND CONSTRUCTION OF
15KL, 25KL & 45KL AVIATION MODULE
3.7 TANK FITTINGS
3.9 WEB CAMERA AND MONITOR
3.11 ELETRICAL SYSTEM AND CONTROLS
3.12 PROTECTIVE AND SAFETY DEVICES

3.1 TANK FITTINGS
Rules for transporting Aviation Turbine Fuel. Actual detailed fabrication drawing is
to be prepared by the vendor and will have to be approved by BPCL before
No. of Hoses Size of Hose Flow Rate

(Dia x L)
2 Deck Hose 2 ½ ” x 12’ 2500 lpm
1 Deck Hose 2 ½ ” x 12’ 1400 lpm

Yield Strength : 23.5 KG/SQ.MM (MINIMUM)
UTS : 36.0 KG/SQ.MM (MINIMUM)

(Mandrel Dia)
Thickness : 3.5 mm
Z channel : IS 2062
Product Capacity : 45,000 Ltrs.
No. of baffles : 8 (Minimum)
No. of compartments : 9 (Minimum)
No. of Manholes : 6 (Minimum)
No. of Manholes with all : 2 Nos. Emco Std., balance 4 Nos. Fixed,
Standard fittings on each
Pressure/Vacuum valve : 6 (Minimum)

Gauge
Tank Outlet : 150 mm (3 Nos.)
Tank drain : 25 mm

(all SS pipe lines in use should be
kept to glossy finish through buffing).
3.1.4 DIMENSIONS:
Capacity: 45 KL
Width : 3050mm(120) also no fittings should be protrude

outside cab width.


Coupling.
Notes:-

3.1.5 Tank will be made of mild steel of approved make as per following
specifications :
g. It will be structurally strong and designed to carry ATF of 45000 Ltrs on a


specified above.
h. Tank dimensions should be such that stability ratio is not more than
0.9 and does not violate RTO regulations.
i. Emco type manholes with GI dome covers painted internally and the safe
Each will also have a fusible plug of 50 mm size with melting temperature
of 93 degree C, design approved by CCOE.
j. End baffle plates will be dished type end of suitable curvature. Each
baffle will have at least an area as great as 80% of the cross-sectional
area of tank Baffle plates should be affixed to the tank shell by welding 3
mm thick M.S.angles curved. These reinforcements shall be
circumferentially welded to shell tank completely all round. Baffle plates
will have openings of adequate size at top middle and bottom for
interconnecting all the compartments. Each opening in baffle plate will
be adequately strengthened.
k. No tack welding will be done inside tank in any manner and no gaps left
inside tank that cannot be sand blasted / epicoated. All welding
inside/outside tank will be ground smooth prior to sand blasting / painting.

l. Tank will have following connections:
ix. Tank outlets 150 mm dia.
x. Tank drain 25 mm dia.
xi. Tank circulation point to suit 100 mm pipe.
xii. Sampling connection of 25 mm.
xiii. Two no. inlet / outlet for Two No. deck hose at suitable location.
xiv. One No. 100 mm circulation point for deck hoses on top.
xv. One No. ¾ " (20 mm) opening for return ATF line from Air
eliminator of filter.
xvi. 10” Dial type content gauge.
at bottom surface which come in the path of water drain. The size and
locations or rings will be indicated in drawing of tank submitted with Technical bid.
3.1.7 Bottom loading shall be via the tank internal valve. Two ground half shall be
provided, one on each side of the unit. They shall be connected together via a 3
inch cross manifold which connects into the internal valve. A pressure gauge shall
be installed downstream of each adapter to read bottom load manifold pressure
should be provided with butterfly type isolation valve & a non return valve.

shall act to bleed product from the bottom load manifold to fill a can around the jet
sensor and simulate a full tank. The tank can be drained at a controlled rate via
tubing to the tank bottom to avoid splashing.
3.1.11 A continuous MS section channel will be welded underneath the tank on all along
the length of tank pad plate of 6 mm thick and adequate width. No. of joints in `Z'
channel will be minimum and these joints will be strengthened by welding 6 mm
thick patch plate complying to IS: 2062.
3.1.12 Pneumatically operated emergency valves 6" size with fusible link will also be
provided on Gauge panel.
hand railing.
3.1.14 Ladder with hand rail and additional steps from bumper to ground for comfortable
climbing deck platform would be provided on the rear. Ladder will be fabricated of
M.S. flat / angles and duly painted. The position of the ladder should not so adjust
so as not to cover BPCL logo.
3.1.15 An electro pneumatic interlocking with the brakes when the hand rails are in open
position shall be provided at the entry of the ladder to restrict movement of the
refueller.

3.1.17 Deck platform of heavy duty Aluminum grating shall be provided across full width
of the tank and length of deck hose. Suitable opening for manholes covers, deck
pipes & circulation pipes will be provided in the platform.
3.1.18 The tractor chassis shall be strengthened to raise the height of liquid fifth
wheel and take load of complete trailer assembly. The centre line of liquid fifth
wheel assembly would be at offset recommended by tractor chassis
manufacturer.
3.1.19 Bidder shall arrange to install Dual Liquid Fifth Wheel assembly ( suitable for 45
KL refueller) matching the loading , along with 150mm swing joint assy., flexible
hose. And it will be installed strictly as per manufacturer’s recommendations, after
providing mounting plates on the tank bottom and tractor. These mounting plates
will be adequately strengthened.
3.1.20 The Liquid Fifth Wheel Assembly shall be at a suitable height considering the
space required for module and to prevent fouling of tank bottom with tractor
chassis at rear end.

3.1.21 Liquid fifth wheel (Dual type) should made of composite fabricated steel and
comprises of:
h. Steel upper mounting plate.
i. High strength alloy steel, ball type ring bearing with the inner
bearing race secured to the upper mounting plate.
j. Steel lower mounting plate secured to the outer bearing race.
k. Structural steel sub-frame welded to the lower mounting plate.
l. Two lowering bearing brackets with sock bushing & securing pins.
m. 6” size liquid tight rotating Al swing joint.
n. Flexible rubber joint 6” size
installed adjacent to the centre manway and operate in conjunction with the
internal valve during fueling, defueling and bottom loading. Venting capacity must
be at least 150% of the maximum fueling rate.
3.1.23 One internal valve of 6” size should be installed centrally on the tank bottom centre
line & discharge directly to the pump suction / bottom load manifold. A 1” high wire
shall be installed around the valve to break suction when 1” of the product remains
in the tank. A vortex breaker / anti splash plate shall be installed above the internal
valve.
locking arrangement would be provided. The dip hatch should be provided with a
1.5” SS pipe ending 35 mm from the bottom of the tank. A calibration certificate to
be provided with each refueller at the time of delivery.
3.1.27 Rear bumper will be provided to protect the tank and piping in the event of rear
end collision and minimize the possibility of any part of colliding vehicle
striking the tank. The bumper shall be located at least 150 mm to rear of
refueller component. Structurally the bumper shall be designed to successfully
absorb (No damage which will cause leakage of product) the impact of the
vehicle with rated payload, with deceleration of 2 g using a factor of safety of
two based on UTS of bumper material.

3.1.28 Tower with locking arrangement of suitable strength shall be provided on the front
& rear bumper.
3.1.29 Deck hose circulation points should be located suitably away from the swivel joint
so as to avoid kink in hose while circulation test. Height of deck hose circulation
point should be as low as possible.
3.1.30 All sample points should be covered with canopy arrangement (covering of top &
Capacity : 200 Lts

Material : SS
Thickness : 10 G

3.1.32 The slop tank should be constructed of SS with a heavy duty large size
funnel, a 250 mm (minimum) hinge type lockable cap and having 60 mesh
gauze filter with sufficient support. The tank is to be totally weather proof
and sealed against ingress of contaminants. The tank is to be given a 20-
mm drain with a spring loaded ball valve in line. The slop tank shall have the
following additional fittings:
f. An audio alarm along with light indication on Auxiliary panel shall be

provided in the slop tank when the level of product reaches 75% of
the capacity.
g. A free vent with an inverted “U” opening to prevent ingress of

water.
h. A 10 “flanged type manhole cover with a neoprene gasket.
An alarm should be raised as soon as the level in the slop tank

reaches 75 % of the capacity.
3.1.33 Tamper proof covers or locking devices are required on the following controls
to prevent inadvertent alteration:-
e. Air Pressure regulator

f. Master override switch
g. Interlock override switch
h. DMC override switch

by the bidder.
a. Running Gear 32 MT capacity with two speed / suitable landing gear
b. Liquid Fifth Wheel assembly (Dual).
c. 6” bottom valve fitted with fusible plugs.
d. 6” slim seal butterfly valve.
f. 6”x 4" centrifugal pump with gear box.
g. ATF pump by-pass valve.
h. 4” slim seal butterfly valve.
i. 3” SS Swivel joints (self-lubricating type).
j. 150mm Pressure Control valve.
k. 75mm high performance ball valve.
l. 50 mm Aluminium swing check valve.
m. 10” Content Gauge
n. Bobbin type motorized hose reel with swivel suitable for 2" x 60' long hose.
All moving parts to be provided with safety guards.
o. Hoses should conform to specification ISO 1825: 2010 Third edition, Type-
C. End fittings of SPANNLOC coupling fittings both ends (As per ISO
1825:2010 stds), male to male NPT thread..
p. Reel hose to be provided with wear rings at the interval of 2’ up to 20’.


q. Hose reel should be provided with flame proof / CCOE approved rewinding
motor.
r. Power of winding / unwinding of reel hose drum with speed control is to be

s. Hose rewinding motor specification:
Capacity : 0.5 HP
Current : 53 amps
Type : Class B
Max. winding speed : 0.72 m/second (DC motor is fixed and
variations in speed to be achieved thru
gear/chain mechanism)
t. 2.5" under wing pressure coupling.
u. 2 ½" 3-lug adaptors
v. 25mm spring loaded valve
w. 150mm pneumatically operated drain valve and sampling valve
x. 100mm cable operated emergency valve
Typical Bobbin type reel hose drum

3.2.3 In defueling of 45 kl refueller, the refueller pump is used to create suction up to the
delivery couplings by using Eductor in defueling mode. Defuelled product should
not passes thru Filter monitors.
3.2.4 Bidder shall supply 150mm size bottom loading internal valve, jet level sensor with
precheck testing arrangement. Water preventing ring 12 mm wide will be provided
around this valve.
3.2.5 The product entering the tank goes through the bottom loading system and hence
is subjected to the high level shut off control system.
3.2.7 The product pump should be of self – priming centrifugal type, mounted rigidly and
PTO driven. PTO shall be provided with suitable Chassis & with suitable running
gear
Make : Gorman Rupp

flow rate.

3.2.8 A pressure limiting pump by- pass valve ( size 3”) shall be installed to limit pump
output pressure in a range 75 psi to 150 psi, the valve shall also function as an
on/off valve actuated by an air reference signal from the dead man control.
g) Body / Cover : ASTM A216/A216M-04
h) All trim materials : ASTM A351/A351M-06
i) Elastomers : BUNA N
j) Ò' Rings : BUNA N
k) Internals : AISI 316
l) Nuts/Studs : ASTM A193

preferably in horizontal position. The pilot shall be located at convenient place
for easy access. Bidder will arrange to set the valve as per BPCL requirement.
pump inlet.
3.2.12 1000 USGPM capacity fuel monitor with air eliminator, of S S construction fitted
monitor will be of size 2”x25 or 2”x30” only. 2 Nos. 25 mm spring loaded valves
with SS elbow will be fitted for drain and 25 mm sampling lines in such a way that
fitted with crocodile clip. Sampling lines shall end in elbow, and fitted with Camlock
type SS cap & chain. Tank bottom sample point should be covered with four sides
with canopy arrangement to draw samples easily during heavy rains on refueling
operations.

3.2.13 The following instruments and controls are required and are to be neatly located at
the pumping control station. A typical panel layout is shown in attached drawing.
A. Main Gauge Panel


of 2 psi.

LC of 2 psi.
indicator)
B. Auxiliary Panel
♦ Engine Stop
♦ Deadman Light
♦ PTO Light
♦ Millipore Point

swing check valve.
shall supply one set of spare new filter elements in a properly sealed box & should
be delivered along with the refueller. (Total 2 sets of filter elements). Butterfly valve
on inlet and outlet of the filter vessel shall be provided.
filter drain. A label stating size and no. of fuel monitors to be fixed using engraved
laminated SS plate.

Visi- flow Air eliminator Pressure relief
of proper sampling probes. The probes should have provision for sampling as well
as tapping off pressure for differential pressure gauge. A quick coupler of male
adapter along with aluminum cap attached with chain should be provided on
auxiliary panel.
3.2.20 A direct reading piston – type gauge with auto check push button to be provided to
check its performance, shall be installed with panel to measure the differential
3.2.21 A proper spring loaded normally closed pressure release valve should be installed
on the filter vessel.
control and dead man control will be installed as per manufacturer's instructions.
The SS fuel sensing line from venturi will be connected to the pilot of the PCV and
pressure gauge on panel. The opening/closing time of PCV will be adjusted to
BPCL’s requirement.
3.2.23 Primary pressure control (HECV) shall be set to control the down stream pressure
at 45 psi.
application of an air reference signal. The operating time of the valve by dead man

control shall be adjustable within the range of 5 to 10 seconds and closing time adjustable
within the range 2 to 5 seconds.
6” flanged type inlet & outlet. Make – Whittaker,

(Compensator) shall be capable of providing between 15 & 35 psi compensation in
order to maintain a flow rate of between 70% & 100 % of maximum flow. The
3.2.27 6" x 3" fuel-defuel valve will be installed preferably in vertical place. Pneumatic

3.2.28 A push pull fuel/ defuel knob with sealing arrangement to be provided on auxiliary
panel.
3.2.29 Bulk meters with mechanical counter, fitted with suitable pulsar & reset switch shall
be installed as per recommendations of bulkmeters manufacturer. One 4"
butterfly valve shall be installed on outlet, for the bulkmeters supplied without
faucet valve.
copy is to be provided to location for stamping purpose after delivery. The supplied
bulk meter should be of latest model and the bulk supplier should have wide sales
& services network across India.
adequate capacity.
a. Application: Delivery to Aircraft

b. Product to be measured: Aviation Turbine Fuel
c. Specific Gravity: 0.775 to 0.830
d. Operating Pressure: 150 psi
e. Measurement units: Litres
f. Flow Direction: Bi- directional
g. Connections: Flanged ends

Typical Flow meter of Avery Hardoll,make :

PART NO. 767163—303

TECHNICAL

1. Input Supply 10 # 15 VDC
2. Current 50 mA at max 10 - 15 VDC
3. Switching Times
4. Rotation Bidirectional
5. Input Shaft Speed 600 rpm max
6. Output Pulse Dual channel at 50 ppr

7. Operating Temperature: 42°C to 82°C
8. Storage Temperature: 55°C to 125°C
9. Housing Explosion Proof
10. Mounting Three ¼ - 20 UNC # 2B blind tapped holes, spaced 120° apart
on a 2.5# diameter bolt circle
11. Cable Gland BASEEFA (UK) or equivalent approved with Group IIA, IIB or
IIC enclosures
12. Cable Type 2, 3, 4, 5 or 6 core tinned copper conductors with metallic
screen
13. Cable Length 10 # 15 meters
14. Approval BASEEFA (UK) or equivalent

Model: 8064/21

1. AC Current 11 # 2.5 amp
2. AC voltage 400 V
3. DC Current 11 # 6 amps
4. DC Voltage 250 V
5. Compliance IP # 66
Description:
a) 8064 with flexible lead, single micro switch, with snap action contact, plunger
with plastic roller. 1 c/o contact with 3 core cable, 3 mtrs. in length.
In this case model approval for bulk meter along with pulsars & reset switch is with
the fabricator before dispatch of refueller.
3.2.34 Suitable compensator, separate for reel hoses & deck hose shall be installed with
needle valves, pressure gauges, shuttle check valve etc.
3.2.35 3" x 3½" x 2" Eductor unit of aluminium construction with victaulic connection will
be supplied and installed.
3.2.36 3" aluminum wafer type swing check valve will be supplied on defuelling line and 4”
size on the self loading point.

3.2.38 The loading / circulation point will have 2 Nos. 2½" ground half unit adaptors with
2 Nos. 3” butterfly valves. One No. 3" butterfly valve and ground half unit will be
provided for self loading point. All the 2½” adaptors should have :

3.2.39 Similarly 2 no. ground half unit will be supplied and installed for deck hose
circulation with a butterfly valve for HEPC testing.
3.2.40 2.5 " Reel hose BOBBIN type with swivel suitable for 2" x 60 ft long Aviation hose
will be installed with manual rewind & DC motor rewind mechanism and HEPCV
testing arrangement . The hose should have protection beads every 2 feet upto 20
ft to avoid abrasion. End fitting with easy locking nut adaptor to be provided on
reel & Deck hoses for easy unlocking of hose for pressure testing, also yellow
color band at end of reel & deck hoses should be provided.
isolation valves. Provision for IN – SITU hose testing arrangement along with 5
mts. long additional rubber pipe with SS quick connector to be provided.

3.2.42 SS material of > 300 psi rating swivel joint shall be used on deck hose to carry out
IN – SITU hose testing.
pipeline connection only, flange joints to be used.
3.2.46 All the flanged joints will be provided with copper strip jumper of 25 mm wide
x 0.93 mm thick. These jumpers should not be coated with the paints. The
pipeline and components will be adequately supported.

Valve Type : 803
Class : 300
Ball : AISI 316
Seat : PTFE
Stem : AISI 316
3.2.49 All the ATF sensing line for compensators, PCV, FWS, PD gauges shall be of
Metal : SS 304

Least Count : 2 psi
connection in the sensing line to enable testing of gauges with respect to a gauge
comparator.
hose connection. However, sample points should not be too high off the ground to
prevent splashing and spillage. Tank bottom sample point should be covered with
canopy arrangement (covering of top & four sides) to draw samples easily during
heavy rains on refueling operations.
3.2.55 A SS engraved plate for fuelling circuit and operating instruction to be provided on
the gauge panel.

1:1)
mudguards.
3.2.59 One no. of structurally strong step ladder of Aluminum to be provided along with all
refuellers of 6’ height suitable for refueling of A320 aircrafts shall be supplied along
with the Refueller. There should be provision of keeping ladder with sliding
arrangement on the rear of the Refueller. Suitable locking arrangement also to be
provided, so that latter does not slide or move during refueller movement.

3.3 WEB CAMERA
Specification:
Signal System : PAL/NTSC
Image Device : 1/3.7” High resolution digital
Image sensor
Effective pixel : 648(H) x 488(V)

Horizontal Resolution : 520 TVL
Lens Furnished : 1.7 mm in Built, Optional:
2.8mm, 3.6 mm
Shutter Speed : 1/50~1/100,000 Sec
Min Illumination : 0.5 Lux / F1.2,
White Balance/ Back Light Compensation : Yes
Exposure Control/AGC/ Color Correction : Auto
Synchronization : Internal synchronization
Video Output Signal : 1V p-p Composite video
Power:

Specification:
Camera Pixels : PAL: 500(H) x 582(V) ; NTSC: 510(H) x

494(V)
Resolution : 480 TVL
Min Illumination : 0.05 Lux / F2.0
Electronic Shutter : NTSC: 1/60~1/10,000 PAL: 1/50~1/10,000
IR : 24 IR LED, Ø5 mm, 850nm, IR distance- 20 Mtr.
White Balance : Auto Tracking White Balance
Lens Furnished: Built in : 3.6mm , optional: 2.8mm/6mm/8mm
Video Outpu t: 1V p-p Composite, 75 Ω
Power:
Full Function Remote Control, Random Camera Selection through Numeric Keys on
the Remote Handset, Individual Dwell Time Setting for each Camera from 01 to 99
Seconds in AUTO Mode, Changeover from AUTO to MANUAL or Vice-versa through
Single Key, Memory Retention in case of Power failure
Specification:
Particulars: Video with 2Way Audio
Camera Inputs (n): Min two
Display: Min two
Camera Input: 5 Pin Din
Monitor Output: RCA
Video Input: 1 V p-p Composite, 75 Ω
Video Output: 1 V p-p Comp., 75 Ω
Audio Output: 2 V p-p, 50 Ω
Operating Temperature: 0°C to 50°C
Power:

Features
3 auto triggers
Audio
Sun shield
Auto dimmer
Remote control
Multi-lingual menus
Picture Quality
Anti-glare screen
Resolution: 480 x 3 x 234
Contrast ratio: 400.1
Brightness: 350 cd/m2
Viewing angles
Power

Current: 0.8 Amps

RUNNING GEAR ASSEMBLY
Running gear shall be designed for the actual loading.

Running gear assembly:
The running gear assembly shall consist of an under carriage with twin axles, wheels
and tyres, tandem suspension, brake assembly, with a landing gear assembly but
without king pin assembly.
Axles:
All the axles shall be made of EN 16 or equivalent alloy steel, suitably heat treated
with precision finished bearing journals & fitted with taper roller bearings. The axles
should be designed for rough driving conditions.
Running gear of 45 KL shall have 3 axle with 12 tyres of 10 X 2000 x 16 PR tyres
Suspension:
Tandem suspension assembly shall have adequate leaf springs. The spring shall be
made of En 45 spring steel material.
Brake System:
The foundation brakes shall be of design approved by manufacturer of chassis. Twin
air line brake system shall be provided with all fittings like RE valve etc. of Sundaram
Clayton make. The manually operated braking system shall also be provided.
Wheels and tyres:
The wheels shall be of standard size matching with chassis. A spare wheel will be
also be provided with suitable bracket for fixing. The tyres shall be of same make as
that of chassis.
Capacity:
Design load: To be designed
Axle Load: suitable for for 45 KL Refueller

Dimensions:
Wheel track: 1900mm
Over all width: 2500mm
Landing gear assembly: A suitably designed landing gear assembly consisting of
two legs will be installed on tank bottom side near liquid fifth wheel assembly at a
location so selected that the tank will remain stable on disconnecting from tractor.
Two speed Jost make landing gear should be hand operated.

3.4.1The pneumatic system consists of dead man control of pressure control valve and
brake interlock system.
c) Palm couplings
and SS metal knob.
e) 3/8" BSP 4 way adapted to 3 way push button operated valve without
spring return and SS metal knob, sub base type.
make)
mounted master emergency override valve will be provided. 1 No direction control
valve to be provided in cab for engaging ATF pump along with pressure regulator
and gauge. The pneumatic interconnections will be done through Dunlop
make RI series pneumatic hose, palm couplings and Audco IN 123 valve.
Additional 30 liter air tank with drain cock, Audco IN 123 valve, pressure gauge,
unloader valve will be provided.
couplings are lifted from coupling holder trailer brakes should be applied. Brakes
should also be applied when ATF pump is engaged or the refueller is connected
for topping up operation.
should be of legris make PU type which has found to be of good quality with proper

weather proof conduiting for protection. No copper lines should be used in the
system
interlock override switch should be provided on control panel and master switch in
cabin with sealing arrangement.
select engine RPM at preset levels for high & low fueling rates and defueling rates.
Selected RPM setting shall be actuated by the deadman control.
colours respectively for easy identification.
3.4.11 Brake interlock on PTO to be provided.
3.4.12 A written warning in addition with light indication shall be displayed on control
panel as “BRAKE INTERLOCK ON”.
3.4.15 Brake interlock shall be provided on hand brake. Brake interlock override valve on
control panel shall be push pull type with sealing arrangement. Master brake
arrangement.

should be located away from fuelling panel so that it is not used by the operator on
routine basis. Provide proper sealing arrangement for deadman override switch.
shall be provided.

height of fully elevated deck should not be more than 1.0 m. A free – standing area
immediately outside the ladder is required. The railing shall be connected with
electro – pneumatic interlock to protect air craft from any potential damage and
prevent refueller to move without closing the collapsible railing.
under:

Typical Brake interlock light arrangement:
White - PTO ON
Green - DMC ON
engaged)
Red - DMC override

conduits will be of adequate size to accommodate number of wires passing
through it, without any damage to insulation. Electrical wires will be of `Finolex'
make or equivalent.
viii) Brake lights
ix) Turning lights
x) Cabin lights - 2 Nos.
xi) Instrument panel lights
xii) Adjustable spot-lights / flood lights for night operations near the deck
hoses.
xiii) A large flashing amber beacon light of Lumax make with speed 60 – 90 per
light fitting arrangement is shown in Fig. In addition to this, 2 Nos. red lights
on front cab corners of approved make.
xiv) Four numbers, red lights on top of tank - 2 at the front and 2 at the rear end
of high lumens of approved make.
All lights and switches in module compartments of shall be weather-proof CCOE

approved.


3.5.5 Battery compartment in cab/under the cab will be of safe and suitable design. It
will be fabricated out of SS Plates and lined with thick hard rubber. Lid will be
provided under co-driver seat. Also made provision to take out battery for charging
without tilting of cabin.
3.5.7 FLP heavy duty pin plug of Sudhir Switch Gears or equivalent make approved will
be provided for interconnecting tractor and trailer.

a. PD gauge (Gammon) 0 - 30 psi range with auto check facility.
b. Inlet pressure gauge
c. Pressure gauges for venturi - 2 Nos.

d. PCV air reference gauge
e Air tank pressure regulator valve
specification.

iv). LC - 2 psi
v). Glycerin filled
f. Interlock on (red), Interlock override knob, Emergency shut off knob (As
shown in Fig.), PCV air regulator knob, Flow diagram.
g. Brake interlock indication for each interlocks (2 deck hose coupling, 2 reel
hoses couplings, one at loading point and one at rear on ladder point).).
h. Pump throttle arrangement. – Pump throttle could be brought on to the main

panel with gradual control arrangement.
i. All the gauges for ATF & pneumatic will have testing with SS quick acting
with a gauge comparator. Provide in-situ gauge testing provision as per
BPCL standard.
j. Protective roof / canopy shall be provided on top of panel and bulkmeters and
all sampling points. It will be painted white from inside.
k. Two Nos. CCOE approved Weather proof lights shall be provided and
l. Panel to have emergency fuelling stop knob painted in Red colour.
m. Sketch of ATF pipeline circuit with all valves and equipment etched on an
steel or a suitable material will be also fixed near the control panel, along
with operating instructions. All the valves and equipment will be clearly
labeled for easy identification.

n. Emergency Shut off knob shall be provided on control panel as per
enclosed BPCL standard drawing.
o. In addition to control panel an auxiliary panel would be also provided as per
drawing.
p. A written warning in addition with light indication shall be displayed on

control panel and in cabin as” BRAKE INTERLOCK ON”.
q. A written warning in addition with light indication shall be displayed on

control panel and in cabin as” BRAKE INTERLOCK OVERRIDE”.
r. Green light for DMC “ON” , red light for ’DMC OVERRIDE ON” white light for
“PTO ON” , yellow light for “SLOPE TANK OVERFLOW” , and blue light for
“HAND BRAKE ON” indication on auxiliary panel.
3.6 PROTECTIVE/SAFETY DEVICES
3.6.1 Two nos IS approved make 9 KG DCP type fire extinguisher(IS -15683) will be
3.6.2 Two vertical type fire extinguisher brackets / holders to be provided on either side
of the vehicle at the rear end on single chassis at height not more than 18” from
ground level. To remove the F.E. easily, two semicircular 2” strip having hinge at
one end & locking pin at the other as shown in the photograph. The strips when
secured with locking pin should not hold F.E. loosely. Canvas padding of
appropriate thickness is to be provided on the inner layer of the strips to hold F.E.
tight and also to avoid scratches on F.E.

Typical DCP FE bracket/holder arrangement:

3.6.5 Two Nos. suitable earthing bonding reel of SS material shall be supplied with each
refueller. One bonding reel to be fitted near to control panel & another on the
opposite side of the control panel. Exact position of the bonding reels will be
crocodile clip.

3.6.9 Fuel dispensing system will be bonded for electrical continuity by providing copper
strips at all flanged joints.

g) Fire screen at the rear cab, to extend upto 300mm from ground level. Fire
h) Exhaust pipe of engine will be modified to be on front of cab on the Co-

driver's side and will be fitted with CCOE approved flame arrestor. This
flame arrestor will be suitable for tractor chassis.
3.6.11 Diesel tank will be provided with locking arrangement. The arrangement should
be such that when tank overturns, product does not spill.

3.6.13 6 mm x 10 mt. long flexible rubber hose will be provided for tyre inflation and fitted
with suitable tyre valve at the free end. An air charging pin with 1/4" ball valve will
be provided on panel on tractor and connected to air tank.
necessary.
for bonding. All sampling drains (Picture is enclosed ), Millipore & Gauge testing
ports will have aluminum caps with chain (QDC type ).
chassis supplier.
3.6.20 2 nos. of chokes (hard rubber type, more user friendly, applicable at Apron use) to
be provided including making provision for holding chokes.
purpose of consolidation and display of important dates e.g. fitter changed on/due
on/inspected on tank cleaned on/due on, gauge tested on / due on etc.

SECTION – 04
PAINT SPECIFICATIONS,
PAINTING PROCEDURES &
VM
SECTION – 4 PAINT SPECIFICATIONS, PAINTING PROCEDURES &
VM
4.1 GENERAL
4.2 SCOPE
4.3 COLOUR SCHEME WITH SPECIFICATIONS
4.4 EXTERNAL PAINTING SCHEME FOR ALL REFUELLER
PAINT SPECIFICATION,PAINTING PROCEDURE & VM ISSUE: 02 DATE: 01.10.2013

4 PAINT SPECIFICATIONS, PAINTING PROCEDURES & VM
4.1 GENERAL
The refueller may be operated in humid atmosphere, having humidity above 90%
and high / low temperature ranging from 4 - 5º C to 45 - 48º C. These technical
specifications shall be applicable for the work covered in fabricator’s contract, over
and above and without prejudice to the various codes of practice, standard
specifications etc. The fabricator shall carry out the work in all respects with the
best quality of materials and workmanship and in accordance with the best
engineering practice and instructions of BPCL. Whenever it is stated in the
specification that a specific material is to be supplied or a specific work is to be
done, it shall be deemed that the same shall be supplied or carried out by the
fabricator at his own cost.
Coating should also not be harmed or readily discoloured by contact with grease,
oil, ATF or routine chemical washing.
The mating faces of bolted assemblies must be sealed with a mastic type
compound to prevent corrosion resulting from the entry of water.
In respect of labour and other personnel directly or indirectly employed in the work,
the fabricator shall arrange for all safety provisions.
4.2 SCOPE
Scope of work covered in the specification shall include, without being limited to
the following: -
• Surface preparation
• Supply of all primers, paints and all other materials/equipments required for
painting and proper application as per specifications and as specified by paint
manufactures.
• Carrying out painting with all safety precautions and be able to use own skill
and judgment to provide a high quality and durable finish.

4.3 COLOUR SCHEME WITH SPECIFICATIONS:
4.3.1 PAINTING
The surface is to be sand blasted as per IS - 1477 - Part (1) - 1971. The
degree of blast cleaning will be as per SA 2 1/2 which means blast cleaning
to near white metal to give a light grey white uniform metallic colour slightly
roughened to form a suitable anchor pattern for coatings. The surface when
viewed without magnification shall be free of all corrosion products, rust mill
scale oil paint, or any other foreign matter.
The time gap between the blast cleaning and application of primer should not
be more than 3 hrs. Blast cleaning work to commence from top to bottom.
Arrangements for inspection at various stages of work will be made available

so that entire sand blasted area is accessible for inspection. Any defective work
noticed must be immediately rectified by re-blasting, if necessary.
4.3.2 INTERNAL PAINTING
1. Epicoating :
a) Primer and finishing coats :

After cleaning the sand blasted surface with dry compressed air the
surface shall be treated with two coats of blast primer at a dry film
thickness of 50 microns per coat and two coats of high build epicoating at
a dry film thickness of 80 microns per coat. The total dry film thickness of
the above paint system should be minimum 250 micron. Only white coat
epicoat will be used.
b) Application of Primer :
The first coat of primer shall H/B blast primer which is an epoxy primer /
poly amine cured and pigmented with Zinc Phosphate. The primer will be
cold cured two pack epoxy product and shall be mixed at site in the
proportion of 3 : 1 by volume between base to harder. The mixed primer
shall be applied by brushing.
The second coat of primer shall be applied with an interval of 24 hours. The
dry film thickness of each coat of primer shall be 50 microns. For
structural steel members such as columns and roof members which are
stitch welded may have some gaps that will need filling. The filling should
be done by means of Epoxy putty made in situ by mixing Epoxy and whiting
in the proportion of 1: 1 and gaps filled with putty knife/trowel. After the

application of epoxy putty the same shall be allowed to cure for minimum 24
hours prior to application of finishing coats.
c) Application of finishing coats :
After 24 hours from the time of application for second coat of primer, the
first coat of high build Poly-amine cured finish coating shall be applied. This
epoxy paint which is a two pack cold cured high solid epoxy coating shall be
mixed at site in the ratio of 3 : 1 by volume between base to hardener.
The mixed paint shall be applied immediately after mixing by brush to a
uniform glossy finish and to a dry film thickness of 70 to 80 microns for each
coat. The first coat epoxy paint shall be white in colour and the finishing
coat shall be of off white / white colour. The time gap between the first and
second coat shall be 24 hours. The dry film thickness of the final coat
shall be 70 to 80 microns and the total dry film thickness of the above
paint system should be at least 200 to 260 microns as stated earlier.
Only white epicoat paint shall be used.
After application of final coat, the painted surface shall be allowed to cure
for minimum seven (7) days so as to enable it to attain tough, abrasion
resistant and chemical resistant surface.
d) Curing Test :
The following test shall be carried out in order to ensure that the epoxy
painting has cured properly:
A swab of cotton wool soaked in Methyl - Iso Butyl - Ketone (MIBK) is

laid on the painting surface and covered with a watch glass. After one
hour there should not be any softening of the painted surface. If softening is
noticed, the painted surface should be allowed to cure for a further period of
one or two days and tested again.
e) Thickness Test :
Calibrated measuring gauges like Elcometer shall be arranged by

contractor to measure the dry film thickness of each coat of paint and
also the entire paint system.
2. Use of Thinners :
The addition of thinners shall be limited strictly to the paint manufacturers
Instructions.
Each coat of primer and finishing coat shall be applied only after ensuring
that the paint is free from dew or moisture and the surface is hard dry and
free from dust.

3. General Inspection :
a) Painting shall follow immediately after blast cleaning. No painting
shall be carried out when there is danger of dew / moisture / high
humid condition or during monsoon on the surface to be provided.
b) Tools used shall be clean and not excessively worn. The paints in the
drums shall be mixed thoroughly prior to application. The drums
shall be inspected to the correct grade and to see that no sediment is
left in them. In case the paint is thickened because of the
evaporation of the solvents, its viscosity shall be adjusted as
recommended by the paint manufacturer.
c) Each coat shall be inspected and allowed drying time to make the
surface hard dry but not excessively before applying the following
coat. Manufacturer’s instructions for drying time shall be adhered
to properly.
d) Each individual coat shall be properly applied reasonably level

and smooth, free from runs and holidays. To avoid partly finish
and poor flow, painting shall not be carried out against direct
sunlight and draughts.
e) Paint used shall be of batch which is of recent manufacture and

is acceptable for uses as per paint supplier recommendation.
Under no circumstances shall paint / primer etc. will be used which
has expired shelf life.
4. Make of paints and thinners :

The prior approval of BPCL shall be obtained before selecting the
manufacturer of paints and thinners. The paints selected shall tally with the
composition of constituents of paints specified.
The General approved list of manufacturers is as follows:
a) Jenson & Nicholson (India) Ltd.
b) Shalimar
c) Berger Paints (India) Ltd.
The final choice of selection of particular make of paint shall rest with
Corporation. Contractor shall furnish the test certificates from paint
suppliers for satisfactory MIBK Test and thickness test.

4.4 External painting of Refuellers:
The refuellers will painted as per Corporation's painting scheme, applicable for
aviation mobile equipment. Painting scheme will be according to the drawing, to
be provided subsequently. All SS pipe lines, slop tank, Gauge panel & filter
housing should be kept to glossy finish through buffing.
Following colors are used in painting scheme:
4.4.1 For Printing Jobs CMYK values:
Blue : C -100, M - 40
Yellow : Y -100, M-10
Brilliant white:
Solid grey :
4.4.2 For painting jobs RGB values are:
Blue : R - 0, G - 103, B - 172
Yellow : R - 252, G - 219, B – 0
1. Surface preparation prior to applying primer coat and final paint will be
strictly as per paint manufacturers recommendation. Drying time in
between various coats of paint will be given as per recommendations. This
recommended procedure for painting will be followed to achieve maximum
and long lasting gloss of the paint.
2. Lettering and emblem: All lettering & emblem shall be of sticker. Lettering
will be written in Hindi and English. Detailed color scheme and other details
will be given subsequently.
3. Circuit Diagrams: Various valves/controls in the circuit, ATF, pneumatic and

hydraulic, will be numbered and metal stamped/engraved plates
attached firmly to these valves. Circuit diagram in miniature, will be
engraved on suitable size, black colour plastic sheet fitted in frame,
giving the numbers of valves/controls. Instructions for carrying out various
operations will be engraved on metallic sheet. White colour illuminating

paint/material will be fitted in the engraved lines/litters. These will be
mounted suitably at approved locations.
4.5 EXTERNAL PAINTING SCHEME FOR REFUELLER
4.5.1 Painting scheme-15 KL




4.6 Painting scheme-25 KL




4.7 Painting scheme-45 KL




NOTE: Exact details of external painting would be provided later conforming to our
Aviation painting scheme
The refueller including cabin, chassis, tank, wheels, aviation module etc. shall be painted
as per BPCL colour scheme. Our Manual on “Visual Manifestation Mobile
Equipment” has detailed drawings, dimensions and procedure for painting, emblem &
lettering etc. and the same to be followed for reference.

SECTION – 05
STATUTORY
REQUIREMENTS
INSPECTION / TESTING /
COMMISSIONING
SECTION – 5 SATUTORY REQUIREMENTS
INSPECTION/TESTING / COMMISSIONING
5.1 RTO/CCOE/INSURANCE/STATUTORY FORMALITIES
5.2 INSPECTION
5.3 TESTING
5.4 COMMISSIONING
SATUTORY REQUIREMENTS ISSUE: 02 DATE 01.10.2013

RTO / CCOE / INSURANCE & STATUTORY FORMALITIES
The bidder should comply with the following requirements & quote
considering all aspects given below:
5.1.1 Temporary Registration :
All the RTO formalities required for temporary registrations, non-use, road
tax, chassis tax, trailer/running gear approval etc. is included in the scope.
Bidder shall quote considering all the above requirements.
5.1.2 Permanent Registration/ Goods permits :
Permanent registration /Goods permits will be carried out by BPCL at AFS

locations. However if the delivery location of refueller & place of fabrication
happens to be the same place, (Covering near by areas-Delhi and NCR,
Mumbai and Navi Mumbai etc.) bidder will also carry out permanent
registration/ Goods permits of the Refuellers at his own cost.
5.1.3 Transit Insurance :
Transit insurance required for delivery of the completed vehicle up to the

destination is in the bidder’s scope.
5.1.4 Transportation :
Bidder shall arrange collection of Chassis from Chassis

Manufacturer’s RSO
Bidder shall arrange for the transportation of completed vehicle to the

intimated BPCL Location or as advised by the BPCL at later stage. Toll tax,
octroi, any enroute taxes shall be reimbursed on production of original
receipts.
5.1.5 Insurance for Free issue items :
Bidder to arrange the comprehensive custody insurance coverage for the

free issue item for the entire fabrication period. BPCL shall be the principal
beneficiary in the insurance cover.

5.1.6 MODEL / TYPE approval (METER ASSEMBLY) :
Bidder to get the type / model approval from the department of Legal
Metrology with the calibration certificates
5.1.7 STATUTORY / GOVT. formalities :
Any other formalities (Like NOC’s, route permits etc.) required for
completion & delivery of Refueller be obtained by bidder.
5.1.8 CCOE FORMALITIES:
a) Party has to get the approval of Refueller from the CCOE

department along with critical items fitted on vehicle.
b) Party has to submit the CCOE approval test certificate of all

the Electrical/safety fittings.
5.1.9 CALIBRATION OF FLOW METER:
All necessary assistance as detailed in chapter 9 shall be arranged by

fabricator at our AFS for initial stamping of flow meter by local legal
metrology department. It would be fabricator’s responsibility to ensure that
the legal metrology department’s seal is intact on flow meters and the flow
meter procured is duly approved by legal metrology department.
5.1.10 Approval for Tractor-Trailer design:
Vendor to furnish approval for the tractor trailer design from the competent
authority viz. The State Transport Authority.

INSPECTION, TESTING & COMMISSIONING OF REFUELLERS
5.2 INSPECTION
a) Bharat Petroleum Corp. Ltd. And / or approved third party inspection

agency appointed by the bidder (out of DNV, BVQI or LRS) will carry
out stage-wise / final inspection of refueller. Bidder will provide all
facilities / information requested for above.
b) Detailed quality assurance plan for raw material, in-process and

final testing will be submitted within 15 days from date of LOI along
with Bar chart. Also detailed fabrication drawings for tank, cab,
module etc. will be submitted for our approval within 20 days from
date of LOI.
c) Stage-wise inspection of raw material, fabrication work of refuellers,

welder qualification, welding etc. will be carried our as per above
approved plan and drawings. Final assembly of piping components,
tank etc. will also be inspected and tested.
d) Vendor will submit all test certificates in compliance with inspecting

agency.
e) Vendor will submit fortnightly report prepared in MS Office – project

software or any other equivalent package on status of
fabrication/Procurement to the Engineer in-charge.
5.3 TESTING
As mentioned in above paragraph, testing of all equipment will be as per

quality plan and broadly involve following job:
5.3.1 Tank ( Inspection shall be carried out by BPCL / TPIA )
5.3.2 Material test certificate giving chemical composition (C, Si, p) mechanical
properties complying with requirements, mentioned in the technical
specification of chapter 5, will be arranged from an approved test lab.

5.3.3 Welder qualifications will be carried as per relevant code. Only approved
electrodes would be used.
5.3.4 Test certificates / CCOE approval to be submitted for all the bought our
items like PV valve, fusible vent etc.
5.3.5 Complete production process of tank fabrication to be approved. Welding

quality to be checked by DP test. And finally dimensional conformity,
installation accuracy and fitments check of tank to be carried out. Tank will
be hydro tested to 5 psi using 12 feet high pipe fitted on top of tank and
gauged using pressure gauge having least count of 1/2 psi, at which time
all joints under pressure shall be inspected for the issuance of liquid
to indicate leaks. All the closures shall be in place while test. During
these tests, operating relief devices shall be damped, plugged or
otherwise rendered inoperative. During hydro-testing, the temperature of
water will not exceed 37.8 C. The tank will be kept under pressure for 30
minutes.
5.3.6 Tank capacity to be checked physically using IS approved water meter.

Care shall be taken while loading / decanting for the venting to avoid
damage to tank.
5.4 Aviation Module
5.4.1 Vendor will send unpriced copies of Purchase Order to BPCL for physical
monitoring and keep us informed on status of procurement of each
equipment
5.4.2 Material test certificate will be submitted for each module components used
from the supplier.
5.4.3 Welders will be qualified for fabrication of SS pipeline and all the weld will
be inspected and checked as per relevant IS codes.
5.4.4 Complete module layout drawing will be submitted by Vendor for approval.
Dimensional accuracy will be checked as per above drawing.
5.4.5 Complete pipeline assembly will be hydraulically tested to 300 psi.

5.5 Pneumatic System
5.5.1 Material test certificates to be obtained for each component from the
supplier.
5.5.2 Complete layout drawing to be submitted for our approval. Assembly

check will be carried out as per this drawing.
5.5.3 Pneumatic test using soap solution to be carried out at 150 psi.
5.6 Electrical / Instrumentation System
5.6.1 CCOE approvals to be submitted for all the equipment required as per
tender.
5.6.2 Material Certificates to be obtained from all the suppliers. Electrical layout
drawing to be submitted for our approval.
5.6.3 Assembly / Circuit to be checked as per the drawing.
5.6.4 All the electrical fittings will be tested thoroughly for its operations.
5.7 Safety fittings etc.
5.7.1 Test certificate of all the safety fittings relevant to IS code as per the details
of technical specifications of chapter 5.
5.7.2 Checking specifications / quantity of all items supplied as per the details of
technical specifications of chapter 5.
5.8 COMMISSIONING
5.8.1 Performance trial will be carried out at bidder’s works. At least 5 KL of ATF
will be made available in tank of refueller. Special care will be taken for
quality of ATF used. It should be filtered through 100 mesh filter and free
from water.
5.8.2 The bidder must have the facility to carry out circulation & testing at his
works.

5.8.3 Fuel will be circulated through system. During initial circulation, bulkmeter
will be removed from the line and matching spool & pieces to be provided to
avoid any damage. This flushing will be carried out at low speed. Used
filter elements required will be provided by BPCL.
5.8.4 Detailed performance chart will be prepared giving all parameters at various
engine speeds as per schedule given by BPCL. Fuel will be circulated
through 2 hoses using all combinations of one deck hose and two hose
reels. Defuelling to be carried out at various speeds to determine
performance.
5.8.5 During circulation test, pressure test of pipelines, gauges etc. will be carried
out by closing delivery nozzles and pump run at rated RPM for about 4
minutes. Any leaks and abnormal pressures noticed during this test will be
rectified.
5.8.6 Refuellers will be tested for road worthiness on road and driven at a speed
of 30 km/h for malfunctioning of brake interlock and brake system in
general for proper operation.
5.8.7 After completion of performance trial, product shall be drained out

completely from tank, pipeline, module components, sensing lines before
dispatch. Tank shall be cleaned thoroughly and boxed up prior to dispatch
to our aviation fuelling stations given later.
5.8.8 At our AFS, the refueller will be loaded fully with ATF and calibrated
through Master meter provided by BPCL. And the dip rod shall be suitably
marked with proof level etc. Complete performance trial will be conducted
using new filter elements supplied by the successful bidder. All the
manpower necessary for above commissioning at AFS will be provided by
the Bidder. The refueller shall be commissioned to the satisfaction of the
user and handed over locally.
5.8.9 Bidder will arrange weighing of refueller on weigh bridge with two crew
but without product in tank. Loading across each axle will be found and
certificate shall be submitted for the same.
5.8.10 Documents of vehicle received by us will be handed over to bidder. On

receipt of chassis, the same will be handed over to RTO for non-utilization
of these chassis on public road. Bidder shall, before delivery of refueller,
arrange for CCOE, VJTI (If applicable) and other govt. approvals for tank /
trailer design. RTO charges, entry taxes / permits or govt. levies. will be
reimbursed at actual on production of valid documents.

5.8.11 The refuellers shall be commissioned and registered permanently (if
applicable as per the details of chapter 7.) at any one of our all India
location. Bidder to furnish cost of transportation on per Km basis and that
the octroi, enroute taxes will be reimbursed against original receipts.
Bidder will also obtain necessary NOCs and route permits or other govt.
clearances required for transportation of the vehicles to the intimated
destinations.
5.8.12 Bidder will maintain chassis strictly as per manufacturer’s

recommendations. Maintenance of chassis during fabrication stage will be
entirely in Bidder’s scope. The chassis given will carry warranty from
chassis manufacturers. It will be Vendor’s responsibility for regular servicing
of chassis.
5.9 DOCUMENTS PERTAINING TO REGISTRATION
Following documents shall be provided by fabricator in separate folder in 2

copies.
a. Road Permit.
b. Transit Registration (Temporary in case of outstation vehicle, permanent in

case of local vehicle).
c. Insurance for one year.
d. Fitness for one year.
e. Certificate of un laiden weight of vehicle (copy of approved way bridge or

on fabricators letter head).
f. NOC from local RTO in favour of registering RTO.
g. Endorsement of RTO on VJTI approval (Applicable for higher capacity

refuellers and in case of Mumbai AFS only).
h. Fabrication certificate from fabricator.
i. Flow meter register movement certificate from fabricator.
j. Original copies of Form 21 & 22 of chassis supplier.
k. Any other document required for registration.

5.10 TEST REPORTS, RECORDS AND MANUAL
1. Refueller Operations & Maintenance manual shall be prepared and

forwarded to AFS’s and Aviation H.O., which should includes
technical details of all imported / indigenous components, spare
parts catalogue, servicing instructions and name / address of the
spare suppliers.
2. A separate folder for inspection test reports. All test and QA records
as per Section 9 would be completed and forwarded to AFS’s and
Aviation H.O.
5.11 DOCUMENTATION
On receipt of order, successful bidder will have to submit the followings for
BPCL approval (in duplicate):
a. Bar chart for procurement, fabrication, testing & delivery schedule.
b. Fabrication drawing of tank, Z channel, with welding schedule.
c. Module components layout drawing.
d. Drawing for installation of Liquid fifth wheel, Pump and tractor

chassis strengthening.
e. Schematic layout drawing for ATF pneumatic and electrical circuit.
f. GA drawing for refueller giving overall dimensions of tank, trailer,

tractor length and height. All the safety fittings will be shown. Also
loading at various axles to be indicated.
g. Detailed Quality Assurance Plan for raw material, in-process and

final process.
h. Any technical information or further drawings requested by BPCL will

be submitted by fabricator.
i. CCOE’s Approval for the design of the refueller.
j. Model approval for flow meter.

5.12 THIRD PARTY INSPECTION AGENCY: SCOPE
a. Testing of MS plates, structural and Z section for composition and

strength as per the specification
b. Welder qualification test
c. DP test for welding
d. Hydrotesting of the tank
e. Pneumatic test for baffle leak
f. Soap solution leak test for pneumatic system
g. Electrical insulation test for electrical equipments and wiring.
h. Hydrotesting of pipelines.
i. Dimensional check
j. Shot blasting, primer and paint application as per the paint suppliers
painting scheme for external & internal painting.

SECTION – 06
INSTRUCTION MANUAL
SECTION – 6 INSTRUCTION MANUAL
6.1 QUALITY
6.2 APPROVAL
6.3 CONTENT AND FORMAT
6.4 MISCELLANEOUS SECTIONS
6.5 SYSTEM DETAIL SECTIONS

6.5.1 FUELLING SYSTEM A
6.5.2 PNEUMATIC SYSTEM B
6.5.3 HYDRAULIC SYSTEM C
6.5.4 ELECTRICAL SYSTEM D
6.5.5 MISCELLANEOUS ITEMS D
6.6 MAINTENANCE SECTIONS
6.6.1 ROUTINE INSPECTION AND LUBRICATION

6.6.2 TROUBLE SHOOTING
6.6.3 RECOMMENDED SPARE PARTS
6.6.4 MPONENT SERVICING AND REPAIR
6.7 QA / TEST CERTIFICATES
6.8 ILLUSTRATED PARTS LIST AND DRAWINGS
INSTRUCTION MANUAL ISSUE: 02 DATE: 01.10.2013

INSTRUCTION MANUAL
6.1 QUANTITY
6.1.1 Each chassis must be supplied with the operating and routine maintenance
manuals provided by the chassis manufacturer in English language.
It must also be ensured that the chassis spare catalogue manual is supplied to
obtain spare parts from the local dealer / elsewhere in future.
6.1.2 The refueller fabricator must compile a manual covering the remainder of the
vehicle and added interface equipment. One copy is to be supplied with the
vehicle and in addition, one copy is to be supplied to Aviation Technical Service
Dept., Noida.
6.1.3 The cost of these will be deemed to be included in the price quoted for the vehicle.
6.1.4 Additional separate folder consisting of QA / Test certificated shall be supplied

along with each refueller.
6.2 APPROVAL
A draft of the manual is to be submitted for approval prior to dispatch. It should be

noted that this approval will only be granted if the manual provides clear and
comprehensive operation and maintenance guidance and makes due allowance
for the lack of expertise that may be available at the final destination.
This does not apply where refuellers are repeat orders or are very similar to
previous units and incorporate only minor amendments.
6.3 CONTENT AND FORMAT
The purpose of the manual is not to train people to become aircraft fuelling
operatives or maintenance technicians, nor to give guidance on routine checks and
tests required by the BPCL Aviation Quality Control and Aviation Operations
manuals.
Nevertheless, the manual should provide clear and comprehensive guidance on

vehicle operation and maintenance, so that it can be kept in good working order.
All due allowance should be made for lack of user familiarity with a completely new
vehicle.

A typical content / arrangement would be as described in 7.4 to 7.8
6.4 MISCELLANEOUS SECTIONS
6.4.1 A title page showing manufacturer’s name / address / telecommunication details,

customer, purchase order number, works order / serial number.
This should be followed by 4 colour photographs (or colour photocopies thereof)

showing the vehicle right and left views, the rear, and tank top (to include fittings /
manholes / vents)
6.4.2 An index / contents list showing the various sections and list of illustrations.
6.4.3 A list of applicable specifications and standards – e.g. BS, ISO, EN etc.
6.4.4 General safety precautions relating to workshop practices, fire prevention /

precautions, toxic vapours / fumes, the battery, welding, mains electrical
equipment, asbestos packing (if any). Also list sources of potential danger when
loading, driving, fuelling etc. and stress that the equipment should only be
operated by personnel qualified to do so by the user company.
6.4.5 A list of threaded fastener sizes used – metric / UNC / UNF / BSW / BSF etc. with
spanner / hexagon sizes and recommended torque values.
6.4.6 Basic vehicle data – chassis details (make / model / engine model / power output /
serial no. / wheel base etc.) actual measured weights per axle when loaded – tyres
size / pressures – actual dimensions ( heights of cab, tank, platform, overall length,
width ) – tank fabrication number – scissor lift fabrication number etc.
6.4.7 General description
This should be written to aid understanding of the more complex details later in the
manual. Content can be sort or long according to the other information provided. A
simple diagram should be included.
6.4.8 Tank and fittings
This details information is necessary as preparation for the operating instruction

and commissioning procedure sections.
To cover topics such as – description including attachments and their controls –

bottom loading valve – high level shut off and test cock – manhole lids and vents –
contents gauge – dip stick – sampling and rapid draining.

6.4.9 Operating instructions
To be read only at first, in preparation for carrying out the commissioning

procedure (6.4.10)
To cover such topics as – loading from the depot – self loading – engaging /
disengaging the pump – reeling out and rewind the hose reels – starting flow ( to
recirculate or fuel aircraft ) fuelling operations – stopping flow – depressurizing the
hoses – defuelling aircraft – use of emergency engine stops – use of the sampling
cabinet and dump / recovery tank – use of the interlock override – etc.
6.4.10 Commissioning procedure
It is essential that the operator has a full understanding of the system before
undertaking this procedure.
To cover topics such as – packing removal – installing (as applicable) nozzles,

filter elements, fire extinguishers bonding reels or anything else such as lights,
fuses and relays which may have been removed for safe keeping during shipment
/ transportation –loading – purging air from the fuelling pipe work – purging air from
the SPCV / deadman valve – recirculating via each hose – checking / cleaning
nozzle strainers – purging air from the defuel pipework – clearing of tank and filter
sample / drain lines - etc.
6.5 SYSTEM DETAIL SECTIONS
These sections are needed to describe very clearly, details of the various systems
as follows. For clarity, it is suggested that numbered items on circuit drawings also
be given a letter prefix. Where the systems interface, the diagrams should so
indicate and thus, the related or linked item will be easier to identify.
It is suggested that the following letter prefixes be used –
A – Fuelling system – e.g. A5 Meter, A17 Fuel sense pressure gauge.

B – Pneumatic system – e.g B17 Foot valve control, B9 Interlock override
switch.
C – Hydraulic system – e.g C23 Cylinder, C4 Flow Control valve, reel.
D – Electrical system – e.g D35 Pump tachometer, D12 I/S relay unit.
E – Miscellaneous – e.g E17 Drawbar coupling, E6 Pump Speed Control
Cable.

Each of these sections should include a clear circuit diagram, on large size paper
(A3 folded) for clarify if necessary, with all components given a discreet item
number such as C5, D23 etc with any interfaces to other systems shown.
For example, the electrical circuit diagram will have most items marked with the
prefix D but when electric interlock switches are used, there will also be a B item
shown representing the solenoid actuated pilot valve for the brake system.
Where components can fall into two categories, it is suggested that the code letter
to apply is that for the first diagram in which it appears.
For example, the pneumatic operator of a foot valve, code A, would also have a
Code A. When the same pneumatic operator was illustrated with other pneumatic
B components, it would still be code A.
Similarly, a pneumatically operated switch to activate a warning light would appear

as code B in both pneumatic and electrical systems.
Item Part No Description Qty Location Supplier
A20 N2005060010 Non return 1 Tank rear, right Northvale
valve hand side, defuel Korting
line
Each section should also include a table showing, for example, the following
information:-
Where it is not feasible to describe the item location such that it could be easily
found, then simple sketches or photographs should be provided.
For wholly bought out / unmodified items, the original manufacturer’s part numbers
must be used. Where items have been purchased and modified or added to by the
refueller fabricator to form a distinguishable separate assembly, then preferably
the separate part numbers should be given. Where this is really not feasible, a
new unique part number may be given and the refueller fabricator may be
mentioned as the supplier.
6.5.1 Fuelling system A
Comprising – Diagrams of the fuelling circuit and operating panel, parts list,
operating / functional descriptions of fuelling / defuelling, secondary pressure
control system, depressurizing etc.
Reference should be made to the item numbers on the circuit and what occurs
when each control is selected.
6.5.2 Pneumatic system B

Comprising – A diagram of the pneumatic circuit including inter connections with
other systems, parts list, operating / functional description of pump selection, fuel /
defuel selection, dead man control system (if pneumatic) air reference supply to
the SPCV, brake interlock system, engine stop control system, trailer interlock and
foot valve controls etc.
Reference should be made to the item numbers on the circuit and what occurs in
what sequence to what component, where air can go and does go under various
circumstances.
6.5.3 Hydraulic System C
Comprising – A diagram of the hydraulic circuit including, parts list, descriptive

information on safety, cleanliness, the reservoir, pump. Pressure relief and flow
control system, hose rewind and elevating platform operations / controls.
Reference should be made to item numbers on the circuit and where the oil travels
in each situation.
There should also be a section here, or under “Trouble Shootting” per item
describing how to remedy a “stuck up” platform and reset the various flow controls.
This may be necessary following injudicious opening of the platform cylinder

outward flow control, allowing excess flow rate and triggering of the cylinder
emergency fuses / restrictors. In turn, this would cause the platform to stick in the
up position or only descend exceptionally slowly.
6.5.4 Electrical system D
Comprising – A diagram of the electrical circuit including wire colours and inter
connections with other systems, parts lists, operating / functional descriptions of
operations lights, obstruction lamps, deadman system (if electrical), pump speed
tachometer, pump / road drive warning lights, platform alarm, brake interlocks if
electrical switches), brake override warning light, battery isolator, alternator
protection circuit etc.
6.5.5 Miscellaneous items E
Comprising – itemized parts list / location description etc. Components to be

included with diagrams if necessary can include such things as pump speed
controls, sampling cabinet, chain tensioners, hose reels guide rollers, trailer
drawbar coupling, bonding reel, nozzle stowage assemblies / shrouds, scissor lift
assembly, cab fire extinguisher, drive shaft modifications (gearbox to pump,

pump to rear axle), recovery tank contents gauge, earthing / bonding lugs, tamper
proof covers for adjusters, hydraulic drive coupling on the product pump extension,
latch on bottom loading coupling interlock lever etc.
6.6 MAINTENANCE SECTIONS
6.6.1 Routine inspection and lubrication
This part of the manual applies to the items and equipment installed by the
refueller fabricator as opposed to the chassis itself.
Aspects covered should include recommended lubricants and schedules – daily,

weekly, monthly, 3 monthly, annual etc. as appropriate.
Typical details should include checks as per daily, weekly, monthly, quarterly and
annual check list formats supplied by BPCL.
6.6.2 Trouble shooting.
Clearly it is not possible to cover every eventuality and difficulty which might be
encountered in a complex system. Sections covering the automobile, fuelling,
pneumatic, hydraulic and electrical systems should be good enough for users to
educate themselves and decide what may be causing trouble.
Nevertheless, the following major difficulties should be addressed and suggestions
made to investigate and remedy the situation.
• Brakes cannot be released.

• Interlock action to apply brakes slowly or not working.
• No fuel flow when in the fuelling mode.
• Flow rate unusually low in the fuelling mode.
• Release of the deadman handle does not stop flow or flow stops too slowly
• Release of deadman does not return pump speed to idle.
• No fuel flow when in the defuelling mode
• No fuel flow when bottom loading
• Fuel pump will not engage or disengage or gears bulks
• Reels will not rewind, lock or free wheel out.
6.6.3 Component servicing and repair
In this section, it will not be sufficient only to enclose manufacturers’ general

leaflets and information sheets.

In some cases, for the more simple assemblies, it will be sufficient to provide only
the drawings covered by item 7.8 below.
In other cases, complete and current information will be required for such items
as:-
Bulk meter – Fuel pump – Hose reel swivels.
Fuelling nozzles and regulators – Secondary pressure control / deadman valve.
Tank foot valve – Bottom loading valve and high level sensor – Filter monitor
element changing – Fuel / defuel valve – Differential pressure gauge – Hydraulic
pump and motors ( if fitted).
6.7 QA / TEST CERTIFICATES
QA / Test Certificates should be provided for hoses, filters & filter housing, delivery
couplings, pressure gauge, DP gauge, the tank pressure test, bulk meter
calibration, hydrotest certificate of Fire Extinguishers, the 15 bar general circuit
pressure test, the 20 bar system test downstream of the closed line isolating
valves.
In addition, the manufacturer should enclose a copy of his own test schedule /
results. This may be similar to or the same as that shown in section 9 of this
specification.
Another useful, but not essential document could be a copy of a check list used to
verify that all the chassis options and type variants specified on the purchase order
have indeed been fitted. This might be requested if the customer’s appointed
inspector is not wholly familiar with the equipment or able to distinguish, for
example, road springs of different strengths.
6.8 ILLUSTRATED PARTS LIST AND DRAWINGS
General arrangement, sub assembly and any useful details drawings or descriptive
sketches which are not included elsewhere should be placed here, together with
an index.
The aim should be to provide as much information as possible in the form of an

“illustrated catalogue” of components, with readily available (not necessarily
specially created) exploded views and parts lists so that locally, equipment can be
dismantled / repaired if necessary without specialized overhaul instructions to
hand.
As necessary, the drawings should be marked with the item number from the
detailed parts lists and placed in sections A, B, C, D and E.

Full size drawings should be carefully folded and kept in plastic pockets, together
with any other booklets and leaflets and leaflets covering complete units, such as
pressure control equipment, meters, etc.

SECTION – 07
MAKE / SPECIFICATION
DETAILS OF MAJOR
COMPONENTS
SECTION – 7 MAKE / SPECIFICATION OF MAJOR PARTS
MAKE/SPECIFICATION DETAILS ISSUE: 02 DATE: 01.10.2013

MAKE / SPECIFICATION DETAILS OF MAJOR COMPONENTS
Sr. No. Equipment Make/Model Remarks

01 Under wing nozzle Carter / 64348 End fittings with 2.5” &
3” spannloc, meets ISO-
1825:2010 third edition
02 Over wing nozzle Carter-std model End fittings with 1.0” &
1.5”
03 Ground half unit adaptor Carter-2.5” size
04 Aviation hose Elaflex / Hewitt/ Elaflex/Hewitt/trelleborg/
trelleborg ( ISO 1825: 2010 third
edition)
05 Hose Reel / drum Catherine type- Suitable for 2” Dia and
15KL, Bobbin type 60’ long hose along with
motorized hose reel- hose protection beads.
25/45KL
06 Reel hose / Deck hose end Spannloc type As per ISO 1825: 2010
connection couplings third edition
07 Bulk Meter LC / Avery Model depends up on
Hardoll/ISOIL capacity of Ref
08 Venturi Carter / Alfons Haar Std type
09 4-way valve(FDF) Garmon Fuel-defuel valve
Rupp/Garsite,/Carter
10 Pressure control valve Carter / Whittaker Pneumatic type
11 Fuel Monitor vessel Velcon / Facet / Meets std EI 1583 latest
Faudi edition
11a Fuel Monitor elements Velcon / Facet / Meets std EI 1583 latest
Faudi edition
12 Pressure relief valve Gammon / Fitted on filter
Rockwood
13 Air eliminator Armstrong with SS- Armstrong with SS-
body body
14 Visi-flow indicator Standard make with Standard make with SS
SS body body
15 Spring loaded valve Apollo (imported) Apollo (imported)
16 Butterfly valve Audco Audco
17 Swivel joints OPW / Garsite OPW / Garsite
18 All pipe lines SS 304 Schedule 10 Std make as per specs
19 Eductor unit Carter/Garsite
20 ATF pump Gorman Rupp Suitable for chassis
21 Rubber bellow Elaflex Imported

Sr. Equipment Make/Model Remarks
No.
22 Liquid Fifth wheel assembly GNY Suitable for 27kl & 45kl
(Dual type) trailers
23 Bottom loading Internal valve Carter / Whittaker Size depends on Cap of
tanks
24 Jet level sensor Carter / Whittaker Suitable model
25 Gauge control Panel S.S. body with 615mm length
glossy finish 500mm height
through buffing 3mm thick
(should not be
painted)
26 Pressure Gauge Waaree / Weskler SS body with glycerine
/Waika, (range 0- filled- dia 2.5”; back
150 psi with 2 LC) connection
27 DP Gauge Gammon-USA Model-GTP534
Model-GTP534 0-30 lbf/in2
28 QDC nipples(3/8”) Std make of SS Double check valve;
body quick releasing coupling
29 Dead Man Control Aljack / Handy type-new model
Fluid transfer - UK (electrical type with
suzy cable)
30 Air Pressure Regulator Schrader Bellows Type-346
Range 150 PSI
31 Close Circuit Sampler Aljack / Indian make also
Fluid transfer consider
32 Brake Interlock override Schrader Bellows Type-push-pull 3 way
Model-53004H valve
33 Emergency shut off valve Schrader Bellows Type-push-pull 3 way
Model-53004H valve with knob
34 Shuttle check valve Sundaram Clayton Sundaram Clayton
35 Micronic Air Filter Shavo Norgen/
Schrader
36 Pneumatic tubing Legris make PU
37 Metal Tubing (Fuel lines) S.S. tubing with
std make
38 Sampling lines SS pipe lines
39 Dust caps to sampling lines Camlock coupling
type
40 Tank content Gauge Bayham Ltd Size 250mm

41 Bonding Reels Standard make as
per BPCL design-
SS Material
42 Man hole covers Emco type Std make
43 Coupling stowage Electro pneumatic Material-S.S
operated push pull Push pull switch
valve(single strip; operates with micro-
new type) switch
44 Electrical light & fittings Make: FCG Model no: GG311025
Type-“A”
45 High Performance Ball Valve Xomox Sanmar 300 PSI rating
46 SS Swivel joint OPW/Garsite 300 PSI rating

(self lubricated type)
47 Pulsar Veeder-Root, Series 7671
PART NO. 767163—
303
48 Reset Switch STAHL (Germany) Model: 8064/21
49 Tank Air vent valve Carter/Whittaker

SECTION – 08
CHECKS OF CHASSIS &

REFUELLER AFTER
FABRICATION
SECTION – 8 CHECKS OF CHASSIS & REFUELLER AFTER
FABRICATION
8.1 GENAERAL DESCRIPTION OF CHASSIS
8.2 AVIATION MODULE CHECKLIST
8.3 AUTOMOTIVE MODULE CHECKLIST
8.4 OBSERVATION DURING CIRCULATION / TESTING
8.5 CHECKLIST FOR REFUELLER INSPECTION AS PER TENDER

SPECIFICATION
8.6 LIST OF CERTIFICATES
CHECKS & CHESIS AND REFUELLER ISSUE: 02 DATE: 01.10.2013

CHECK LIST OF CHASSIS & REFUELLER AFTER FABRICATION
(FOR AVIATION TECH. DEPT)
8.1 GENERAL CHECKLIST FOR CHASSIS
S. No. Description Remarks /

Comments
1 Date of Inspection
2 Name of Chassis Supplier
3 Make
4 Model
5 Engine No.
6 Chassis No.
6 Fuel Pump Make & Sl. No.
7 Provision of Power Take Off unit as per BPCL requirement
8 Working of Power Stearing
9 Provision of additional engine cut off switch
10 Provision of double pole wiring
11 Alternator make & No. and its condition & double pole wiring
arrangement
12 Starter make & Sl. No. & double pole wiring arrangement
13 Engine Details
a. General Condition
b. Engine Noise
c. Engine Oil
d. Oil Cap
e. Oil Dip Stick
f. Fan Belt
g. Bonnet Rubber Lock
h. Engine Exhaust System
14 Lights
a. Head Light
b. Side Indicator
c. Brake Light
d. Parking Light

8.1A SHORTCOMING / OBSERVATION (IF ANY)
S. No. Description Remarks /

Comments
15 Condition of Cabin & Accessories
16 Working of brake system
17 Condition of Battery
a. Make & Model
b. Sl. No.
c. Capacity
d. Date & Year of Manufacturing
e. Warranty Card provided
18 Working of Horn
19 Working of Panel Gauges
20 Condition of Dash Board & Keys
21 Working of Wiper
22 Condition of Front & Side glasses
23 Condition of Rear view mirrors
24 Working of Ignition
25 Provision of Spare wheel & wheel mounting bracket
26 Provision of cushion type driver & co-driver seats
27 Provision of retractable type seat belts on driver & co-driver
seats
28 Provision of Diesel tank locking arrangement
29 Working of Main brakes & hand brake
30 Tools supplied with chassis
31 Chassis warranty card cum Service Manual supplied
32 Service manual (bilingual) supplied
33 Spare catalogue supplied

8.2 CHECKLIST FOR AVIATION MODULE
1. Are fittings like Bonding reel, Gauge panel etc as per std design?
2. Is Cargo tank condition / finishing satisfactory?
3. Is Tank level gauge calibrated?
4. Is Dip rod calibrated? All Pipes provided with holes so that no air
remains trapped inside.
5. Are Spring loaded self closing valves provided for Sampling lines,
dump tank release & close circuit sampler?
6. Is Bonding wire quality as per required IS std. Bonding clips with wire
provided on sampling points.
7. Are hoses fitted with span lock couplings at both ends?
8. Sampling box of sufficient size provided. ( W18” x H15” x D25”)
9. Are Beacon lights provided? Is Centre beacon with flashing rate 60 to
90 per minute provided? Side beacon lights of amber colour provided.
10. Is The slop tank is fitted with lid of 12” dia. hinge type with stainless
steel 100 mesh.
11 Sufficient space for the fitting of TPAFMS dam and TPAFMS junction
box on the rear side in the cabin provided.
12. In refuellers an arrangement is required preferably below the chassis
for keeping the ladder having size L99” x W29” x H14”
13. Are Refueller Painted with latest colour scheme?
14. All cables are numbered and the wiring diagram on aluminum
engraved sheet provided in the junction box.
15. Is electrical cable coiled through metal reinforced rubberized heavy

duty weatherproof conduit?
16. Is CCOE approved drawing available (Refuellers only)?
17. Is QC board on due and done dates provided near the panel?
18. Is quick release adapter (male type 3/8”) provided near panel for
testing panel gauges?
19. Check provision for keeping soak mat.
20. Is Earthing plate fixing point provided as far as possible?
21. Check Fabricators certificate .
22. Is Service manual, Operation Manual ready?
23. Is Flow meter provided on Refueller is approved by W&M Dept?
24. QA certificates of all critical equipments available with fabricator.
25. Check all papers like, warranty card, service book, spares catalogue
of the vehicle available.
26. Check Fuel sensing line should be of stainless steel.
27. Pneumatic tubing should have number tags on both ends to trace the
line for maintenance purpose. Pneumatic tubing used should be of
legris make PU type which has found to be of good quality with
proper weather proof conduiting for protection.
28. Check position of Bonding reel drum (both sides). Chain cover on reel
hose drum chain connected to rewinding motor.
29. Check Operation of vents.

30. Check Emergency shut off linkages & valve for positive operation.
31. Check auxiliary panel provided near the main panel having provision
for Millipore point (quick release adopter), panel light switch, tyre
pressure inflator valve (quick release adopter),DMC override valve
Individual needle valves for each gauges on back side of fuelling
panel.
32. Check all switches are flameproof type.
33. Are Fire Extinguishers available with proper type of stands? Fire
extinguisher bracket should be vertical type with hinge arrangement
(At lower level).
34. Check 4 way valve functioning (Defuelling / Refueling).
35. Is P & I Diagram available on the panel? Sealing arrangement
provided for the PCV air regulator on the panel. Engine cut off Switch
in panel. P& I diagram on panel should be of aluminum embossing.
36. Is HEPCV checking adapter fitted?
37. Is CCOE approved flame trap fitted on the vehicle?
38. Check all swivel joints for free movement.
39. Check Hose end strainers (cone filters).
40. Are reel hoses fitted with wear rings.
41. Is Fuel dump tank slope / drain system ok.?
42. Is platform limit switch provided and working satisfactory?
43. All the dual check valves in the brake interlock system should be
located at one place for better aesthetic appearance. (Especially on
the refueller tank top).
44. In refuellers the tank bottom sample point should have the protective
shed to prevent rain water entering the ATF sample.
45. Spring loaded self closing valves should be provided for Sampling
lines, dump tank release.
46. Labels SS type engraved bonded or riveted should be provided.
47. Check interlocks override system. Individual interlock override
indicator should be available on panel.
48. Check condition of Epoxy painting inside the Cargo tank.
49. Check whether Clear Instruction i.e. Pull to Operate / Push to
Operate or Pull to Override etc is mentioned near the Pneumatic
Valves inside the cabin / on Panel Board etc.
50. Check interlock of ground half where we are connecting the filling
hose should be working.
51. Filter should have details as capacity, no. of elements and type which
can be fitted.
52. Panel light provided in such a way that Totalizer reading will be
clearly visible in night.
53. Cannopy on Aviation module in 15 kl Refueller should be proper type
(There should not be any riveting).

8.3 AUTOMOTIVE MODULE CHECKLIST
1. Electrical cable junction boxes, Light fittings should be of flameproof

type with proper flameproof gland. Electrical cables should have
rubber reinforced with flexible copper wire
2. Are Cabin quality puff, cabin mat, glass rewinding / gate opening
handles etc. of good quality / satisfactory?
3. Are Seat belts provided, confirming to approved standards.
4. Whether vehicle approved by RTO. Speed Governor in case of Delhi
approval obtained.
5. Check light indication of PTO “ON” on the cabin panel adjacent to the
brake interlock override indication.
7. Is Maintenance, Part Cat log & Operating Manual of chassis
available?
8. Check RC book in original
9. Check Fitness certificate
10. Check Insurance Certificate
11. Check Pollution control certificate
12. Copy of chassis Invoice
13. Form 22 (A) Part I & II
14. Check Battery warranty card.
15. Is Service manual of chassis available?
16. Check warranty card of the vehicle.
17. Check Condition / Combination of tyres.
18. Is Tool kit / Spare wheel available?
19. Is Choke of lighter weight(hard rubber type) available?
20. In case of Refueller, check air pressure require for PTO engagement.
22. Is the automobile sensing lines serviced if chassis of equipment is
parked for a long before fabrication?
23. As built electrical drawing should be provided in operating manual.
24. Is reverse gear fitted with Audio alarm different than platform of
Dispenser?
25. Check insulation & mating provided inside the cabin.
26. Check proper & easy steps arrangement available in Refuellers cabin
on both sides.

8.4 CHECKLIST FOR CIRCULATION / TESTING
S. No Description
1. Circulate the Refueller at maximum flow rate using all hose, check
the following:
A. Flow Rate.
B. Differential Pressure.
C. Pump Pressure .
D. PCV Pressure.
E. L.H. Venturi Pressure.
F. R.H. Venturi Pressure.
2. Working of Brake Interlock.
3. Observe for leaks/defects after pressurizing the hose for oil / fuel
leakage.
4. Working of Jet Level Sensor.
5. Check Air Eliminator for functioning.
6. Checking of DMC operation.
A. Closing – Time from initial flow reduction to zero flow (2-sec. Min.).
B. Overshoot – Volume passed from Dead man release to zero flow
(200 ltr. Max.).
7. Check outside painting as per latest color scheme.
8. Operation of Platform/ collapsible railing/hose reel winding
mechanism .
9. Check Bonding reel for its operation.
10. Make / Date of Manu. of Hoses.
11. Make / Date of Manu. of Fuel Monitors.
12. Check Pneumatic system (PCV, DMC, PTO, Tank Bottom Valve,
etc.).
13. Check Flow meter for any abnormal noise. Is ROF is satisfactory.
14. Is AFPCV / HEPCV functioning satisfactory.
E Status of earlier observations (if any):
F Any Other comments:
BPCL, E&P BPCL, Aviation Fabricator

8.5 CHECK LIST FOR REFUELLER INSPECTION AS PER TENDER SPECIFICATION
(FOR ENGG. & PROJECT)
Date of Inspection
Name of Fabricator
Refueller / Dispenser No.
Tank Capacity
Chassis Make / Model
Engine No.
Chassis No.
S. No. DESCRIPTION Observation / Comment

Tank is made of mild steel and designed / fabricated
1
as per IS 5986
Stability ratio is maintained less than 0.9 and meeting
2
the RTO rules.
Adequate slope is maintained towards sump for free
3
flow of water (in loaded & unloaded condition)
Internal bottom surface is smooth & free from
4
pockets & depressions.
Access ladder of aluminum (1 no.) at the rear of tank
5
& behind the cabin.
Calibrated Aluminum dip rod provided with dip rod
6
holder.
7 Tank is bonded with braided copper strap.
8 Any pressurized delivery pipe passing through tank.
1” ball valve with 1” Kamlock coupling & sealing dust
9
cap secured by chain provided on sample line.
EMCO type manholes provided on each
10
compartment.
Heavy-duty non-corroded hinges provided on
11
manhole dome covers.
Auto close arrangement provided for manhole dome
12
covers when vehicle moves forward.
SS studs/fasteners provided for attaching manlids &
13
cover plates to the top of the tank.
Recess on top of the tank with drain arrangement
14
provided.
Jet level sensor provided to stop over filling of
15
refueller.
Bottom loading valve fitted with deflector to minimize
16
splash.
Tank outlet/foot valve & isolation valve (in defuel
17 return line) provided with temperature sensitive link or
fuse.
Location of content gauge finalized in consultation
18
with BPCL.
19 Epikote paint used, suitable for use with ATF.
20 Prior to coating surface grit blasted.
21 Tank hydro tested to 5 psi for minimum 30 min.

22 Lights provided by fabricator
a Cabin Light (2 nos.)
Aircraft / Obstruction warning light on cabin topsides
b
& rear of the tank (2 nos.).
c Amber flasher light on cabin top center (1 no.)
d Brake lights (2 nos.)
e Turning lights (2 nos.)
f Licence plate light (2 nos.)
Brake interlock lights gauge panel as per drawing
g
provided by BPCL
h Lights inside the refueling module (2 nos.)
i PTO engage indication light (1 no.)
23 All lights/switches are CCOE approved.
24 Canopy provided on bulk meter & control panel.
Junction boxes/connectors and all electrical
25 equipment’s adequately protected & shielded from the
ingress of moisture.
Audio alarm with Recorded voice “Please move away
26
this vehicle is reversing” provided.
27 Gauge panel as per drawing provided by BPCL.
28 Warning lights (red/amber) provided in cabin for override

& Interlock.
29 Entire pneumatic circuit tested at 150 psi with soap
solution & entire pneumatic lines secured with clamps to
avoid vibrations & mechanical stress.
30 Air sensing lines of PU tubing(Legris)/copper tubing &
joints of brass connectors provided.
31 Prior approval from BPCL obtained before selecting the
manufacturer of paint & primer.
32 Thickness of paint checked (total dry film thickness – 200
to 260 microns) with Elcometer & certificate prepared in
this effect.
33 MIBK test carried out & certified by paint manufacturer &
inspected by BPCL.
34 Fire screen at the rear of cabin, to extend up to 350 mm
from ground level provided.
35 Exhaust pipe fitted with CCOE approved flame arrestor.
36 Flexible rubber hose with tyre valve for tyre inflation
provided.
37 All sampling / drain points connected with 380 mm long
Aluminum cable & standard crocodile clip.
38 All gauges, controls, switches, warning lights, sampling
points etc. are labeled.
39 A fuelling circuit & operating instruction plate provided
near the control panel.
40 Operating instruction plate for PTO operation provided.
41 Labels for tyre inflation pressure fixed on wheel arches.
42 Local RTO informed on non-use of chassis on public
road while under fabrication.
43 All flange joints provided with copper strip jumpers (25
mm wide X 0.93 mm thick)

8.6 LIST OF CERTIFICATE’S
S. No. Name of Item Make Comment

1 Pipeline pressure test
2 Refueller CCOE Approval
3 All light fittings, junction box
CCOE Approval
4 MIBK test report
5 Thickness test
6 Third Party Inspection Report
a DP test for welding
b Tank & Pipeline Hydro test
c Pneumatic test for baffle leak
d Soap solution leak test for
pneumatic system
e Electrical insulation test for
electrical equipment’s & wiring
f DFT of painting
7 Performance chart of refueller
8 Quality Assurance Certificates
a ATF pump
b Fuel Monitor Vessel
c Fuel Monitor Elements
d Differential Pressure Gauge
e Pressure Control Valve
f Bulk Meter
g Venturi
h Underwing Nozzle with HEPC
i Hoses with spannloc end fitting
j Pressure gauges
k Ground Half Coupling
9 Operation & Maintenance Manual
(incl. Warranty cards, list of
spares parts, list of suppliers etc.)

SECTION – 09
TECHNICAL INFORMATION
OF CRITICAL COMPONENTS
SECTION-9
TECHNICAL INFORMATION FOR CRITICAL COMPONENTS
ITEM NO. DESCRIPTION

9.01 Main Gauge Panel
9.02 Auxiliary Panel
9.03 Emergency Shut Off Knob
9.04 EMCO type Manlid with Pressure Lift Cover
9.05 Pressure/Vacuum valve
9.06 Typical foot / emergency valve
9.07 10” Tank Content Gauge
9.08 3 Lug Adaptor
9.09 2 ½” Delivery Coupling
9.10 3” & 4” Pressure Control Valve
9.11 Air Operated Vent Valve
9.12 ShoFlo Indicator
9.13 Differential Pressure Gauge – GAMMON
9.14 Deadman Control – FLUID TRANSFER
9.15 3” & 4” Venturi
9.16 Spring Return Valve – APOLLO
9.17 Sampling Line Dust Cap
9.18 Cabin Flashing Light
9.19 Delivery Pump – Gorman Rupp
TECHNICAL INFORMATION AND CRITICAL COMPONENTS ISSUE: 02 DATE: 01.10.2013

9.01 MAIN GAUGE PANEL

9.02 AUXILIARY PANEL

9.03 EMERGENCY SHUT OFF KNOB
FRONT VIEW SIDE VIEW
1”
1”
2.5”

9.04 EMCO TYPE MANLID WITH PRESSURE LIFT COVER
16" Manhole Cover F0337 Left Hand & F0338 Right Hand
• Pressure and vacuum vent fitted as

standard for tank breathing; various
ratings are available to suit operational
requirements; two vents may be fitted if
required.
• Spring-loaded fill cap provides emergency
fire engulfment venting to NTTC DOT 406,
required in the event of the tank being
exposed to a fire.
• Emergency venting capacity 7000m3/h air
at 350mb.
• Automatic sealing of the Pressure and
Vacuum vent in a roll over situation
prevents dangerous and costly spillage.
• Steel crossarm exceeds the requirements of F0337 Left Hand
the Australian DROP test (AS 2809-2-1990).
• Aluminium crossarm is also available on
some variants.
• Self-aligning seal ensures pressure tight F0338 Right Hand
operation at all times.
• Two-stage opening allows safe release of
residual compartment pressure before fully
opening fill cap.
• Secure 24-bolt fixing.
• 250mm (10”) fill hole for easy drop pipe
insertion when top loading.
• Lightweight aluminium baseplate for
increased payloads.
• High quality die cast baseplate and fillcap
to international standards are used for
durability and performance.
• Low profile design minimises roll over
protection requirements.
• Lockable options use a standard F0053
key.
• Two accessory ports for either dip-tube
mandrel, over-spill prevention probe or an
additional P/V vent.

9.05 PRESSURE / VACUUM VALVE
Available with various pressure and vacuum settings

(Viton seal version listed):
Part No. Pressure Vacuum

00609097 20mbs (2kPa) 4.5mbs (0.45kPa)
00607271 70mbs (7kPa) 4.5mbs (0.45kPa)
00612337 70mbs (7kPa) 20mbs (2kPa)
00619233 100mbs (10kPa) 20mbs (2kPa)
00609187 120mbs (12kPa) 4.5mbs (0.45kPa)
00616274 120mbs (12kPa) 20mbs (2kPa)
Available with Rain Cap (Viton seal version listed):

00615879 20mbs (2kPa) 4.5mbs (0.45kPa)
00615767 70mbs (7kPa) 4.5mbs (0.45kPa)
00619439 70mbs (7kPa) 20mbs (2kPa)
00616244 120mbs (12kPa) 20mbs (2kPa)
Available with solvent compatible seals:

00618451 20mbs (2kPa) 4.5mbs (0.45kPa)
00618452 70mbs (7kPa) 4.5mbs (0.45kPa)
00618453 70mbs (7kPa) 20mbs (2kPa)
00618454 120mbs (12kPa) 4.5mbs (0.45kPa)
Other variations or combinations of the above are available
P V Vent with rain cap for fitting either

in the manhole cover base plate or on the
tanker shell.

9.06 TYPICAL FOOT / EMERGENCY
VALVE
Lanyard
Attachment
Cover
Primary
Pilot Valve
CAF
Valve
Body
Screen
Mounting
Flange

9.06.01 TYPICAL FOOT / EMERGENCY VALVE

9.07 10” TANK CONTENT GAUGE

9.07.01 10” TANK CONTENT GAUGE

9.07.02 10” TANK CONTENT GAUGE

9.08 3 LUG ADAPTOR

9.08.01 3 LUG ADAPTOR

9.09 2 ½” DELIVERY COUPLING

9.09.01 2 ½” DELIVERY COUPLING

9.10 3” & 4” PRESSURE CONTROL VALVE

9.10.01 3” & 4” PRESSURE CONTROL VALVE

9.10.02 3” & 4” PRESSURE CONTROL VALVE

9.11 AIR OPERATED VENT VALVE

9.12 SHOFLO INDICATOR

9.13 DIFFERENTIAL PRESSURE GAUGE – GAMMON
Model: GTP – 534 PB

9.14 DEADMAN CONTROL – FLUID TRANSFER

9.14.01 DEADMAN CONTROL – FLUID TRANSFER

9.15 3” & 4” VENTURI

9.16 SPRING RETURN VALVE – APOLLO
S. Part Material
N.
1 Deadman handle SS w/vinyl
2 Stem packing Multifill PTFE
3 Stem bearing RPTFE
4 Ball A276-316
5 Seat (2) Multifill PTFE
6 Retainer A276-316 (1/4" to 1")
A351 - CF8M (1-1/4" to
2")
7 Gland nut A276-316
8 Stem A276-316
9 Lever nut 18-8 SS
10 Body seal PTFE (1-1/4" to 2")
11 Body A351-CF8M

9.17 SAMPLING LINE DUST CAP

9.17.01 SAMPLING LINE DUST CAP

9.18 CABIN FLASHING LIGHT

9.19 DELIVERY PUMP – GORMAN RUPP
Specifications
Size: 2" (50 mm), 3" (75 mm), 4" (100 mm),
6" (150 mm)
Max Capacity: 1,350 GPM (85 lps)
Max Head: 400' (122 m)
Max Solids: 1.19" (30 mm)
Max
Temperature: 160 F (71 C)
Materials of Aluminum, Bronze, Cast Iron, Ductile
Construction: Iron

SECTION – 10
DIAGRAM OF GENERAL
ARRENGEMENT /FULL
FLOW/ELECTRICAL/PNEUMA
TIC SYSTEM
SECTION – 10 DIAGRAM FOR GENERAL ARRANGEMENT/FUEL
FLOW/ELECTRICAL/ PNEUMATIC SYSTEM
10.01 GENAERAL ARRANGEMENT DRAWING FOR 15KL REFUELLER
10.01.01 TYPICAL FUEL FLOW DRAWING FOR 15 KL CAPACITIES

REFUELLER
10.01.02 TYPICAL PNEUMATIC CIRCUIT DRAWING FOR 15KL CAPACITY

REFUELLER
10.01.03 TYPICAL ELECTRICAL CIRCUIT DRAWING FOR 15KL CAPACITY

REFUELLER

REFUELLER

REFUELLER

REFUELLER

REFUELLER

REFUELLER

REFUELLER

10.01 TYPICAL GENERAL ARRANGEMENT DRAWING FOR 15KL CAPACITY
REFUELLER

10.01.01 TYPICAL FUEL FLOW DRAWING FOR 15KL CAPACITY REFUELLER

REFUELLER

REFUELLER

10.02 TYPICAL GENERAL ARRANGEMENT DRAWING FOR 25KL
CAPACITY REFUELLER


REFUELLER

REFUELLER

10.03 TYPICAL GENERAL ARRANGEMENT DRAWING FOR 45KL
CAPACITY REFUELLER


REFUELLER

REFUELLER


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Refueller Fabrication Manual

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SPECIFICATION MANUAL

BHARAT PETROLEUM CORPORATION LIMITED

BPCL – REFUELLER SPECIFICATION MANUAL

No. HOLDER OF CONTROLLED COPY

MANUAL DISTRIBUTION LIST ISSUE: 02 DATE: 01.10.2013

MANUAL DISTRIBUTION LIST ISSUE: 02 DATE: 01.10.2013

MANUAL DISTRIBUTION LIST ISSUE: 02 DATE: 01.10.2013

MANUAL DISTRIBUTION LIST ISSUE: 02 DATE: 01.10.2013

ABBREVIATIONS ISSUE: 02 DATE: 01.10.2013

SECTION – 1 GENERAL REQUIREMENTS

SECTION – 2 CHASSIS SELECTION – BASIS AND FEATURES

SECTION – 3 FUNCTIONALITY AND CONSTRUCTION OF AVIATION MODULE

SECTION – 4 PAINT SPECIFICATIONS, PAINTING PROCEDURES & VM

SECTION – 5 STATUTORY REQUIREMENTS INSPECTION / TESTING /

SECTION – 6 INSTRUCTION MANUAL

SECTION – 7 MAKE / SPECIFICATION DETAILS OF MAJOR COMPONENTS

SECTION – 8 CHECKS OF CHASSIS & REFUELLER AFTER FABRICATION

SECTION – 9 TECHNICAL INFORMATION OF CRITICAL COMPONENTS

SECTION – 10 DIAGRAM OF GENERAL ARRANGEMENT/ FUEL FLOW

LIST OF SECTIONS ISSUE: 02 DATE: 01.10.2013

1.2 ENQUIRIES AND OFFERS

1.3 PURCHASE AND MANUFACTURE

1.4 TESTING AND HANDING OVER

1.5 STANDARDS AND SPECIFICATIONS

GENERAL REQUIREMENTS ISSUE: 02 DATE: 01.10.2013

1.2 ENQUIRIES AND OFFERS

GENERAL REQUIREMENTS ISSUE: 02 DATE: 01.10.2013

1.3 PURCHASE AND MANUFACTURE

1.4 TESTING AND HANDING OVER

GENERAL REQUIREMENTS ISSUE: 02 DATE: 01.10.2013

The following standards would be followed during fabrication.

GENERAL REQUIREMENTS ISSUE: 02 DATE: 01.10.2013

2.1 CHASSIS SPECIFICATIONS FOR 15KL

2.2 CHASSIS SPECIFICATIONS FOR 25KL

2.3 CHASSIS SPECIFICATIONS FOR 45KL

2.4 MODIFICATIONS BY THE REFUELLER FABRICATOR

2.5 ELECTRICAL REQUIREMENTS

2.6 MISCELLANEOUS REQUIREMENTS

2.7 GENERAL DESIGN

2.8 CIRCUIT PROTECTION

2.9 BRAKES INTERLOCKS – PNEUMATIC / ELECTRICAL

GENECHASSIS SELECTION – BASIC AND FEATURES ISSUE: 02 DATE: 01.10.2013

2.1 CHASSIS SPECIFICATIONS FOR 15 KL

2.1.1 CABIN & CHASSIS

i) The chassis should be FULL FORWARD CONTROL TYPE

ix) In addition to normal panel / dashboard instruments, an engine revolution

xi) Arrangement for washing / cleaning of windscreen to be provided

GENECHASSIS SELECTION – BASIC AND FEATURES ISSUE: 02 DATE: 01.10.2013

a) Flange type clutch dependent Power Take Off should be provided.

GENECHASSIS SELECTION – BASIC AND FEATURES ISSUE: 02 DATE: 01.10.2013

2.1.14 HYDRAULIC POWER ASSISTED STEERING for added driving comfort.

2.1.16 Chassis detailed drawing to be provided to fabricator on demand for installation

2.1.19 Vendor to comply with the requirements of CMVR/RTO/Statutory agencies. Any

GENECHASSIS SELECTION – BASIC AND FEATURES ISSUE: 02 DATE: 01.10.2013

Kindly note that Chassis required is for the following locations:

2.1.23 Chassis details for 15 KL refueller

The chassis shall be rigid type with the following requirements:

a. Drive - 6X2, Right Hand

GENECHASSIS SELECTION – BASIC AND FEATURES ISSUE: 02 DATE: 01.10.2013

2.2 CHASSIS SPECIFICATIONS FOR 25 KL

2.2.1 CABIN & CHASSIS

ix) In addition to normal panel / dashboard instruments, an engine revolution

xi) Arrangement for washing / cleaning of windscreen to be provided

GENECHASSIS SELECTION – BASIC AND FEATURES ISSUE: 02 DATE: 01.10.2013