DCS Spec - EIL - Jacobs PDF

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Table of Contents
Document Number Rev. Document Title Page
Number
A133-000-YE-MR- C Distributed Control System 4
1500
A133-000-16-51-SP- A Preamble 11
1501
A133-000-16-51-SP- A List of Documents (Section-II) 14
1502
44NC-4600- 0 Standard Specification for Distributed Control System 16
0000/J.SS/0102/A4
44NC-4600- 0 Standard Specification for Programmable Logic Controllers 55
0000/J.SS/0103/A4
6-78-0001 0 Specification for Quality Mgt. System Requirements from Bidders 74
6-78-0003 0 Specification for Documentation Requirement from Suppliers 83
A133-00-6-82-0001 1 Spec For HSE 95
REV 1
7-51-0332 2 Safety measures for electrical installations during construction 196
A133-000-16-51-SP- B Specific Project Requirement 198
1503
A133-000-16-51-ED- B Logistic Support Formats (Section-III, Annexure-I) 202
01
A133-000-16-51-ED- B Responsibility Chart (Section-III, Annexure-II) 206
02
A133-000-16-51-ED- B Power Consumption & UPS Requirements (Section-III, Annexure- 213
03 III)
A133-000-16-51-ED- A Ventilation & Air-conditioning Requirements (Section-III, Annexure- 218
04 IV)
A133-000-16-51-ED- A Air Quality Requirements (Section-III, Annexure-V) 225
05
A133-000-16-51-ED- A Proven Track Record Format (Section-III, Annexure-VI) 227
06
A133-000-16-51-SP- B Table of Contents 232
1504
A133-000-16-51-SP- A Project Information 234
1507
A133-000-16-51-SIV- B Special Instructions to Vendor 238
1500
A133-000-16-51-OD- A Additional Requirements of DCS / PLC System (Section-IV, 263
01 Annexure-A)
A133-000-16-51-OD- B Specification for F&G System (Section-IV, Annexure-B) 285
02
A133-000-16-51-OD- A Tagging Philosophy for Junction Boxes, Panels & Cables (Section- 297
03 IV, Annexure-C)
A133-000-16-51-OD- A Cables & Junction Box Requirements (Section-IV, Annexure-D) 304
04
44NC-4600- 0 PMC Job Specifications (Instrumentation) 307
0000/J.02/0101
44NC-4600- 0 Instrument Cable Duct Fabrication Drawing 339
0000/JSD/0004
A133-000-16-51- A Scope of Works 359
SOW-1500
A133-000-16-51-OD- C I/O Summary and Sizing Consideration (Section-V, Annexure-VII) 364
05
A133-000-16-51-MD- 0 System Configuration Diagram (Part-A) 373
008
A133-000-16-51-SK- 0 110V AC UPS Power Distribution Diagram 376
3101
A133-000-16-51-OD- A 110V AC UPS Non DCS Power Supply Distribution List (Section- 377
06 V, Annexure-VIII)
Page 1 of 564
Table of Contents
Number
A133-000-16-51-SK- 0 230V AC Power Supply Distribution Diagram 380
3102
A133-000-16-51-OD- A 24V DC Non UPS Power Supply Distribution List (Section-V, 381
07 Annexure-IX)
A133-000-16-51-SK- A Control Room Layout 383
1101
A133-000-16-51-SK- 0 Control Room Ground & Basement Floor Plan 384
0009
A133-000-16-51-SK- 0 Control Room-Terrace Floor Plan, Section 385
0010
A133-000-16-51-SK- 0 Control Room Elevations, Sections 386
0011
44NC-4600-0000/L- B Overall Plot Plan 387
01/0001/A1
A133-000-16-51- 0 VENDOR DATA REQUIREMENT 388
VDR-1500
A133-000-16-51-OD- A Fieldbus Design and Implementation Criteria (Section-V, 392
08 Annexure-X)
A133-000-16-51-OD- B1 Vendor List (Section-V, Annexure-XI) 407
09
A133-000-16-51-OD- B Mandatory Spare Parts List (Section-V, Annexure-XII) 412
10
A133-000-16-51-SP- A Vendor's Proposal Outline 415
1506
A133-000-16-50-SP- A JOB SPECIFICATION 421
1500
A133-000-16-50-DS- A DATA SHEET 430
1500
44NC4600ESS025 0 STATIC UNINTERRUPTIBLE POWER SUPPLY UNIT (UPS) 433
44NC4600ESS026 0 ELECTRICAL INSTALLATION 453
44NC4600ESS008 0 MEDIUM AND HIGH VOLTAGE HEAVY DUTY CABLES 486
7-51-0335 2 Typ. installation details of electrical panels on false flooring 494
A133-000-16-50-VL- 4 VENDOR LIST 495
1500
A133-000-16-50-VR- A VENDOR DATA REQUIREMENTS 508
1500
44NC-4600-0000- 0 DRAWING 511
E.01-0007-A4
44NC4600ITP025 1 ITP FOR UPS SYSTEM 512
A133-000-16-51- B Scope of Works (Part-C) 514
SOW-1501
A133-000-16-51-ED- A Responsibility Definition (Part-C, Annexure-A) 519
07
A133-000-16-51-ED- A Distance Table (Part-C, Annexure-B) 523
08
A133-000-16-51-ED- A Proven Track Record 525
09
A133-000-16-51-ED- A Logistics Suppor Format (Part-C, Annexure-D) 528
10
A133-000-16-51-ED- A Compliane Statement (Part-C, Annexure-E) 530
11
A133-000-51-16-DS- B CCTV Datasheet 532
5001
A133-000-16-51-SIV- B Special Instructions to Vendor 534
1501
44NC-4600- 0 Standard Specification for Instrumentation Works 540
0000/J.SS/0101
A133-000-16-51- A VENDOR DATA REQUIREMENT 562
VDR-1501
Page 2 of 564
Table of Contents
Number
A133-000-16-51-MD- 2 System Configuration Diagram (CCTV) 564
08D
Page 3 of 564
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned and on the borrower's express agreement that they will not be reproduced,
MATERIAL REQUISITION (TOP SHEET)
ITEM DESCRIPTION: Distributed Control System
GROUP ITEM CODE 16EA DESTINATION : As per Commercial Document
ITEM CATEGORY II DELIVERY PERIOD :
DOCUMENT NUMBER
(Always quote the Document Number given below as reference)
A133 000 YE MR 1500 C 13/03/2014 16 51

copied, exhibited or used, except in limited way permitted by a written consent given by the lender to the borrower for the indended use. EIL-1641-515 Rev.1 A4-210x297
JOB NO UNIT/ MAIN DOC. SR.NO. REV DIVN. DEPT.

COST CODE DATE
ORIGINATOR
Notes:
1. This page is a record of all Revisions of this Requisition
2. The nature of the Revision is briefly stated in the "Details" column below, the Requisition in its entirety shall be considered for
contractual pupose.
3.Vendor shall note the MR category and shall submit his offer in line with the requirements included in attached
'Instructions to Bidders'
REV DATE BY CHK APPD DETAILS

A 17/01/2014 RK ZH AR Issued for Bids
B 03/02/2014 RK ZH AR Issued for Bids
C 13/03/2014 RK ZH AR Revised & Issued for Bids
This is a system generated approved document and does not require signature.
Project : RESID UPGRADATION PROJE

ENGINEERS INDIA LIMITED
Client : M/S CPCL Sheet 1 Of 5
NEW DELHI
Page 4 of 564
S.NO TAG NO . DESCRIPTION QUANTITY
/ ITEM CODE
1 Design ,engineering,manufacture,procurement of materials and

bought out items/components, assembly at shop, system engineering,
internal testing, integration, inspection, Factory testing and
acceptance at manufacturer's works, packing, delivery of the
following consumables, commissioning spares, special tools and
tackles, consumables, erection materials and documentation as per the
enclosed specifications, instructions to vendors, job specification, data
sheets etc and other codes and standards attached or referred in the
MR.
1.01 000-DCSSYS-00 Complete DCS System including CCTV and UPS systems 1 Lot
1.01.01 [000-DCS-01] Complete DCS System 1 Lot
1.01.01.01 [01-CDAS-100] Controller and Data Acquisition Subsystems 1 Lot
1.01.01.02 [02-OIS-100] Operator Interface Subsystems 1 Lot
1.01.01.03 [03-ENGS-100] Engineering Interface Subsystems 1 Lot
1.01.01.04 [04-PLC-100] Programmable Logic Controllers Subsystems 1 Lot
1.01.01.05 [05-FDI-100] Dedicated Foreign Device Interface Subsystems 1 Lot
1.01.01.06 [06-CAB-100] Cabinets, Panels and Racks 1 Lot
1.01.01.07 [07-HWC-100] Hardwired and other Consoles 1 Lot
1.01.01.08 [08-HWI-100] Hardwired Instruments,Barriers,Relays,Power Supplies,Fieldbus 1 Lot
accessories,Interconnectin cabling etc
1.01.01.09 [09-IAMS-100] Instrument Asset Management System 1 Lot
1.01.01.10 [10-OPC-100] Open System Connectivity including OPC server 1 Lot
1.01.01.11 [11-AIMS-100] Alarm Information Management System 1 Lot
1.01.01.12 [12-GTS-100] Giant Screens along with connectivity to DCS and CCTV 1 Lot
1.01.01.13 [13-MCT-100] MCT frames and Blocks 1 Lot
1.01.01.14 [14-FJB-100] Fieldbus Junction Boxes complete with all Fieldbus accessories 1 Lot
1.01.01.15 [15-CIVIL-100] Base Frames, trays, ducts 1 Lot
1.01.01.16 [16-DON-100] Documentation Node with CD retrieval and storage system 1 Lot
1.01.01.17 [17-OTR-100] All system cables including all interconnecting cables & FO cables with 1 Lot
necessary connectors
1.01.01.18 [18-TRKIT-100] Training Kit for DCS & PLC 1 Lot
1.01.01.19 [19-UPS-100] Complete UPS system as per Part B 1 Lot
1.01.01.20 [20-CCTV-100] Complete CCTV system as per Part C 1 Lot
2 Unloading, handling at site, transportation to site store and from store
to work site, storage at site, assembly at site, installation, testing, pre-
commissioning, loop checking, system commissioning, site acceptance
test, handing over to client and associated site works including
residual civil / structural works for the following as per the enclosed
standard specifications, instructions to vendor, job specification, data
sheets etc. of the MR.
2.01 {2}000-DCSSYS-00 For Item 1.01 1 Lot
3 Transportation from Vendor's shop to site for the following as per
enclosed standard specifications, special instructions to vendors,job
specification,data sheet etc. of MR.
3.01 {3}000-DCSSYS-00 For Item 1.01 1 Lot
4 Supply of Mandatory Spares for Item 1.01.
5 Supply of two years operation and Maintenance Spares,as per
Project : RESID UPGRADATION PROJE REQUISITION No. REV

A133-000-YE-MR-1500 C
NEW DELHI Client : M/S CPCL
Page 5 of 564 Sheet 2 Of 5
S.NO TAG NO . DESCRIPTION QUANTITY
/ ITEM CODE
specification and special instructions to vendor.

6 Unit Rates for addition/deletion purpose.
6.001 Unit Rates of each DCS & its constituents/PLC/CCTV/UPS/sub systems 1 Lot
hardware and software items, as per enclosed special instruction to vendor
/ MR.
7 Training for Owner Personnel as per MR:
7A At Manufacturer's Work
7B At Site
8 Five Years Post Warranty Annual Maintenance Contract as per MR.
Vendors shall quote prices against these items in their price schedule
Vendor to note that the numbers given in square '[]' and curly '{}' brackets are not for their use and
meant for store purpose only.Items shall be tagged as per equipment Tag No. only.
Project : RESID UPGRADATION PROJE REQUISITION No. REV

A133-000-YE-MR-1500 C
NEW DELHI Client : M/S CPCL
Page 6 of 564 Sheet 3 Of 5
This document, drawing, and the design/ details given in this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrowers express agreement that they will not be
LIST OF ATTACHMENTS
REV
S. NO. DOCUMENT TITLE DOCUMENT NO. SHEETS
DATE
PART-A (DISTRIBUTED CONTROL SYSTEM)
reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.EIL-1641-507. A4-210 x 297.
SECTION-I A
1 A133-000-16-51-SP-1501 3
(Preamble) 17-01-2014
SECTION-II
2 - - -
(Standard Specifications)
a. A
List of Documents A133-000-16-51-SP-1502 2
17-01-2014
b. Standard Specification for Distributed Control 44NC-4600- 0
39
System 0000/J.SS/0102/A4 12-03-2010
c. Standard Specification for Programmable 44NC-4600- 0
19
Logic Controllers 0000/J.SS/0103/A4 12-03-2010
d. Specification for Quality Management System 0
6-78-0001 9
Requirements from Bidders 04-06-2009
e. Specification for Documentation 0
6-78-0003 12
Requirements from Suppliers 04-06-2009
f. Specification for Health, Safety & 1
Environment (HSE) Management at DCU, A133-00-6-82-0001 101
30-12-13
CPCL, Chennai
g. Safety Measures for Electrical Installation 2
7-51-0332 2
during construction 02-03-2013
SECTION-III B
3 A133-000-16-51-SP-1503 4
(Specific Project Requirement) 11-03-2014
a. A133-000-16-51-ED-01 B
Logistic Support Formats 4
(Annexure-I) 11-03-2014
b. A133-000-16-51-ED-02 B
Responsibility Chart 7
(Annexure-II) 11-03-2014
c. A133-000-16-51-ED-03 B
Power Consumption & UPS Requirement 5
(Annexure-III) 11-03-2014
d. A133-000-16-51-ED-04 A
Ventilation & Air-conditioning Requirements 7
(Annexure-IV) 17-01-2014
e. A133-000-16-51-ED-05 A
Air Quality Requirements 2
(Annexure-V) 17-01-2014
f. A133-000-16-51-ED-06 A
Proven Track Record Format 5
(Annexure-VI) 17-01-2014
SECTION-IV -
4 - -
(PROJECT SPECIFICATION)
a. B
Table of Content A133-000-16-51-SP-1504 2
11-03-2014
b. A
Project Information A133-000-16-51-SP-1507 4
17-01-2014
c. B
Special Instructions to Vendor A133-000-16-51-SIV-1500 25
11-03-2014
A133-000-16-51-OD-01 A
d. Additional requirements of DCS/PLC system 22
(Annexure-A) 17-01-2014
A133-000-16-51-OD-02 B
e. Specification for F&G system 12
(Annexure-B) 11-03-2014
Tagging Philosophy for Junction Boxes, A133-000-16-51-OD-03 A
f. 7
Panels & Cables (Annexure-C) 17-01-2014
A133-000-16-51-OD-04 A
g. Cables & Junction Box Requirements 3
(Annexure-D) 17-01-2014
PROJECT : RESID UPGRADATION

SPECIFICATION NO. REV
ENGINEER INDIA LIMITED
NEW DELHI
PROJECT, LSTK-01 A133-000-YE-MR-1500 C
CLIENT : CPCL, CHENNAILTD
Page 7 of 564
LIST OF ATTACHMENTS
REV
DATE
h. 44NC-4600- 0
PMC job specifications (Instrumentation) 32
0000/J.02/0101/A4 19-07-2010
i. 44NC-4600- 0
Instrument Cable Duct Fabrication Drawing 20
0000/JSD/0004 30-03-2010
5 SECTION-V
- - -
(Specific Requirements for DCS/ PLC)
a. A
Scope of Works A133-000-16-51-SOW-1500 5
17-01-2014
b. A133-000-16-51-OD-05 C
I/O Summary and sizing consideration 9
(Annexure-VII) 11-03-2014
A133-000-16-51-MD-08 2
c. System Configuration Diagram
(Sheet 1 of 4, 2 of 4 and 3 3
(DCS/ESD/F&G) 11-03-2014
of 4)
d. 0
110 V AC UPS Power Distribution Diagram A133-000-16-51-SK-3101 1
17-01-2014
e. 110 V AC UPS Non DCS Power Supply A133-000-16-51-OD-06 A
3
Distribution List (Annexure-VIII) 17-01-2014
f. 230 V AC Power Supply Distribution 0
A133-000-16-51-SK-3102 1
Diagram 17-01-2014
g. 24 V DC non UPS Power Supply Distribution A133-000-16-51-OD-07 0
2
List (Annexure-IX) 17-01-2014
h. E
Control Room Layout A133-000-16-51-SK-1101 1
03-12-2013
i. 0
Control Room Ground & Basement Floor plan A133-000-16-51-SK-0009 1
18-12-2013
j. 0
Control Room -Terrace floor plan, Section A133-086-16-51-SK-0010 1
18-12-2013
k. 0
Control Room Elevations, Sections A133-086-16-51-SK-0011 1
18-12-2013
l. 44NC-4600-0000/L- B
Overall Plot Plan 1
01/0001/A1 23-08-2010
m. B
Vendor Data Requirements A133-000-16-51-VD-1500 4
11-03-2014
n. A133-000-16-51-OD-08 A
Fieldbus design and implementation criteria 15
(Annexure-X) 20-12-2013
o. A133-000-16-51-OD-09 B
Vendor List 5
(Annexure-XI) 11-03-2014
p. A133-000-16-51-OD-10 B
Mandatory Spare Parts 3
(Annexure-XII) 11-03-2014
6 SECTION-VI A
A133-000-16-51-SP-1506 6
(Vendors Proposal Outline) 17-01-2014
7.
PART B (UPS)
A133-000-16-50-SP- A
7 AC UPS system for DCS Package 7
1500 17-01-2014
a. A133-000-16-50-DS- A
Data sheet for Static UPS system 3
1500 17-01-2014
b. 0 20
Standard Specification for Static UPS unit 44NC-4600: ESS025
03-05-2010
c. Standard Specification for Electrical 0 33
44NC-4600: ESS026
Installation 03-05-2010
ENGINEER INDIA LIMITED PROJECT : RESID UPGRADATION
NEW DELHI
Page 8 of 564
LIST OF ATTACHMENTS
REV
DATE
d. Standard Specification for Medium & High 0 8
44NC-4600: ESS008
Voltage Heavy Duty cables 03-05-2010
e. Typical Installation details of Electrical panels 2

7-51-0335 1
on false flooring 02.03.2012
f. A133-000-16-50-VL- A
Vendor List
1500 17-01-2014
g. A133-000-16-50-VR- A 3
Vendor Data Requirement- UPS system
1500 17-01-2014
h. 44NC-4600- 0 1
Typical Single Line Diagram UPS System
0000/E.01/0007/A4 22-07-2010
i. 2
ITP for UPS System 44NC-4600: ITP 025
PART-C (CCTV SYSTEM)

8
Cover Sheet Part-C
a. B 5
Scope of Work A133-000-16-51-SOW-1501
11-03-2014
b. A133-000-16-51-ED-07 A 3
Responsibility Definition
(Annexure-A) 17-01-2014
c. A133-000-16-51-ED-08 A 2
Distance Table
(Annexure-B) 17-01-2014
d. A133-000-16-51-ED-09 A 3
Proven Track Record
(Annexure-C) 17-01-2014
e. A133-000-16-51-ED-10 A 4
Logistics Support Format
(Annexure-D) 17-01-2014
f. A133-000-16-51-ED-11 A 2
Compliance Statement
(Annexure-E) 17-01-2014
g. B 2
CCTV data sheet A133-000-16-51-DS-5001
11-03-2014
h. B 6
Special Instructions to Vendor A133-000-16-51-SIV-1501
11-03-2014
i. Standard Specification for Instrumentation 44NC-4600-0000- 0 22
Works /J.SS/0101/A4 12.03.2010
j. A 2
Vendor Data Requirements A133-000-16-51-VDR-1501
17-01-2014
k. A133-000-16-51-MD-08D 2 1
System Configuration Diagram (CCTV) (Sheet 4 of 4) 11-03-2014
PROJECT : RESID UPGRADATION

ENGINEER INDIA LIMITED
NEW DELHI
Page 9 of 564
Engineers India Limited Vendor Drawing/ Document Submission Schedule
Client/ Project:M/S CPCL/ RESID Vendor's Name : Contact Person (Name/ Tel/ Fax/ email) : Status Date:
UPGRADATION PROJECT
Item Description:Distributed PR No.: Review Status Code:

Control System 1. No Comments
Date of LOI:
2. Proceed with manufacture/ fabrication as per commented document.
PO No.: Revised document required.
3. Document does not conform to basic requirements as marked.
Page 10 of 564
Date of PO: Resubmit for Review. R: Retained for Reference V: Void
EIL Originating Department :Instrumentation Contact Person(EIL):
Anticipated (Ant) Date of submission by vendor

Schedule
Drg/ Doc. Nomenclature Vendor Drg/ Doc No. Category Date of 1st Actual (Act) Date of submission by vendor Form
S.No. as per EIL Vendor Data Review(R)/ Submission Date of Return (Rew) by EIL Electronic Remarks
Requirement Records(I) (Rev. 0) (E)/ Print (P)
Title Review Status (Code)
Rev. 0 Rev. 1 Rev. 2 Rev. 3
Ant
Act
Rew
Code
Ant
Act
Rew
Code
Ant
Act
Rew
Code
Ant
Act
Rew
Code
Ant
Act
Rew
Code
Form No. EIL-1641-1923 Rev.1
Part A - Section: I
PREAMBLE A133-000-16-51-SP-1501 Rev. A
RESID UPGRADATION PROJECT
CPCL,CHENNAI Page 1 of 3
SECTION-I
(PREAMBLE)
A 17.01.2014 Issued with MR PR AB AR

Prepared Checked Approved
Rev. No Date Purpose
by by by
Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved

Page 11 of 564
Part A - Section: I
1.0 General:
1.1 Chennai Petroleum Corporation Limited (CPCL), formerly known as Madras Refineries Limited
(MRL) was formed as a joint venture in 1965 between the Government of India (GOI), AMOCO and
national Iranian Oil Company (NIOC). In 1985, AMOCO disinvested in favour of GOI. As a part of
restructuring steps taken by the Government of India, Indian Oil Corporation Limited (IOCL) acquired
equity from GOI in 2000-01. In view CPCL becomes subsidiary of IOCL in 2001, presently the equity
of CPCL is held amongst Indian Oil Corporation, Naftiran Intertrade Company and
Public/FI/FII/NRIs/Others.
1.2 CPCL intends to execute Coker Block consisting of Delayed Coker and LPG CFC Treating Unit on
Lump Sum Turn Key (LSTK) Basis. CPCL has appointed Engineers India Ltd (EIL) to do
Engineering, Procurement, Construction and Commissioning (LSTK route), for Coker Block.
1.3 The process unit shall be shall be monitored and controlled using Distributed Control System (DCS)/
Programmable Logic Controller (PLC), which shall be located in Main Control Room (MCR).
1.4 This Material Requisition (MR) defines the functional requirements of Distributed Control System,
Programmable Logic Controller (PLC) and UPS system to be supplied for Resid Upgration project
located at Manali, in the state of Tamil Nadu, India.
1.5 This MR consists of the following parts and sections:-
PART A: - Distributed Control System ( DCS)
a. Section-I (Preamble)
b. Section-II (Standard Specifications)
c. Section-III (Specific Project Requirement)
d. Section-IV (Project Specification)
e. Section-V (Specific Requirement for DCS/PLC)
f. Section-VI (Vendors Proposal Outline)
PART B: - UPS
PART C: - CCTV System
1.6 Bidder shall prepare their technical proposal as per Section-VI (Vendors Proposal Outline) and the
item summary of this MR. Bidder shall categorically state whether their proposal meets all the
technical specifications listed in the standard and project specification enclosed with this MR.
1.7 Bidder to note that one lump-sum cost must be submitted for all the control system together including
UPS and CCTV system
1.8 Bidder shall sign and stamp each and every sheet of the following documents indicating deviations
wherever applicable and filling the necessary information wherever asked for:-
a. Project Specification
Page 12 of 564
Part A - Section: I
b. Standard Specification
c. Special Instruction to Vendor
d. Specific Project Requirements
1.9 The proposal shall be evaluated, as received. Bidders are required to quote strictly as per the
requirements of this MR. Purchaser reserve the right to reject any or all alternatives, if proposed by the
Bidder, without assigning any reason thereof.
1.10 Bidder to note that they should desist from making comment or observations or explanation on any of
the clauses in the specifications. Only the deviations from the specifications should be listed in the
deviation chapter of the proposal (refer clause 1.11 of this section)
1.11 Generally, deviations will not be accepted and the Owner/ EIL reserve the right to reject any proposal
without seeking any further clarifications from the Bidder.
Deviations with proper technical reasons shall only be listed under SectionVI of the proposal.
Deviations mentioned elsewhere in the proposal shall not be considered. Bidder shall not contractually
refer to any of the comments or observations except deviations those listed in Section-VI in all or any
future correspondence.
Any comment or explanation in the deviation section of any point or requirement without highlighting
deviation shall be construed as non-compliance to the specification leading to the rejection of their
offer without assigning any reason and referring the same to the Bidder.
1.12 Bidder shall provide written guarantee for the availability of back-up engineering, maintenance
support and spare parts for a period of ten (10) years as per the format enclosed.

Page 13 of 564
STANDARD SPECIFICATIONS Part A - Section: II
DISTRIBUTED CONTROL SYSTEM A133-000-16-51-SP-1502 Rev. A
RESID UPGRATION PROJECT
CPCL, CHENNAI Page 1 of 2
SECTION-II
(LIST OF STANDARD SPECIFICATIONS)
A 17-01-2014 Issued with MR RK NZ AR

Rev. Prepared Checked Approved
Date Purpose
No by by by

Page 14 of 564
STANDARD SPECIFICATIONS Part A - Section: II
DISTRIBUTED CONTROL SYSTEM A133-000-16-51-SP-1502 Rev. A
LIST OF STANDARD SPECIFICATIONS
S. No. Document title Document no. No. of sheets
1. Standard Specification for Distributed Control 44NC-4600- 39

System 0000/J.SS/0102/A4
2. Standard Specification for Programmable Logic 44NC-4600- 19
Controllers 0000/J.SS/0103/A4
3. Specification for Quality Management System 6-78-0001 9 sheets
Requirements from Bidders
4. Specification for Documentation Requirements 6-78-0003 12 sheets
from Suppliers
5. Standard Specification for Health, Safety & 6-82-0001 87 sheets
Environment Management at Construction Sites
6. Safety Measures for Electrical Installation 7-51-0332 2 sheets
during construction

Page 15 of 564
Page 1 of 39
SPECIFICATION NO: 44NC-4600-0000/J.SS/0102/A4
TITLE: STANDARD SPECIFICATION FOR DISTRIBUTED

CONTROL SYSTEM
PROJECT REFERENCE:
- Project No: 44NC-4600
- Project Location: Manali, Chennai
- Project Title: RESID UPGRADATION PROJECT
- Client: Chennai Petroleum Corporation Limited
- Project Manager Authorization: B.B. DARAK Date:
- Client Authorization: Date:
APPROVALS
Rev. Issue Pages Revision Description By Check Approve
No. Date
0 12- Mar-10 39 Issued For Feed ADM MSD BSP

Entire Specification SPECIFICATION ISSUED FOR:
Issued this Revision In-house Review Purchase
Revised Pages Only Client Approval Construction
Issued this Revision Enquiry Engineering
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PROJECT NO.: 44 NC-4600 SPEC. NO. 44NC-4600-0000/J.SS/0102/A4
TITLE: STANDARD SPECIFICATION FOR DISTRIBUTED REV. NO / ISSUE DATE - 0 / 12-Mar-10

CONTROL SYSTEM Page 2 of 39
CONTENTS
1.0 PURPOSE
2.0 GENERAL
2.1 SCOPE
2.2 BIDS
2.3 DEFINITIONS
2.4 SYSTEM AVAILABILITY
3.0 DESIGN AND CONSTRUCTION
3.1 GENERAL
3.2 SPARES PHILOSOPHY
3.3 SYSTEM COMPONENT / INSTRUMENT ENCLOSURES
3.4 POWER SUPPLIES AND DISTRIBUTION
3.5 TRANSIENT, STATIC AND EMI / RFI PROTECTION
3.6 SYSTEM SIZING / LOADING CRITERIA
3.7 UPS SIZING CRITERIA
3.8 HEAT LOAD CALCULATIONS
3.9 SYSTEM FURNITURE
4.0 SYSTEM CONFIGURATION & FUNCTIONAL SPECIFICATIONS
4.1 SYSTEM COMPONENTS

4.2 FUNCTIONAL REQUIREMENTS
4.3 PROCESSOR SYSTEM
4.4 I/O SYSTEM
4.5 OPERATOR INTERFACE SYSTEM
4.6 ENGINEERS INTERFACE SYSTEM
4.7 COMMUNICATION SYSTEM
4.8 PLC INTERFACE WITH DCS
4.9 THIRD PARTY INTERFACE
4.10 OPEN SYSTEM CONNECTIVITY
4.11 INTERFACE WITH SMART TRANSMITTERS
4.12 DOCUMENTATION NODE (DN)
4.13 HARDWIRED INSTRUMENTATION
4.14 ALARM AND ANNUNCIATOR SYSTEM
4.15 CABINETS
4.16 CABLING
4.17 EARTHING
5.0 TESTING AND ACCEPTANCE
5.1 GENERAL
5.2 FACTORY ACCEPTANCE TEST (FAT)
6.0 INSTALLATION, TESTING AND COMMISSIONING
7.0 PROJECT MANAGEMENT
8.0 TRAINING
9.0 DOCUMENTATION
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10.0 WARRANTY
11.0 MAINTENANCE CONTRACT
12.0 SHIPPING
13.0 REJECTION
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1.0 PURPOSE
The purpose of this specification is to define the minimum requirements of a Distributed

Control System (DCS) designed for reliable, effective and optimum control and
monitoring of a process plant.
2.0 GENERAL
2.1 SCOPE
2.1.1 This specification defines the minimum requirements of system design including
hardware & software, configuration, manufacture, engineering, programming, inspection
and testing, documentation, installation, commissioning and shipping of Distributed
control system (DCS). This shall include as a minimum
- Manufacture, procure, supply, testing, installation, handling and commissioning of all

equipment and accessories.
- Building of all operator interface, screen displays, database and reports.
- System Hardware & Software configuration.
- FAT of all hardware / software and system integration testing under simulated
conditions.
- Supply, install, test and commission marshalling racks, system cabinets and consoles
/ printers. Including cables, terminals, IS barriers, power supplies and cubicle internal
mountings
- Supply of all system as well as control room furniture as per ergonomic and Owner
requirements.
- Proving of DCS system functionality as per requirements
- Training of Owners personnel at factory and at site on functional, operational and
maintenance aspects of the system.
- Supply of complete technical and as built documentation in electronic form as well as
hardcopy.
- Supply of all software on CDs along with required software licenses.
2.1.2 The detailed scope of work, specific job requirements, exclusions, deviations, additions
etc shall be indicated in the material requisition and job specification.
2.1.3 Where any conflict exists between this specification and other job specification, the
purchaser shall be consulted. Vendor shall not deviate from this specification without
prior approval from the purchaser.
2.2 BIDS
2.2.1 Vendors quotation shall enumerate and include the detailed specifications of each
subsystem and each module of distributed control system, detailed system configuration,
hardware and software capabilities, programming aids, display facilities and other
relevant information.
2.2.2 Vendor shall furnish a detailed list of deviations / confirmations clause-wise described in
this specification. Vendor must provide enough supportive reasons for the deviations
listed.
2.2.3 Vendors quotation shall include catalogues, drawings, technical specification sheets,
operating and maintenance manuals, performance evaluation certificates etc. All
documents shall be in English language only.
2.2.4 Vendor shall also supply the following items.
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Mandatory spares as indicated elsewhere in this specification.

Spare parts for start-up, commissioning and two (2) years trouble free operation
Consumables for six (6) months such as printer ink cartridges etc.
Special tools and test equipments.
2.3 DEFINITIONS
2.3.1 Distributed Control System

The class of instrumentation which in addition to executing the stated control functions
also permits transmission of control, measurement and operating information to and from
a single or a plurality of user specified locations connected via a communication system.
2.3.2 Accessible
A system feature that is viewable by and interaction with the operator and allows the
operator to perform user permissible control action e.g. set point change, auto-manual
transfers or on-off actions.
2.3.3 Assignable
A system feature that permits an operator to direct a signal from one device to another
without the need for change in wiring, either by means of switches or via key board
command to the system.
2.3.4 Configurable
A system feature that permits selection through entry of key board commands of basis
structure and characteristics of a device of system, such as control algorithm, display
format or I/O termination.
2.3.5 I/O
Input / Output with respect to process / operator.
2.3.6 System Size
System size shall be defined as maximum number of process inputs or tags those can
be connected to the system and viewable from any one of the TFT of an operating
console in all hierarchical displays without changing the configuration or without operator
interaction considering
All inputs as close loops
All inputs as open loops
2.3.7 Operator Console

Operator console is the main operators interface device via which operator can view the
plant and can give instructions to peripherals to execute commands and can configure
and maintain the system
2.3.8 Engineering console

Engineering console shall be the engineers main interface device via which engineer can
view the plant give instructions to peripherals to execute commands and can configure
and maintain the system.
2.3.9 Switch Over time

Time required for a back up instrument to come on-line automatically in case of the
failure of the main instrument.
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2.3.10 Loop integrity

A system shall be said to have loop integrity if the failure of one component in the
system / sub-system does not affect more than one loop.
2.3.11 Interchangeability
System / sub-systems shall be said to have full interchangeability if the functions and
information available on one system / sub-system shall also be available on the other in
totality.
2.3.12 sers memory

Free memory space available in addition to the memory required for system configuration
and other system related functions which a user can utilize to execute his own programs
for plant calculations, process optimization or MIS (like free formatting of certain logs).
The programs shall normally be written in high level languages.
2.3.13 Redundancy
A system component shall be termed as redundant if it automatically takes over the
operation in the failure of the main component without causing any interruption in the
system and upsetting the process. The repaired or replaced device shall be brought in
line only through operator action and can be replaced on line without affecting the
operation of the system.
2.3.14 Scan time
2.3.14.1 Close-Loops
Scan time for a close-loop shall be defined as the cycle time taken by controller to read
and process input, perform control calculations, and update control output for all the
loops configured within the controllers.
2.3.14.2 Open-Loops
Scan time for an open loop shall be defined as the cycle time required to read and
process input and perform computation of all the open loops.
2.3.15 Data base

Data base shall be defined as the information stored, temporarily or permanently in the
system to meet all its functional requirements.
2.3.16 Bus-degradation
Bus-degradation shall be defined as a change in the system performance from the
specified one while loading the communication sub-system from 10 through 100
percent.
2.3.17 Event
An event shall be defined as any action taken by the operator via operator keyboard and
switches on hardwired console like change of set point, change of control mode,
start/stop of motor, open/close of shut down valves, alarm acknowledge etc.
2.3.18 Real time trend

Real time trend shall be defined as a continuously progressing graphical record showing
continuously updated parameter with most recent value and a past record of minimum of
10 minutes without pressing any additional key for moving backward in time.
2.3.19 Call-up time

Call up time shall be defined as the time taken by the system to display a particular
display/data on 20.1 TFT after getting the corresponding command from the operator.
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2.3.20 Display update rate

Display update rate shall be defined as the rate at which the information present at the
system input terminal is getting updated on the current display on 20.1 TFT.
2.3.21 Central Level

Operator consoles and Engineering Console shall be referred as Central Level.
2.3.22 Local Level

All those sub-systems which directly interface with field devices shall be referred to as
local level.
2.4 SYSTEM AVAILABILITY
Vendor shall not quote any product / item which has become obsolete or going to be
obsolete in next 10 years time.
All updates / upgrades, hardware upgrades, software patches to fix bugs shall be
provided free of cost for above period. Vendor shall confirm that service support of the
supplied product / items shall be offered for at least 20 years from date of
commissioning. Bidder shall guarantee the availability of replacement spares for this
period. This guarantee shall also include all third party equipment supplied by vendor
alongwith his system. DCS vendor to submit written undertaking for the same to the
owner.
3.1 GENERAL
3.1.1 This DCS system shall be of latest evolutionary type with Open System Architecture
having networking capability with other systems distributed geographically in the various
units of a plant over a plant wide information network such as Ethernet / DEC net or other
industrially recognized open network.
3.1.2 This system shall be designed fault avoidant as a minimum by selecting high grade
components of proven quality and proper design of system electronics. Redundancy shall
be provide, as a minimum, as per this specification to improve the system availability and
reliability. Due considerations shall be given to the environmental conditions particularly
for field mounted sub-system, if specified in job specifications during system design.
3.1.3 All components of the system shall be able to operate satisfactorily from 150C to 300C
and 0% to 95% non-condensing humidity.
3.1.4 The system shall be of modular construction and expandable in future by adding
modules. The type of modules shall be kept to the minimum possible in order to have
interchangeability and low inventory.
3.1.5 The system software shall be governed by the operating system running in a real time
mode and shall be able to meet all specified functional requirements as a minimum. Any
other standard / special software package, if available shall also be offered describing
the full capabilities.
3.1.6 The system shall have a high MTBF value (Minimum 15 years) and shall have a well
proven record of operating satisfactorily in a Hydrocarbon processing plant for a
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minimum of one year. No prototype instrument of an experimental nature shall be

offered or supplied. .Control systems shall be designed with a minimum availability
requirements of 99.99% with a MTTR figure of 8 hours. Minimum level of redundancy
have been specified in the specification. Additional redundancies if required, must be
provided by Vendor to meet these specified availability requirements.
3.1.7 Galvanic isolation shall be provided for all field signals. Isolation shall also be provided
between Engineering / operator console and related sub-system connected to it.
3.1.8 On-line replacement of any module shall be possible in such a way that removal and
addition of a module shall be possible without de-energising the system. Furthermore,
there should not be any interruption of the system while replacing a faulty module
wherever redundant modules are provided.
3.1.9 Unless otherwise specified, all electronic modules / equipments shall meet the
environmental classification class G3 as per ISA-S71.04
3.1.10 The system shall be upward compatible i.e. new enhancements can be incorporated in
the system for future up gradation
3.2 SPARES PHILOSOPHY
3.2.1 Installed engineering spares of 20% shall be provided in each sub-system for each type
of module to enhance the system functional requirements including and hardwired
instrumentation.
3.2.2 In addition the system shall have the following minimum spare compatibility :
3.2.2.1 The controller and I/O system shall have 20% usable spare space for installing
additional I/O modules in future. However, the control processor shall have additional
20% capacity to handle these I/Os. In addition, internal wiring for the same shall be
completed upto I/O terminals.
3.2.2.2 Each operator console shall contain 10% usable spare group and related display
capability in addition to above
3.2.2.3 The system shall have capability to extend its historical trending, logging and users
memory by 40% to meet future expansion with / without adding additional memory
modules.
3.2.2.4 The communication system shall have sufficient capability to execute additional 30%
logics. Further it shall be possible to extend the memory by at least 30% at a later stage.
3.2.2.5 Usable spare space in panels and cabinets to install 20% spare hardwired items like
barriers, trip amplifiers, receiver switches, panel mounted instrument, relays etc in future
3.2.3 Sufficient additional software capacity shall be available in the system to take care of
spares requirement as specified to meet all functional requirements.
3.2.4 Mandatory spare module of 10% or one module of each type, whichever is higher must
be supplied for each type of modules being used including in consoles. This shall include
spare modules for hardwired instruments, assignable recorders, personal computers,
programmable logic controllers etc.
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3.2.5 Consumable Spares

Any paper, ribbon, printer heads and ink required for printers, assignable recorders,
video copier or any other consumable items shall be supplied along with system required
for minimum of six months duration after system acceptance.
3.3 SYSTEM COMPONENT / INSTRUMENT ENCLOSURES
3.3.1 All the equipment covered in this specification shall be located in general purpose non
hazardous area, normally in control room. All control room mounted equipment shall be
weather proof to IP-42.
3.3.2 Intrinsically safe certified transmitters and E/P positioners shall be used if located in
hazardous area. Distributed system shall have either built in intrinsic safety or shall use
external barriers for intrinsic safety. Safety barriers shall also be used whenever intrinsic
safety is specified for contact inputs. All solenoid valves shall be flame proof, in general.
3.3.3 The system as a whole shall be intrinsically safe based on entity concept. It may be noted
that the transmitters and E/P positioners bought separately can be of different make and
models certified intrinsically safe by any of the recognised statutory body lime BASEEFA,
PTB, FM, CMRI etc. Safety barriers selection shall be done based on the type of
transmitter or E/P positioners and shall be certified intrinsically safe by any of the above
statutory bodies. Any limitation or special requirements for cables to meet the intrinsic
safety requirements shall be bought out in the offer.
3.3.4 In case of smart transmitters, the entity parameters of the hand held terminals shall also
be considered while selecting proper barriers.
3.3.5 All intrinsically safe barriers shall be of the isolating type only, shunt diode type of safety
barriers shall not be used. Only single channel type of barriers shall be used.
3.4 POWER SUPPLIES AND DISTRIBUTION
3.4.1 The DCS system shall normally operate on uninterrupted power supply with the following
power supply specifications
Voltage 110 V +/- 10%
Frequency 50 Hz +/- 3 Hz
Harmonic contents Less than 5%
3.4.2 All cubicles lighting shall be on 240 V, 50 Hz normal power supply.
3.4.3 Power supply shall be made available at one point. Further power distribution network
shall be designed such that a single power fault in any instrument branch system shall
not cause a trip of the entire system. Each consumer shall be provided with a separae
MCB of proper rating for isolation and protection of the system. Earth leakage circuit
breakers or isolators shall be provided.
3.4.4 The vendor shall be responsible to derive any other required voltages required for proper
functioning of system. Redundant power supply units shall be considered for DC source.
When several transmitters are powered by a common DC source each power supply
branch shall have a separate switch and fuse. The distribution network shall be designed
in such a way that overload in any branch shall not trip the main power supply. All power
supplies shall be sized for 150%of full load. Status indication of each power supply shall
be made available at operator console. The individual system shall be designed to take
care of reverse polarity from DC source.
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3.4.5 On event of any of the following conditions , system shall go to fail-safe mode
Power Failure (Voltage variation more than +/- 10%)
Frequency Variation more than +/- 3%
Air-Conditioning Failure
3.5 TRANSIENT, STATIC AND EMI / RFI PROTECTION
3.5.1 The system shall be internally protected against system errors and hard ware damage
resulting from :-
Electrical transients on power wiring
Electrical transients on signal wiring
Connecting and disconnecting devices or removing or inserting printed circuit
boards in the Distributed Control System (DCS)
3.5.2 The DCS system shall be capable of accepting various signal inputs for its direct use
while preventing noise errors due to electromagnetic interference (EMI) or radio
frequency interference (RFI) including nearby radio stations, hand held radios, electrical
storms, solenoids, relays or contactors carrying heavy currents. RFI / EMI noise immunity
shall be as per SAMA standard PMC-33.1. The surge withstand capability of input/output
modules shall be as per IEEE standard 472.
3.6 SYSTEM SIZING / LOADING CRITERIA
The contractor shall submit calculation and basis of determining the availability of
equipments and architecture of the system to meet all the requirements in this
specification and at the same time observe the maximum loading indicated. Loading
here is referred to the use of memory, CPU time and communication capacity. The
loading shall consider the worst case of high system activity. During this case, no
degradation of system performance is allowed, maximum loading on various sub-
systems shall be as follows :-
40% : Processor including memory

60% : I/O capacity and other hardware
40% : Communication network (for deterministic networks).
40% : Foreign device interfaces
3.7 UPS SIZING CRITERIA
3.7.1 Vendor shall calculate the UPS load requirements considering following requirements
The instrumentation load which is required to be considered for must include 20%
installed spares and 20% additional load on the overall value
UPS sizing shall be carried out based upon the in rush current, duration of in rush
current and power factor of all major loads.
3.7.2 Redundant power feeders will be made available (by others) from UPS distribution board
3.7.3 Redundant system in control room shall have separate feeders from power distribution
cabinet in control room.
3.7.4 Non-redundant systems shall have two feeders for power distribution.
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3.8 HEAT LOAD CALCULATIONS
Supplier shall provide Heat load calculations for the total system , considering the
installed spares as well as components which would be installed in space reserved for
future expansion.
3.9 SYSTEM FURNITURE
All system furniture required for mounting and operation of the system including
mounting of table top equipments shall be supplied. Furniture for operating personnels
shall be as defined in job specifications.
4.0 SYSTEM CONFIGURATION & FUNCTIONAL SPECIFICATIONS
4.1 SYSTEM COMPONETS
Basic system configuration shall be as per Job specifications , however the system shall
consist of the following major sub-systems :
- Processor system
- I/O system
- Communication system
- Operator interface system
- Engineer interface system
- Supervisory computer system, as required
- Foreign device interface
- Hardwired instrumentation
- Information network system
4.2 FUNCTIONAL REQUIREMENTS
The system as a minimum, shall meet the following requirements without the supervisory
computer :
- Control
- Data acquisition and monitoring
- Alarming
- Logging and report generation
- Historical data storage
- Trending
- System shall have free memory space available for the user and CPU shall
have additional capability to perform advanced control functions,
processoptimisation programs or generate management reports as specified
in job specification
- Plant process interlocks and safety shutdown shall be independently
performed by programmable logic controller (PLC) which shall have
connectivity with DCS communication system
4.2.1 The system when specified along with supervisory computer, shall meet the fllowing
requirements in addition to above:
- Advanced control
- Unit and plant optimization
- Management information service reports
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4.2.2 Whenever information network is specified,the system shall meet any or all of the
following requirements.
- Centralised information system
- Statistical process control / quality control
- Plant optimization, data reconcillation, overall mass balance etc.
- Plant planning and scheduling
- Computer integrated manufacturing with information transfer to achieve
functions like productionand preventive mainenance scheduling and plant wide
coordination etc.
4.3 PROCESSOR SYSTEM
4.3.1 The control function of the system shall be executed by microprocessor based single or
multi-loop controller consisting of I/O ports and a set of algorithms which are easily
configurable.
4.3.2 This system shall be capable of executing following control functions and set of
algorithms as a minimum :
- General : Monitoring and alarms

- Control : P, PI, PID, adaptive gain, ratio, cascade, feed forward, etc
- Arithmetic : Addition, subtraction, multiplication, division, overaging, square root,
ramp, rate of rise / fall, etc.
- Linerisation :Flow pressure / temperature compensation, linearisation, polynominal
etc.
- Dynamic : Lead / Lag, dead time, timer, etc.
- Modes : Auto , Manual , Cascade or Computer.
- Limiter : Low Limiter, High Limiter, set point.
- Comparator : Less than, greater than etc.
- Selector : Low, High, etc.
- Logic : AND, OR, NOR, NOT, XOR, Start / Stop, etc.
- Miscellaneous :Bumpless transfers, direct / reverse output , Anti-reset windup , slow
fast ramping of setpoint & output etc.
4.3.3 The processor shall be able to scan critical close loop in less than 250 msec and non-
critical close loops in less than 500 msec unless otherwise specified in job specification.
The scan time for open loops shall be less than 1 second.
4.3.4 The controller shall be able to operate in either manual, auto, cascade or computer
mode. Mode change-over in either direction shall be procedure-less and bump-less. It
shall be possible to change set-point, tuning constant, operating mode, control loop
configuration from the central level i.e. operators interface keyboard and engineers
interface keyboard.
4.3.5 In computer mode, controller shall be able to track computer generated set point and
shall hold the last generated value in case of computer failure. In such case, controller
shall fall back on auto mode and continue to operate at the last received set point, in
general. Other options like pre-defined set point operation and fail safe condition shall
also be possible. On the resumption of computer set point again, the controller shall not
return to the computer mode automatically, Computer failure indicator shall be provided
at central and local level.
4.3.6 The size of the memory shall be sufficient for storage of the program instruction required
by the control schemes. Offer shall indicate the amount of memory occupied by the
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actual program and spare capacity available for later program modifications or additions.
A minimum of 60% spare memory space shall be provided at the time of handover of the
system to owner.
4.3.7 Memory shall be non-volatile. However, in case volatile memory is provided, battery
backup shall be provided for a minimum of one year to keep the stored program
intact. A battery drain indication shall be provided at least one week before the
battery gets drained. A potential free contact shall be provided for hardwired annunciation
in the control room.
4.3.8 Watchdog timer shall be a software device. The healthiness of processors shall be
continuously monitored by watchdog timer. Any hardware or software problem in the
processor system including CPU, memory, power supply, communication interface etc
shall cause the watchdog timer to report processor failure.
4.3.9 In case Multiprocessor configuration is offered , the processors must be able to

communicate with each other over the interconnecting datalink. Vendor shall ensure that
system performance shall not degrade when such a system is offered.
4.3.10 Loop integrity shall be maintained in processor system architecture by providing one to
one processor back-up. In case failure is detected in the active processor all the loops of
the failed processor shall be transferred to the back-up processor. The processor system
shall have automatic control transfer switching, which shall transfer the entire
configuration and data base of failed processor to the back-up processor. Design must
ensure that data integrity is maintained during switch over and no portion of data to be
transferred is corrupted before and during switch over to the back-up processor. The
back-up processor must be dedicated to perform only control functions. The indication of
the failed processor shall be displayed at local as well as on the central level. The switch-
over time shall be indicated which shall not be more than loop cycle time.
4.3.11 Loop integrity shall also be applicable to I/O system, power supply modules and any
other device associated with the processor system.
4.3.12 Whenever multi-loop capability of processor is used for acquiring data each input shall
be displayed in the actual engineering units and shall be independently accessible,
configurable and controllable from local as well as central level.
4.3.13 While downloading any changes, made to a particular tag, from engineer interface
system to the processor system the controller output shall be maintained at its last value
and should not be driven to zero value even momentarily.
4.4 I/O SYSTEM
4.4.1 The I/O system shall be capable of accepting process signals from various process
sensors and switches preferably without requiring external or auxiliary signal conditioning
devices. The system inputs shall include 4-20 mA DC, thermocouple, resistance
temperature detector (RTD) and discrete inputs as a minimum apart from others as
specified in the job specifications. It shall be capable of processing linear and non-linear
analog inputs, providing square root extraction for flow signals, linearisation and
compensation for thermocouples. The system shall be able to generate 4-20 mA DC
current signals for analog outputs and potential free contacts for the discrete outputs as a
minimum apart from others as specified in the job specification.
4.4.2 No. of inputs per Inputs/output (I/O) module shall not exceed either of the following :-
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Analog I/O Modules : 16 channels

Discrete I/O Modules : 32 channels
4.4.3 Each I/O shall be galvanically isolated from external control circuit by suitable means.
The minimum isolation level between I/O and logic circuit shall be 1000 volts DC.
4.4.4 Each I/O shall be protected against the reversal of polarity of the signal. Reversal of
polarity on I/O termination shall be indicated in DCS.
4.4.5 Each digital I/O module shall have a LED per channel to indicate the status of each Input
/ output.
4.4.6 Each input shall be provided with filters to filter out any noise in the input line and contact
bouncing noise.
4.4.7 All the inputs shall preferably be double ended i.e. two wires per input and not with
common return for all inputs.
4.4.8 The interrogation voltage to the input / output contact shall be powered from separate
power supply / supplies and shall not be a part of I/O module unless otherwise specified.
The redundant power supply shall be considered so that the redundancy is maintained at
all levels.
4.4.9 Output contacts shall be potential free/dry contacts. Wet contacts / powered contacts /
TTL outputs etc. shall not be acceptable. Vendor must provide arc suppression device
for each output contact. Each output shall be short-circuit proof and protected by fuse.
Visual indication of fuse down must be provided for each output.
4.4.10 All I/O modules shall have facility to detect wire open condition whenever normally open
inputs ( close on alarms ) are considered.
4.4.11 All I/O modules shall be provided with galvanic isolation or optical isolation using isolation
barriers.
4.4.12 The system shall have capability to provide analog outputs for driving indicator /
recorders (load upto 750 ohms). The analog outputs shall be 4 to 20 mA DC unless
otherwise specified. Each channel shall have current limiting such that effect of short
circuit in one channel does not have operation of other channels and current does not
exceed 30 mA.
4.4.13 All 4-20 mA inputs shall be capable of being software configurable on an individual
channel basis to provide energizing power for a 2-wire transmitter or to receive powered
signal from an external device such as 4-wire transmitter. The 2-wire option shall be
capable of driving the transmitters plus an additional load of 600 ohms such as that
imposed by a local indicator.
4.5 OPERATOR INTERFACE SYSTEM
4.5.1 The operator interface system (OIS) shall perform the function of Man Machine
interface and provide the centralized information to the plant operator / Engineer .
Following data shall be available on OIS :
Indication of all analog and digital process variables of control loops, open loops and
all loop related parameters.
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Manipulation of control loops including changing set point, mode, output,

configuration, running and computational constants.
Alarm displays and annunciation.
Graphic displays and status indication.
Logging and trending including historical trend recording
Self diagnostic messages, operator messages
Maintanence oriented manuals for hardware and software maintanence of the
system on engineer interface.
4.5.2 Operator interface system shall consist of operator consoles. Number of operator
consoles shall depend upon the size and operating philosophy of the plant and indicated
in job specifications. The consoles shall be with keyboards , individual or common
electronics , logging printer , hard copy unit as a minimum. Table top console is not
acceptable.
4.5.3 The system shall have global data base available at each operator console electronics
and all the required functions shall be available / executed at operator console. However,
in case distributed data base / console functions are offered, each data base electronics
must be dual. Further any change made in the data base of one console shall
automatically update the data base of other consoles.
4.5.4 All the functions and displays of operator consoles shall be fully interchangeable. In
general each console shall be dedicated a particular area of the plant , however it should
be able to take the functionality of other consoles , if required .
4.5.5 The real time clock of each operator console shall be crystal controlled one which shall
be independent of line frequency. All the real time clocks in the system shall be
synchronized with each other.
4.5.6 Each console shall be an industrial type high resolution 20.1 or larger color screen
capable of displaying alpha-numeric & graphic displays. Multiple colours shall be used to
distinguish parameters such as control, information, process and alarms etc.The display
screen shall be able to display the full alpha numeric tag number of a process variable. A
minimum of twelve (12) digits shall be provided for the tag number and 24 digits for the
process description , unless otherwise indicated in Job specifications.
4.5.7 Data display update rate shall not be more than one (1) seconds. Cursor control devices
must be available with each console like keyboard & mouse & trackball.
4.5.8 Keyboard shall be touch sensitive sealed type easy to operate with each key clearly
identified. It shall be easy to operate and shall meet all the functions to configure, operate
and maintain the system. A conversational user friendly software shall be used for
operation, configuration and maintenance of system. Each entry shall be registered with
an audio beep. The key board shall not be susceptible to dust and moisture. It shall be
provided with key-lock facility to prevent any un-intentional program modification.
4.5.9 The operator, as a minimum shall be able to access following through key board :
Selection of all the displays including the direct selection of loop in alarm page
turning facility, overview, group view and loop view selection etc.
Selection of loop for operation.
To acknowledge alarms as and when they are annunciated on the operator console.
Facility to enter any changed parameter like set point, manipulated variable digital
commands and to cancel any wrong entry while making such change.
Facility for easy positioning of cursor for the selection of any parameter.
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Selection of hardcopy printout, logging printout, alarm history, printout and

assignable trend recorder points.
Auto / Manual / cascade / Computer mode changeover of each Processor.
4.5.10 The OIS shall provide following process displays
4.5.10.1 Overview display
Overview display shall incorporate a minimum of 128 analog or discrete inputs which
can be monitored simultaneously on the screen (referred as page). Each page shall
be organized into a suitable number of groups. Each groups shall be identified
separately. Each group shall further incorporate suitable number of inputs (referred
as tags). Suitable identification and description shall be shown for each group on the
overview display to relate it to a group or loop display.
All analog points in the overview shall be represented as variable lengths indicating
deviation above or below the normal operating value or set point.
Alarms shall be displayed in change of colour against each variable if the variable
crosses a set value. Control loops operating in manual mode shall be indicated.All
input in alarm condition shall be identified by flashing.
In case any hard wired instrumentation backup is provided, overview pages shall be
assigned indicating the tag number and type of hardwired instrument.
4.5.10.2 Group Display
Group display shall be limited to the group of inputs as displayed in the overview display.
Each group shall preferable include eight (8) numbers of inputs. Each input in the
group shall be identified by the tag number, unit of measurements and process
description which shall be displayed on the screen. Display, as a minimum shall show the
following degree of details :-
Process variable in analog form shall show as a percentage of the transmitter span on
a linear scale bar graph of 0-100% or engineering units and in digital form as alpha-
numeric display in engineering units.
Set point value in analog form as a percentage of the transmitter span on linear scale
bargraph of 0-100% engineering units and in digital form as alpha-numeric display in
engineering units.
Output value in analog form as a percentage of linear scale bar graph of 0-100% and
digital form as percentage.
Processor mode i.e. auto, manual, cascade, computer.
Process alarm on process variable, deviation or velocity.
Selected loop within the group shall be identified by cursor marking or similar
identification.
Control valve failure position.
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The contact input / output shall be represented by simulated graphic lamps and
configurable alpha-numeric status description.
Also It shall be possible to control the process from group views. Following control
actions shall be possible.
Increase / decrease of set point value either slow or fast.
Change of Processor mode i.e. Auto / Manual transfer.
Changing output to the final control element.
For digital points, start/stop or open / close command.
4.5.10.3 Loop Display
Loop display shall provide a separate detailed display for each of the process inputs.
The graphic representation of analog and digital points shall be similar to group display.
However, in addition following information shall also be presented in alpha-numeric form
as a minimum.
Processor tuning constants.

Process variable zero and span values.
Alarm set point on various parameters.
Limits on set point, output, velocity
Processor action (Direction / Reverse)
Failure position of final control element.
Computational constants like ration or bias.
Integrated value.
Output to the final control elements
Engineering units.
It shall be possible to change tuning constant , scale , zero & span , limits on setpoints ,
output , control mode start / stop command through the keyboard of operator console ,
although some functions shall be restricted through key-lock control.
4.5.10.4 Graphic Display.
It shall be possible to display dynamic graphic of different section of plant on the

operator console 20.1 TFT. Graphic displays shall be field configurable only through
engineering key-board with standard / user defined graphic symbols. Different plant
sections dynamics shall be displayed on different pages.
The system shall have the capability of having and developing graphic symbol library
as per ISA-5.1 and 5.3. In addition, standard industrial symbols like distillation
columns, heat exchangers, pumps, compressors, tanks etc shall also be provided as
a standard.
Graphic displays shall be interactive type through which it shall be possible to control
the process. It shall also be possible to send motor start/stop and shutdown valve
open/close command, as specified in job specification from this display.
It shall be possible to view the process variable and alarm points and view and
change set point value, manipulated variable, Processor mode etc from the graphic
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display. Also compressor/pump status and valve status shall be displayed on the
graphic display with different colours.
Various colours used in the generation of graphics like colour of the process lines
utility lines, instrument signal lines and event modifier conditions shall be finalised
during detailed engineering. The colours used to identify event modified conditions
shall generally be as follows unless otherwise indicated during detailed engineering.
It shall be possible to go from any graphic page to related graphic pages or any group
view or alarm summary in single key stroke using soft key function.
4.5.10.5 Trend Display
The system shall be capable of displaying the following trends

Real time trends of the parameters as specified in job specifications displaying
current data. However, it shall be possible to assign any parameter for real time
trend.
Historical trend for number of parameters as specified in the job specification.

However it shall be possible to assign any parameter for historical trending.
Historical data shall be stored on the nonvolatile memory device like hard disc in
such a way that such historical data can be utilized for archival storage and
subsequent recall.
Real time and historical trend shall be possible on any parameter or variable like
measured variable, set point, output, calculated variable etc.
It shall be possible to sample and store data of instantaneous and average value at
the intervals mentioned below. However it shall be possible to display by scrolling or
expanding the time base for all the trends.
At interval 2 second and below for the real time trend.
At 1 minute, 10 minute and 1 hour interval for historical trend.
Historical data trends shall be displayed for a period of minimum upto 25 hours for a
data sampling rate of 1 minute.
Fast trend requirement, (trends with sample time faster than Real time trend) if any
shall be specified in the job specification.
Selection of the tag number and sampling time for real time and historical trending
shall be possible from operator keyboard.
The system shall also have a multitrend capability in such as way that it shall be able
to display set point, measured variable and output on the same display, the trend of
either the same process variable or any other process variable.
Trend display shall be single line type or bar graph type with additional information
like loop tag number, engineering units, span, present value of the trended point.
Alarm status etc displayed.
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4.5.10.6 Alarm Display
It shall be possible to display process as well as system alarms on the operator

console for operators attention and action. Alarms shall appear immediately on the
operator console as and when they occur on priority basis.
It shall be possible to set process alarm limits from the engineering keyboard i.e.
alarm limits on absolute value of measured variable; rate of change of measured
variable., high and low deviation set points, high, extra-high, low and extra-low points
on process variable and output etc. In addition, it shall be possible to derive alarm
conditions on the basis of few calculations performed by the system.
Alarm messages shall be displayed by flashing the page and group number of the
input under alarm irrespective of type of display. It shall be possible to access the
group or tag in alarm condition with a maximum of two key-strokes of operators
console keyboard. The plant overview display, in addition to display alarm message
shall also be able to provide warning by changing colour of excessive deviation of
process variable from their set value.
All alarms shall be displayed as and when they occur or generated with change in
the colour of display in the following sequence, activating an audio signal :
Continuous flashing - Un-acknowledged alarm
Steady display - Acknowledged alarm
The system shall not put off the audio alarm and visual flashing even after the
condition returns to normal unless it is acknowledged by the operator.
It shall be possible to display summary of all alarms in the sequence of their

occurrence and shall disappear from display only when they are acknowledged and
cleared. The alarm display shall list the following for each alarm as a minimum
The date and time of occurrence
Point identification (i.e. Tag numbers)
Point description
Type of alarm (absolute value of deviation
Serial number of alarm in the sequence of its occurrence.
The history of alarm conditions shall be maintained in the data base for alarm history
display and printed on shift-wise basis for the parameters specified in the job
specifications. The alarm display and print out shall list the following for each alarm
as a minimum.
The data and time of occurrence
Point identification (i.e. Tag number)
Point description
Type of alarm (absolute value or deviations)
Time of acknowledgement
Time of return to normal
Serial number of alarm in the sequence of occurrence
4.5.10.7 Configuration display
Configuration display shall provide a separate detailed display for each loop
indicating the configuration of the loop. When control requires more than one loop, all
interrelated loops shall also be displayed. Following information is required to be
available for configuration display.
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Loop configuration giving designation of each blow.

Control block interconnection showing softwaring or hardwaring
Value of each blow parameter like P&ID, ratio, bias, dead-time, lead-time etc.
It shall be possible to configure & reconfigure the loops from this view using user
friendly software.
4.5.10.8 OIS Logging feature
It shall be possible to log all measured and computed parameters, operator

actions alarms etc. from operator consoles.
Logs shall be required on hourly, shiftwise (8 hourly) and daily basis and some
cases for weekly and monthly basis as specified in job specification.
All parameters required for logging shall be stored in memory in accordance with
data base update rate. However it shall be possible to perform basic arithmetic
calculations such as averaging, summing , efficiency calculations etc prior to
logging.
The log format shall be user definable, in general. However the typical log formats
for hourly, daily and shiftwise reports shall be as defined in the job specifications.
For extended logging like weekly and monthly reports, system shall have
capability of writing programs in high level language. High level language compiler
software sufficient memory space and necessary hardware shall be provided.
Number of log reports shall be as per number of log formats defined like hourly
report format, daily reports format etc. Number of pages in each log report shall
be sufficient to accommodate all the parameters for logging as defined in the job
specifications.
Hourly report shall be printed only as and when initiated on demand by the
operator and shall not be printed automatically after the end of the hour. All other
reports shall be printed automatically at the end of the pre-defined time as well as
on demand by the operator. The maximum storage time for a log information shall
be 15 minutes after the pre-defined print out time for a format, within which time
log report must be printed. In case report could not be printed within the
scheduled defined time, data shall remain stored till the report is finally printed.
4.5.10.9 Logging Hardware
Logging printer shall be used for
Printing of hourly, shift-wise, daily and weekly log

Shut down report printing
Any other report defined in the job specification
Alarm and event printer shall be used for
Logging the process and system alarm messages as and when the
occur.
Print the alarm history for every shift of operation or on demand from
operator console
Logging events such as operator actions as and when they are initiated.
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Alarms and Events shall be clearly distinguishable on the report, preferably by

colour.
Print out shall show as a minimum the tag number, description, data and time of
occurrence, time of acknowledgement and time of return to normal.
4.5.10.10 Self Diagnostics
Following diagnostics shall be available as minimum

Analog input Diagnostic - Sensor out of range, open or shorted loop, analog-
to-digital converter check
Analog Output diagnostics Open or shorted loop
Configuration diagnostics Checking compatibility and availability of selected
I/O hardware & software
Memory diagnostic Checksum , Parity etc
CPU / Memory diagnostics O/p of processor from an algorithm checked
against pre-stored answer
Power diagnostics Monitor availability of supply voltages
The self diagnostic message for a system failure shall appear on the operator console
irrespective of display selected. The choice of the detailed self diagnostic displays
shall be made by a key-lock switch.
The system shall have an extensive set of self-diagnostic routines which shall locate
and identify the system failure at least upto module level including redundant
components.
Failure of a system shall be annunciated with the change in colour. To aid system
maintenance and for effective fault location, following display shall be provided as a
minimum.
Communication system status display

The display shall show an over view of different sub-systems connected over
the communication system showing status of each system. When a failure is
detected by the system self diagnostic routing, the display shall indicate the
location and nature of malfunction.
systems diagnostic display

One display page shall be available for each system which can be called on
demand. The same shall display as minimum system number and type, error
code and description and details of failed module.
4.5.10.11 Data Storage, Archival and Retrieval
Historical data shall be stored on a non-volatile memory device like hard disc which
can be subsequently recalled by operator on any screen. System must support
multiple historical data discs in order to avoid data loss in case of disc crash.
It shall also be possible to store and retrieve this data on removable mass storage
media like CD ROM , floppy disc, cartridge or tape etc.
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4.6 ENGINEER INTERFACE SYSTEM
4.6.1 Engineer interface system shall be primarily an engineers interface which shall normally
be used for configuring, tuning and maintenance of the Distributed Control System. This
shall consist of a console provided with one operator key-board and one engineering
keyboard. This as a minimum shall also have one configuration and maintenance printer.
Exact number of such consoles will be as per Job specification.
4.6.2 Engineering console shall have as a minimum the same capability as operator console.
However the operation of the plant shall be restricted from this console only in tuning
mode. All the plant views as specified under operator console shall also be available on
Engineering console.
4.6.3 It shall be possible to perform all system configuration functions from the Engineering
console typically.
Data base configuration including overview, group, loop, multiloop and multi-
variable control configuration.
Group or multi-group alarm inhibit from the plant under maintenance.
Configuration or re-configuration of alarm settings, their values, addition or deletion
of any control block or components in a loop.
Tuning of control loops like changing, PID, dead time values
Compilation of graphic displays
Setting of real time clock
Compilation of logs/reports/historical trend points.
To call detailed self diagnostic displays for maintenance aid.
4.6.4 Tuning of a control loop shall be possible from engineering as well as from operator
console, the location shall be selected by the operator using a Tuning mode key-lock
switch provided on the operator console. In tuning mode it shall be possible to operate
only the loop under tuning from engineering console. In case of simultaneous
commands from operator and engineering consoles, operator console shall over-ride.
4.6.5 During the normal operation, the engineering console, in no case shall interfere with the
process operation or system software. However, any change in the configuration shall be
down loaded into the system with proper knowledge of the operator.
4.6.6 All detailed diagnostics of the system shall appear on the engineering console with a print
out on the configuration and maintenance (C & M) printer. A common diagnostic
message on the operator console shall indicate the need of the maintenance. C & M
printer shall be used for printing the configuration or configuration changes, printing
system alarms as and when they appear and to print out any engineers command from
engineering console.
4.7 COMMUNICATION SYSTEM
4.7.1 The communication system shall be a digital communication bus, that provides a high
speed data transfer rapidly and reliably between the operator consoles, process I/O
devices, process computer and other devices connected to it.
4.7.2 Communication system shall be dual redundant, consisting of two separate

communication buses and two separate communication system interface for each
device. In case of systems having traffic directors, redundant traffic directors shall also
be provided.
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4.7.3 Communication speed on the communication bus shall be sufficient to update the
operator console data base once in every second. The overall system performance shall
not be degraded whether communication system is 10% or 100% loaded.
4.7.4 In case of main bus failure or any communication device failure, the transfer to the back
up device or bus shall be automatic without interrupting the system operation and without
any operators intervention. Information about the failed device/bus shall be displayed on
the operator console.It shall be possible to connect or disconnect a device from the
system without disturbing the operation.
4.7.5 In general, the transmitting message shall identify the receiving device. The transmitting
device shall receive a reply from the receiving device on the receipt of correct message.
Lack of response shall be considered as a receivers failure.
4.7.6 The mechanism used by the communication system for error checks and control shall be
transparent to the application information. Error checking on all data transfer shall be
done by cyclic redundancy check and other advanced codes.
4.7.7 All communication cables to be routed in the field shall be fibre optical type. Specific
convertors shall be provided wherever required. All fibre optical cables shall be routed
through hard HDPE conduits and shall be totally enclosed within using HDPE matching
fittings. The HDPE conduits shall be as per IS-4984 or equivalent IEC standard. The
outer colour of the conduit shall be orange with black fittings throughout the run. Use
separate conduits for laying redundant fibre optical cables. Preferably separate routes
may be followed for redundant cables. Wherever fibre optical cable is to be routed
underground, this should only run in concrete trenches with HDPE conduits provided as
above. All such trenches shall be sand filled after installation.All optical fiber cable shall
be armoured type , rodent resistant.
4.7.8 In case of foreign device interfaces (PLC, ASC etc) with DCS, the failure of One
Communication carrier card shall not affect the redundancy of more than one foreign
device interface
4.8 PLC INTERFACE WITH DCS
The PLC shall be interfaced to the offered Distributed Control System bus. The interface
shall be dual redundant unless otherwise specified. The interface shall facilitate the
following functions as a minimum :
Display of all input points under alarm/first out alarm connected to PLC or generated
in PLC on the main operator console.
Generate shut-down reports on the logging printer of distributed control system.
To receive certain operational commands from the hardwired console for the
operation of certain output devices connected to PLC.
To display diagnostic messages of PLC
4.9 THIRD PARTY INTERFACE
4.9.1 Third party interface shall be capable to transfer data from the foreign devices like
analyser system, gas chromatographs, gas turbine system etc to other sub-systems
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connected to communication system and vice-versa whenever specified in the job

specification.
4.9.2 Each device interface shall be redundant unless otherwise specified in job specification.
4.9.3 Interface hardware and software shall be suitable to match the foreign device
communication requirements like hardware interface, communication protocols etc.
4.9.4 While writing software or mapping the input / output in the interface device it must be
ensured that integrity of the data to be transferred like resolution, correctness etc shall
be maintained.
4.9.5 Redundant interface switchover shall be designed based on the type of redundancy
available in the foreign devices.
4.9.6 The total responsibility of selection of hardware, writing or software, switchover of

redundant interface etc shall be of distributed control system vendor only. All necessary
information assistance and help shall be rendered by the Foreign device vendor.
4.9.7 The exact requirements of input/outputs to be transferred shall be as per job

specifications.
4.10 OPEN SYSTEM CONNECTIVITY
4.10.1 The system shall be capable of interfacing with other plant systems and computers over
a well established communication network like Ethernet conforming to IEEE 802.3
4.10.2 The system software shall be support industry standards like UNIX, Windows NT,
OSF/MOTIF, TCP/IP and DDE, SQL, RDBMS etc as applicable.
4.10.3 The method of data access by any user on this network shall be by I/O Tag name and
not by any physical or logical address.
4.11 INTERFACE WITH SMART TRANSMITTERS
4.11.1 System shall be provided with suitable hardware and software to interface with the
communication protocol of specified smart transmitters.
4.11.2 In case smart transmitters are specified with HART PROTOCOL, the maintenance data
related to these transmitters shall be made available on a separate personal computer.
The system shall meet the following requirements as a minimum
The system shall allow the maintenance functions like configuration. Calibration and
monitoring of transmitters data from the associated personal computer in addition to
Hand held terminal whenever used.
The hardware used shall allow unrestricted transfer of digital signal without degrading
the analog data i.e. process variable
The software supplied shall be CORNER STONE OR EQUIVALENT compatible with
the specified transmitter protocol. The software shall allow the following data to be
displayed on the PC :-
Complete configurational data base of all transmitters including data of
commissioning, last calibration, next due calibration etc
Historical data for calibrations and configuration changes
Event and log reports
Multiple authorisation levels for carrying out Configuration changes and
Calibration adjustments
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Manual editing of data base with Password and / or keylock protection
4.12 DOCUMENTATION NODE (DN)
4.12.1 Contractor shall be responsible to supply completely engineered documentation node

including necessary hardware of proper size and the software necessary to meet the
requirements of the node. The relational data base shall be generated by the vendor to
display and print out all unit documentation on the documentation node.
4.12.2 The node shall comprise of a workstation or a PC along with the accessories like
streamer tape, CD drive and a laser printer. The node shall meet the following
requirements as a minimum :
Store complete unit documentation
Store all instrument specification sheets including for field services for all the units.
The specifications will essentially consist of tag number, location, service and all
major attributes to uniquely identify the instruments in the refinery.
Link DCS documentation with unit documentation and instrumentation specification.
Updation and maintenance of documentation file.
Generation of new drawings and document and load these in the system if required.
Provision of transferring / accessing information to / from MS access/ Excel formats
from/to other PCs on network.
Print out various documents as required.
4.12.3 The documentation node shall be dedicated one. The sizing of the node shall be carried
out based on the above facts. Any information should be accessible from the system in a
menu driven program only. Vendor shall be responsible for the complete application
engineering of documentation node including those of packages. Documentation data as
available from sub packagers will be made available to the vendor.
4.12.4 Following documents should be possible to be printed from the documentation node as a
minimum. Vendor shall indicate the capability of their offered system and shall engineer
the same as per Owners requirements :
Loop wiring diagram for every input and output including field interconnection upto
instrument inclusive of junction box.
Loop schematic and instrument hook-up drawing showing sample tubing, fittings,
joints,etc.
Alarm and trip settings (software and hardware along with field settings) for DCS and
PLC tag numbers in tabular form in total or in part as per requirements based on type
of instruments / parameters.
Transmitter calibration ranges, span, elevation / suppression provided.
Safety valve set points.
DCS PLC input / output tag list with location.
The document containing all information attributed to the particular tag number like its
loop wiring diagram, cable schedule number, tubing hook up number, installation
standard number etc.
Provision of viewing / printing logic diagrams, PLC configuration (if possible).
Generate any report in the user definable format.
DCS point database.
4.12.5 It shall be possible to add delete modify any attribute , data, specification, parameter etc.
from the system with proper protection, pass word protection may be provided.
4.13 HARDWIRED INSTRUMENTATION
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4.13.1 Hardwired instruments shall be stand alone type and shall meet their functional
requirements fully without depending on DCS system. Even power supply and
input/output circuits of hardwired instruments shall be totally independent of DCS system.
However hardwired consoles shall be installed alongwith operator interface station as
man-machine interface which shall be equipped with annunciators, indicating lamps,
pushbuttons, selector switches etc.
4.13.2 Hard wired instruments shall be microprocessor based. Each instrument shall have as a
minimum the necessary firm-ware to meet its functional and operational requirements.
Each device shall have its own analog to digital / digital to analog converter. The display
shall preferably be bargraph type.
4.13.3 Processor shall be digital type capable of performing automatic control based on the set
points given locally or from a remote device like another processor or distributed control
system or supervisory computer. The processor as an instrument shall also have
provision for manually controlling the process by means of a manual loader and cascade
/ computer / auto-manual transfer switch. The operation of the transfer switch shall be
procedure-less and bumpless while changing the mode. During such a change the output
shall not change by more than 1% of span. Processor shall have a facia giving
continuous indication of process variable, set value, processor output and processor
mode. It shall be possible to remove an instrument for maintenance without upsetting the
process by use of device like service station. Operation of the Processor like set point
change, manual control, Processor mode change shall be possible from the front of the
rocessor. The processor shall be flush panel mounting type on the panel/hard wired
console. Configuration and tuning of processor shall be possible through a portable and
pluggable configurator.
4.13.4 Recorder shall have independent circuit and pen drive assembly for each channel.
Recorder shall have capability of continuous line marking or digitized marking of input
value with high resolution. Recorder chart drives shall be of multi-speed type and shall be
operator selectable. Recorders shall be flush panel mounting type on the panel / hard
wired console.
4.13.5 Manual loader unit shall have continuous display of process variable and manual loader
output. It shall be possible to manually change the output to control valve. Manual
loaders shall be flush panel mounting type on the panel / hardwired console.
4.14 ALARM AND ANNUNCIATOR SYSTEM
4.14.1 The alarm logic shall be executed in single input plug-in type logic modules. Where
integral logic has been indicated, the logic module shall be accessible from the front of
the annunciator after opening the swing door. The design of each module shall be such
that by simply jumpering suitable point, it may be changed from normally open mode of
operation to a normally closed mode of operation and vice versa.
4.14.2 Lamps shall be replaceable from the front. The power consumption of each lamp shall be
approximately 10 watts.
4.14.3 The initiation of alarm condition in the annunciator shall take place approximately 330
millisecond after the condition sensing contact have assumed the off-normal state.
4.14.4 Hooter in general shall be solid state type with audibility of the order of 100 dB at a
distance of 3 metres.
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4.14.5 An interruption of power supply for a duration of 20 milliseconds or less shall not affect
the functioning of the annunciator.
4.15 CABINETS
4.15.1 Following cabinets shall be required in general

Power distribution cabinets (for AC distribution and DC distribution).
Safety barrier mounting cabinets (if field is hazardous).
Processor system cabinets.
Trip amplifier and other auxiliary card mounting cabinets.
Interposing Relay cabinets ( for MCC interface & powered digital O/ps ).
Marshalling cabinets.
4.15.2 All the cabinets and panels shall be completely wired and/or tubed, if required.
4.15.3 All the cabinets shall be of free standing, enclosed type and shall be designed for bottom
entry for cable connection. Cabinets structure shall be rigid and shall be provided with
removable lifting lugs to permit lighting of the cabinets. Cabinets shall be of RITTAL
make.
4.15.4 Cabinets shall be fabricated from cold rolled steel sheet of minimum 2 mm thickness
suitably reinforced to prevent warping and buckling. Doors shall be fabricated from cold
rolled steel sheet of minimum 1.6 mm thickness. Cabinets shall be thoroughly deburred
and all sharp edges shall be grounded smooth after fabrication.
4.15.5 Cabinet finish shall include sand blasting, grinding, chemical cleaning, surface finishing
by suitable filler and two coats of high grade lacquer with wet sanding between coats.
Two coats of paint in the panel colour and final coat shall be given after assembly at site
for non-glossy high satin finish. Colour of the cabinets shall be as per job specifications.
4.15.6 Each cabinet shall be of maximum 2100 mm height, 1200 mm width and 800mm depth.
Construction shall be modular preferably to accommodate 19 standard electrical racks.
All racks shall be of same height. Maximum swing out for pivoted card racks doors and
drawers shall be limited to 800 mm.
4.15.7 Cabinets shall be equipped with front and rear access doors. Doors shall be equipped
with lockable handles and concealed hinges with pull pins for each door removal. Keys
shall be same for all system cabinets. Similarly all auxiliary / marshalling / non-system
cabinets shall have common key.
4.15.8 In order to effectively remove dissipated heat from the cabinet, vent louvers backed by
wire fly screen shall be provided to cabinet doors, in addition to ventilation fans. In case
of failure of any fan , alarm should be generated on DCS. The cabinets shall also be
provided with Temperature monitoring which will generate alarm in case of high
temperature.
4.15.9 Illumination shall be provided for all cabinets by fluorescent lamps and door operated
microswitches.
4.15.10 Components, within the cabinet shall be laid out in all accessible and logically segregated
manner. Clamping rails shall be provided for incoming cables to prevent excessive stress
on the individual terminal. All metal parts of the cabinet including door shall be electrically
continuous and shall be provided with a common grounding lug.
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4.15.11 The signals shall be segregated in Marshalling cabinets as indicated below :

IS Analog 4-20 mA cables (through safety barriers)
Non-IS Analog 4-20 mA cables
IS Digital contact / alarm signals (through safety barriers)
Non-IS Digital contact / alarm signalse)
Power cables
System communication cables
MCC interface signals
4.15.12 All cabinets , panels & racks shall be designed to avoid congestion for ease of
maintenance.Additionally the rack / cabinets shall be designed as per following
guidelines
No cabinets shall have more than 600 terminals
All spare cores shall be terminated on the marshalling rack. No cable / core shall be
left unterminated in the rack / cabinet
No terminals or terminal strips shall be located on the side panel of the rack /
cabinet.
4.15.13 Items like Isolators , Trip amplifiers , Monitor switches , R/ I Converter , if used shall be
installed in separate cabinet called as Auxiliary cabinet. Signal Isolators shall be provided
wherever an analog signal is to be sent to two sub-systems.
4.15.14 All Digital Output terminals shall be fused type provided with LED indication.
4.15.15 All IS signals shall be terminated on Light blue colored terminal strip.
4.15.16 All cabinets shall have bottom cable entries , provided with removable gland plates. Each
marshalling panel shall have copper bus bar mounted on insulator for termination of
multi-cable screens coming from field. A minimum distance of 300mm shall be provided
between gland plates and terminations to enable easy installation of cables.
4.15.17 Cables shall be supported throughout their run inside cabinets. Clamping arrangements
shall be provided to secure cables at the point they leave the cabinet. There shall be
provision for adequate segregation and separation of power , analog signal , digital signal
, main & redundant network cabling. Cable trunks shall be sized to have 40% spare
capacity after all cabling & wiring has been installed.
4.15.18 All live terminations at a voltage above 60 VAC or DC with respect to earth , shall be
protected against accidental contact by covers requiring tools for removal. Covers shall
carry appropriate warning labels.
4.15.19 Each cabinet shall be provided with 1 no. Electro-static discharge wrist strap , which
shall be used while handling electrostatic sensitive components.
4.15.20 Wiring colour code within cabinet framework and accessory equipment shall be as
follows
Power supply (Line) : Red
Power supply (Neutral) : Black
Ground : Green
Alarm system : White
Control & Shutdown : Yellow
Analog signal intrinsically safe : Light blue
DC Wiring : Red positive
: Black negative
Page 43 of 564

4.16 CABLING
4.16.1 Vendor shall supply and install all interconnecting cables which shall include but not
limited to the following :
Cabling between Marshalling racks , System cabinets , Barrier cabinets & ESD
system
Cabling between Relay racks , Auxiliary consoles , System cabinets
Power supply cabling to all system components from Power distribution cabinets
Earthing cables of IS ground , Signal ground , cabinet body ground , system
consoles , peripherals inside control room.
Communication cabling
Earthing cable from pit to cabinets.
Interconnections shall preferably be done preferably with the help of pre-fabricated
cables with plug-in connectors at both ends.
4.16.2 All interconnecting cables shall be preferably armoured and laid in ducts / tray to protect
from rodents. If unarmoured cables are used , then these shall be suitably routed in
flexible conduits. The cables shall be routed below false flooring in cabinets rooms and in
trenches in console rooms.
4.16.3 All the cable entries / exit shall be through bottom plate only with suitable glands.
4.16.4 Field cables from instruments / Junction boxes / MCC are excluded from Vendors scope
of supply.
4.17 EARTHING
4.17.1 Each panel cabinet console and other equipment in control room shall be provided with
an earthing lug. All these lugs shall be properly secured to the earthing bus as per the
earthing philosophy indicated in design basis.
4.17.2 All circuit grounds of electronic instruments, shields and drain wires of signal cables shall
be connected to instrument ground bus which is electrically isolated from the AC mains
earthing bus. This bus shall be typically 25 mm wide and 6 mm thick of copper. The
instrument ground bus is connected to independent instrument system ground buses
through insulated wires.
4.17.3 Cable shields of thermocouple extension cables for grounded junction thermocouple
shall not be grounded in the control room.
5.1 GENERAL
5.1.1 On the basis of guidelines specified in this specification, vendor shall submit their own
testing, installation, commissioning and acceptance procedure. For hardware, the
procedure shall include purpose of test, test definition of input, procedure, results,
expected and acceptance criteria. For software, it shall include details of the method, list
of test sequence of execution, results expected and acceptance criteria.
5.1.2 The testing and acceptance of the system shall be carried out on the mutually agreed
procedure and criteria based on these guidelines and vendor standard procedures.
Page 44 of 564

5.2.1 Vendor shall test and demonstrate the functional integrity of the system hardware and
software. No material or equipment shall be transported until all required tests are
successfully completed and certified Ready for Shipment by the owner/consultant.
5.2.2 The purchaser reserves the right to be involved and satisfy himself at each and every
stage of inspection. The purchaser shall be free to request any specific test on any
equipment considered necessary by him although not listed in this specification, as a part
of approval of factory testing procedure. The cost of performing all tests shall be borne
by the vendor.
5.2.3 Vendor to note that acceptance of any equipnent or the exemption of inspection or
testing shall in no way absolve the vendor of the responsibility for delivering the
equipment meeting all the requirements specified in Material Requisition.
5.2.4 It shall be vendors responsibility to modify and/or replace any hardware and modify the
software if the specified functions are not completely achieved satisfactorily during FAT.
5.2.5 The schedule for the FAT shall be included in the Vendors proposal. Factory acceptance
test procedure shall be submitted for approval at least 4 weeks before the FAT at vendor
works.
5.2.6 Vendor shall not replace any system component/module/sub-system unless it is failed. A
log of all failed components/modules in a system shall be maintained .If malfunction of a
component/module in a system repeat, the test shall terminate and vendor shall replace
the faulty component/module. Thereafter the test shall commence all over again. If a
system fails during the test and is not repaired and made successfully operational within
4 (four) hours of active repair time after the failure, the test shall be suspended and
restarted all over again only after the vendor has replaced the device in the acceptable
operation.
5.2.7 The inspection and FAT shall be carried out in two phases The minimum requirements
for testing during these two phases shall be as follows:-
5.2.7.1 Under first phase vendor shall perform tests at his works to ensure that all components
function in accordance with their respective specifications for each type of test. A test
report shall be submitted to the owner/consultant for review within two weeks of
completion of each type of test giving details. All systems shall undergo a minimum of 3
days burn-in period. The burn-in time shall start after the system in fully assembled
condition is powered up and shall include any such time for which the system has been
kept powered even for system generation.
Following tests shall be performed by the vendor and report shall be forwarded to the
owner/consultant.
Quality control tests shall be carried out to assure quality of all components and
modules in accordance with vendors quality control and assurance procedures.
Vendor shall forward the details of these procedures for owner/consultants review.
System pretest which shall be physical check of all subsystem components ,
modules and racks.
System Power-up test which shall functionally check the systems hardware and
software including diagnostic software at sub-system level by stimulating the inputs.
5.2.7.2 Second phase of test shall systematically, fully and functionally test all the hardware and
software in the presence of purchaser representative. All the systems shall be inter
Page 45 of 564

connected to simulate, as close as possible, the total integrated system. Vendor

purchased item shall also be connected to the system. Barrier cabinets shall be used as
the connecting points for test inputs and outputs.
The duration of the testing shall be mentioned by the vendor with reasons. System shall
be shipped to site only after this testing and certified ready for shipment by
owner/consultant.
Following steps will be carried out

Data review : Owner/consultant shall perform a comparison of all current data. Any
revision or changes required shall be informed to the vendor. The test reports
forwarded by vendor after first phase testing shall be reviewed. Owner/Consultant
has right to witness any test performed in first phase, if deemed necessary.
Visual and mechanical testing : Visual and mechanical testing shall be carried out in
principle to assure correct, proper, good and neat workmanship by the vendor.
Functional testing shall include the simulation of each input and output to verify
proper system response for both analog and discrete signals. The testing, as a
minimum, shall include the following:-
Complete system configuration loading
Demonstration of all Processor functions from local as well as from central

level e.g. changing of running constants, loop tuning, checking of algorithm
functions changing algorithms, changing Processor mode, changing
Processor action etc.
Checking of scan time values
Checking of loop configuration for correctness with respect to ranges, limits,

alarm points, engineering units etc.
Checking of all types of TFT displays including process and system displays
on operator Engineering and PLC consoles.
Checking of correct functioning of key-board operation for operator and

Engineering console.
System Redundancy Check including correct change-over of the back-up

units in case of main units failure. This shall be carried out for processors ,
power supplies , communication bus and any other redundancy specified.
Checking of Processor loading
System diagnostics check for all sub-systems on local level as well as on

operator/engineering console. These shall include failure of a sub-system,
module, power supply, interface unit, failure of transfer to redundant module
on main module failure etc. and other detailed diagnostic displays. Diagnostic
alarms for any ventilation fan failure shall also be checked.
Testing of proper functioning of all printers and hard copy units.
Page 46 of 564

Testing of system features like interchangeability between consoles,

synchronisation of system clocks, selective running from Engineering
console, key-lock functions etc.
Checking of various log formats, shut down reports, I/O mapping and other
MIS formats printing.
Checking of shutdown and interlock configuration and proper operation

thoroughly.
Proper system operation at power supply specifications specified in the

Material Requisition.
Checking of proper operation of all interfaces with the system like interface
with PLC, computer, analyser system etc. as specified in Material Requisition.
Checking of bus-degradation while loading the bus from 10% to 100%
Simulation of power failure and restarts.
Checking of all hardwired instrumentation including all alarm cards, alarm

annunciator system, switches and other indicating instruments.
5.2.7.3 Testing record
Each test carried out during second phase shall be recorded. Any deficiency or
problem shall be clearly brought-out and shall be corrected.
Any change in the data or configuration etc. informed to the vendor shall be
recorded and carried out by the vendor.
5.2.7.4 The vendor shall notify the owner/consultant at least three weeks prior to final system
testing. In the event that representatives arrive and the system is not ready for testing,
the vendor will be liable for back charges for any extra time and expenses incurred.
6.1 Vendor shall offer the services of the installation team which would install the equipment
in the control room, lay the interconnecting cabling inside the control room, check out,
test and commission the system.
6.2 Vendors responsibility at site shall include all activities necessary to be performed to
complete the job including:
Receipt of hardware/software and checking of completeness of supplies.
Installation of the system including free supply equipment & interconnection
cabling
Check out of the equipment installation.
Checking of interconnection, hardware and software configuration, overall
system functioning etc.
Loop checking
Commissioning and on-line debugging of the system.
Performance of final acceptance test & Assistance in plant commissioning.
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6.3 Exclusion from DCS vendors responsibility shall include the following:
All civil works in the control room including false flooring, control room lighting
and air conditioning ducting.
Laying and identification & termination of field cables ( in marshalling racks )
Field instrument installation and calibration
6.4 All equipments shall be inspected thoroughly by vendor after its receipt at site for
completeness and proper functioning. Vendor must initiate the remedial action in case
unsatisfactory operation of any equipment or item is observed during this testing with an
intimation to Engineer-in-charge.Vendor must document all observations including details
of malfunctions observed, if any. Items/equipments requiring total replacements must
document reasons for the same.
6.5 Vendor shall arrange all necessary tools & equipments like welding machine etc , for
erection of cabinets / consoles , cable laying , glanding & termination.
6.6 All cabinet / consoles shall be installed on separate base frames independent of the false
flooring. Adequate care shall be take during movement of the equipments on false
flooring to prevent it from being damaged. Proper leveling shall be ensured by vendor
and demonstrated to Owner / Consultant. Any minor civil works required for installation
shall be done by Vendor.
6.7 All erection hardware and consumables like nuts & bolts , primers , paints , cable glands,
grommets etc shall be supplied by vendor.
6.8 Labeling & cable identification
6.8.1 All labeling shall use an identification system that is directly interpretable without requiring
reference to additional documentation. Vendor shall provide details of labeling protocol
for approval before implementation.
6.8.2 All labeling shall be with prime reference to the node or stating software address. Any
other hardware reference should be included on all cabinet labels , by using small size
characters.
6.8.3 All cabinets / racks / enclosures shall be labeled in front and rear for easy identification.
6.8.4 All internal & intercabinet wiring shall be ferruled with permanent markers bearing
identifications that can be cross referenced with appropriate documentation. Colored
ferrules shall be used with proper coding philosophy.Tagplate shall be provided for the
cable no. identification on the top of the related terminal strip in the marshalling cabinet.
6.8.5 System cables shall be uniquely labeled at both ends with reference to source and
destination component address.
6.8.6 All cabinet , console , rack , terminal etc labels shall be engraved plastic laminate ( white
background with black lettering ) fixed with self tapping screws.
6.9 Loop checking
6.9.1 Vendor shall be responsible for loop checking which shall also include checking of the
interconnection, at control room end, configuration and ensuring over all system
functioning.
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6.9.2 Calibration and installation of field instruments, installation of junction boxes,

interconnection between instruments and junction boxes, laying of single, multi pair
cables upto control room, tagging all field cables, performing continuity/insulation test of
cable, core identification of field cables etc. shall not be in the vendor scope. This work
shall be carried out by the field contractor.
6.9.3 Vendors scope of work, as a part of system installation and loop checking shall include
checking termination of all field cables in control room, checking of interconnection
between instrument / equipment, ferruling and tagging of interconnecting cables in
control room, ferruling of field cables in control room and performing overall loop
performance check.
6.9.4 Loop checking shall be carried out to check the functional performance of all elements
comprising the loop and thereby ensuring proper configuration, functioning and
interconnection.
6.9.5 Vendor shall coordinate with the field contractor for smooth and proper loop checking.
Any discrepancy found during checking shall be brought to the notice of Engineer-in-
Charge. Complete loop checking shall be performed in the presence of the Engineer-in
Charge or his authorised representative. All reading shall be recorded on a suitable
format which shall be handed over to the vendor by the field contractor after completing
calibration record of each field device. On the completion of loop checking, remaining
information related to loop checking shall be filled by the vendor. Completely filled format
duly signed shall be submitted for approval, to Engineer-in Charge.
6.9.6 All the components of the loop shall be checked for proper functioning. All field
instruments connected to control room shall be loop checked at 0%, 50% and 100% of
FS (for both increasing and decreasing signals). The input signals shall be simulated
using various simulator and applied from field after disconnecting the field cable
connection.
6.9.7 Receiver alarm cards shall be checked by the vendor for different setting on both
increasing and decreasing signals. Shutdown schemes shall be checked for proper
functioning, configuration and actuation.
6.9.8 Performance of individual loops may be accepted for an overall accuracy of + 1.0%
unless otherwise specified. Where deviation exists, recalibration of instruments, based
on the scope of work, shall be carried out either by field contractor or by vendor.
6.9.9 Signal from Processors/shutdown schemes to control valves/shutdown valves shall be

checked at the respective valves. The stroke checking including checking of time of
operation of control valves/shutdown valves also forms a part of loop checking. Vendor
shall coordinate this activity with field contractor and record the same in the loop
checking format.
6.9.10 For the loop checking of loops connected to substation, vendor shall be responsible to
coordinate with the Electrical Contractor.
6.9.11 After loop checking is completed, vendor shall connect back any terminals and
connections removed for loop checking.
6.10 Site Acceptance Test (SAT)
6.10.1 The purchaser shall provisionally takeover the system from vendor after site acceptance
test. SIte acceptance test shall be started only after the satisfactory performance of loop
checking and verification of records by Engineer-in-charge.
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6.10.2 The site acceptance test shall be carried out in the presence of purchasers
representative and Engineer-in-charge or his authorised representative.
6.10.3 Vendor shall carry out the following functional tests, as a part of site acceptance test as a
minimum :-
Hardware verification as per final bill of material.
Visual and mechanical check-up for proper workmanship, identification, ferruling,
nameplates etc.
System configuration as per approved configuration diagram.
Demonstration of all system diagnostics.
Checking of correct change-over of redundant devices
Checking of proper functioning of all disc drives, alarm summary, printers etc.
6.11 Performance Test
The owner shall take over the system after satisfactory full functional performance test
for a period of 3 weeks.
During above period, any malfunctioning of the system components shall be replaced /
repaired as required free of cost. Once the system failure is detected, the acceptance
test shall start all over again from the beginning. The warranty period commences from
the day owner takes over the system.
6.12 Testing/Calibration Equipments
6.12.1 Vendor shall make available all consumable, instruments and equipments necessary for
testing, calibration, maintenance etc. as required by the defined scope of works. All
instruments and equipments used for the above purpose shall be of standard make with
accuracy better than the accuracy expected from the calibrated/tested instruments, and
certified by National Physical Laboratory or other equivalent agencies. These
instruments/equipments are necessary only during testing/calibration/maintenance
6.12.2 Vendor shall arrange for adequate number of test equipments like meggers , multimeters
, CROs , 2-wire transmitter simulators , thermocouple / RTD simulators etc as required.
Also test equipment of adequate specifications to monitor main system power supply
from UPS shall be arranged by vendor to establish power quality before system is
powered ON.
7.0 PROJECT MANAGEMENT
The vendor shall appoint a project team headed by Project manager dedicated to this
contract for complete duration of the project. The appointment shall be subjected to
Owner / Consultants approval.Project manager shall submit Monthly progress report
indicating progress and delays together with an up to date schedule. Monthly progress
meetings shall be held with Owner / Consultant to review progress , further execution
plan , activity schedule etc. Venue shall be decided mutually at Owner / Consultants
office or Vendors office.The Owner / Consultant shall have right to call the meeting if
deemed necessary.
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8.0 TRAINING
8.1 Vendor shall include for training of the engineering /operation/maintenance staff. The
training shall include but will not be limited to the following in general.
The different hardware components to be supplied by the Bidder.
Software training
Maintenance training on the individual instrument being supplied.
Training on the operation of the entire systems as per functional requirement.
Details of training plan for all categories will be decided mutually at a later date.
8.2 Site training facility and training kit
The training kit shall essentially be used for refresher and training courses for process
engineers, operating and instrument maintenance staff. The training kit shall be simple
control system with process simulator for a group of loops and shall include:
An operator console with an operator key board and engineering keyboard.
Processor with auto backup facility
One each of the varieties of modules used in data acquisition.
Signal simulator
All necessary software & hardware to interface with plant DCS
Vendor to provide the details of the kit offered alongwith the proposal.
Training kit system shall be stand alone with respect to hardware and software and in no
way be lined with the main system.
9.0 DOCUMENTATION
9.1 ENGINEERING DRAWINGS
9.1.1 The vendor shall provide a complete set of drawings covering each part of the supply for
the owner/consultant record. The vendor shall include owners project number on each
of his drawings in order to ease owner/consultants record keeping.
9.1.2 As a minimum following engineering drawings shall be prepared by vendor and

submitted for approval to Owner / Consultant :
Nest Loading drawings
Marshalling panels drawings
I/O Assignment details
Internal Cabinet wiring drawings
Inter-cabinet wiring drawings
Cable schedule ( for Vendors scope of cabling )
Communication network drawings
Control & cabinet room layout drawings with console bay arrangement details
Earthing detail drawings
Peripheral connection wiring drawings
Software functional diagrams
Loop wiring diagrams, containing full information of each loop (one drawing per
loop) including field termination, junction box details, cables numbering, rack
number, bus address code, device address code, power supply connections,
final actuating device details including positioner and air supply etc.
Page 51 of 564

The above drawings shall be re-submitted after incorporation of Owner / Consultants

comments until it is approved
9.1.3 One set of documentation shall be used exclusively for the purpose of marking all the
modifications done during erection and commissioning .All field modifications shall be
carefully recorded by the vendors commissioning personnel and countersigned by
Owner / Consultant. All such changes shall be incorporated into final set of drawings
called as AS-BUILT documentation
Vendor shall furnish all the manuals necessary to test, operate and maintain Distributed
Control System hardware and software.
9.2 HARDWARE DOCUMENTATION
The following documentation for all hardware supplied and as built under this contract
shall be submitted for review two months before the start of factory acceptance testing.
The specifications for all off-the-shelf hardware manufactured by vendor, his sub-
contractors or suppliers. Suppliers name and identification of ordered hardware and
expected delivery data to vendors premises shall also be supplied alongwith this.
Documentation relating to off-the-shelf hard ware and hardware developed by vendor

including description, specifications, theory of operation, maintenance procedures,
installation information and drawings. This information shall exclude all non-
applicable information.
Where more than one size, rating or type of construction appears on the submitted
catalogue data, those characteristics applicable shall be identified. Non applicable
information shall be suppressed.
Test plans and test reports for each item of hardware, to be supplied.
Bill of material listing all hardware to be supplied including manufacturers part

numbers, name plates data, approximate volume, weight and overall dimensions.
Spare parts catalogue for all items (at component level) to be supplied.
Recommended spare parts for two years.
9.3 SOFTWARE DOCUMENTATION
The following documents shall be submitted for review before 90 days of the shipment of
the system, for the software packages included in the supply:
The specifications for all software to be obtained in house or from subcontractors or

suppliers. The details supplied shall also include the name of the suppliers, software
identification including latest modification data.
Reference manuals, operating manuals, programming manuals and other software

manuals (if any).
Page 52 of 564

Description of the function of each programme. This shall include the logic,
configuration requirements and constraints and sub-programs used, memory map
and special characteristics.
Input and output details for each program.

Listing of assembled programs with label and symbol tables in assembler/compiler
language.
9.4 SYSTEM MANUALS
Manuals shall be submitted for assuring satisfactory operation and maintenance of the
system. Detailed literature for installation and maintenance of all hardware should be
provided to the owner.
9.4.1 Instruction Manual
Following information shall be provided as a minimum :
A general functional description of the whole system

General software description
General instructions and start up procedures
System software details including its interaction with application programs and other
programs used as supporting software.
9.4.2 Maintenance manuals
9.4.2.1 The maintenance manual shall include details of

Preventive maintenance procedures
Trouble shooting procedures including failure analysis
9.4.2.2 A section on repairs shall provide enough information on repairs including removal,
repairs, adjustment and replacement.
9.4.2.3 The maintenance manuals shall contain a list of all maintenance parts to facilitate quick
identification of the parts for replacement and ordering. Standard hardware structural
parts, or other parts not requiring maintenance shall not be included here. At the end of
the list of parts requiring maintenance, a list of special tools required for the maintenance
of each unit shall be given. List of manufacturers of each part shall also be included.
9.4.3 The final system manuals shall be furnished to owner within a month of completion of
final satisfactory field testing. All field modifications shall be incorporated and system as
built drawings and documents shall be included.
10.0 WARRANTY
10.1 Vendor shall be fully responsible for the manufacture in respect of proper design, quality,
workmanship and operation of all the equipment, accessories etc. supplied by the
vendor. Warranty shall be for 36 months from the date of successful completion of SAT
(Site Acceptance Test). Warranty shall be inclusive of all systems supplied by DCS
vendor inclusive of bought out items like bulk power supply, barriers, UPS (if supplied),
PCs etc.
10.2 It shall be obligatory on the part of vendor to modify and/or replace any hardware and
modify the operating, application and diagnostic software free of cost, in case any
Page 53 of 564

malfunction is revealed even during on line operation after taking over within the warranty
period.
10.3 Vendor shall also provide the total maintenance of the system during warranty period.
The cost for warranty maintenance, if any, shall be included in the proposal separately in
vendor proposal outline and pricing details.
10.4 Any version updating, release of software during the warranty period shall be done free
of cost to the Owner by DCS vendor.
11.0 MAINTENANCE CONTRACT
Vendor shall quote separately for maintenance contract after warranty period for two
years based on per day rate for each category of personnel required. The personnel
deployed shall have thorough knowledge of the system and at least two years of
experience on the maintenance of similar system. Any other conditions of contract
required by vendor shall be explained in the offer.
12.0 SHIPPING
12.1 All the material used for packing, wrapping, sealers, moisture resistant barriers and
corrosion preventers shall be of recognised brands and shall conform to the best
standards in the areas for the articles which are packaged.
12.2 Workmanship shall be in accordance with best commercial practice with the requirement
of applicable specifications. There shall be no defects, imperfections or omissions which
would tend to impair the protection offered by the package as a whole.
12.3 The package shall be suitable for storing in tropicalised climate, the ambient conditions
being specified in the job specifications.
12.4 Shipment shall be thoroughly checked for completeness before final packing and
shipment.
13.0 REJECTION
Vendor shall make his offer in detail with respect to every item of the purchasers
specifications. Any offer not conforming to this shall be summarily rejected.
Page 54 of 564
Page 1 of 19
TITLE: STANDARD SPECIFICATION FOR PROGRAMMABLE

LOGIC CONTROLLER
PROJECT REFERENCE:
APPROVALS
No. Date

Issued this Revision In-house Review Purchase
Revised Pages Only Client Approval Construction
Issued this Revision Enquiry Engineering
Page 55 of 564
TITLE: STANDARD SPECIFICATION FOR PROGRAMMABLE REV. NO / ISSUE DATE 0 / 12-Mar-10

LOGIC CONTROLLER Page 2 of 19
TABLE OF CONTENTS
1.0 GENERAL
1.1 SCOPE
1.2 BIDS
1.3 DRAWINGS AND DATA
3.1 GENERAL
3.4 FIELD INSPECTION
3.5 LOOP CHECKING
3.6 SITE ACCEPTANCE TEST (SAT)
3.7 PERFORMANCE TEST
4.0 GENERAL REQUIREMENTS
5.0 SHIPPING
6.0 REJECTION
Page 56 of 564
TITLE: STANDARD SPECIFICATION FOR PROGRAMMABLE REV. NO / ISSUE DATE - 0 / 12-Mar-10

1.0 GENERAL
1.1 SCOPE
1.1.1 This specification defines the minimum requirements of system design including
hardware & software, configuration, manufacture, engineering, programming, inspection
and testing, documentation, installation, commissioning and shipping of Programmable
Logic Controller (PLC). This shall include as a minimum
- Manufacture, procure, supply, testing, installation, handling and commissioning of
all equipment and accessories.
- Building of all Operator interface, screen displays, database and reports.
- System Hardware & Software configuration.
- FAT of all hardware / software and system integration testing under simulated
conditions at vendors works.
- Supply, install, test and commission marshalling racks, system cabinets and
consoles / printers. Including cables, terminals, IS barriers, power supplies and
cubicle internal mountings
- Supply of all system as well as control room furniture as per ergonomic and Owner
requirements.
- Proving of PLC system functionality as per requirements
- Training of Owners personnel at factory and at site on functional, operational and
maintenance aspects of the system.
- Supply of complete technical and as built documentation in electronic form as well
as hardcopy.
- Supply of all software on CDs along with required software licenses.
1.1.2 The related standards referred to herein and mentioned below shall be of the latest
editions at the time of purchasers enquiry.
ISA-S 71.04 Environmental Conditions for Process Measurement and Control

System. Airborne Contaminants
1.1.3 The detailed scope of work, specific job requirements, exclusions, deviations, additions
etc shall be indicated in the material requisition and job specification.
1.1.4 Where any conflict exists between this specification and other job specification, the
purchaser shall be consulted. Vendor shall not deviate from this specification without
prior approval from the purchaser.
1.2 BIDS
1.2.1 Vendors quotation shall enumerate and include the detailed specifications of each
subsystem and each module of programmable logic controller, detailed system
configuration, hardware and software capabilities, programming aids, display facilities
and other relevant information.
1.2.2 Vendor shall furnish a detailed list of deviations / confirmations clause-wise described in
this specification. Vendor must provide enough supportive reasons for the deviations
listed.
1.2.3 Vendors quotation shall include catalogues, drawings, technical specification sheets,
operating and maintenance manuals, performance evaluation certificates etc. All
documents shall be in English language only.
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1.2.4 Vendor shall also supply the following items.

Mandatory spares as indicated elsewhere in this specification.
Spare parts for start-up, commissioning and two (2) years trouble free operation
Consumables for six (6) months such as printer ink cartridges etc.
Special tools and test equipments.
1.3.1 After placement of purchase order, vendor shall submit certified drawings and
specification sheet for each instrument and its accessories which shall include the
following, as a minimum :
Configuration diagram
Detailed dimensional drawings of internal components
Power consumption in volt-amperes
GA (General Arrangement) drawings
Rack layout including physical I/O module locations.
Logic / Ladder diagrams
Input / Output (I/O) assignments
Power supply distribution drawings
Heat Dissipation figures for all components
Functional Design Specification ( Hardware and Software )
FAT / SAT procedures
Wiring drawings for system cabinet & marshalling racks.
I/O mapping with DCS including MODBUS address.
1.3.2 The required number of reproducible and prints should be dispatched to the address
mentioned adhering to the time limits indicated.
2.1 Programmable Logic Controller (PLC) shall be microprocessor based system which shall
be used for implementation of plant safety shutdown/interlocks, and plant operation
wherever specified in job specification. For critical applications, as highlighted in the
engineering design basis and job specification, the PLCs shall be TMR / QMR (Triple
modular redundant / Quadruple modular redundant) type certified to TUV Class AK5 as a
minimum. For other applications, the PLC shall be with dual processor and dual I/O
certified to TUV Class AK5 as a minimum. The PLC shall incorporate open system
architecture, redundant processing systems and mass storage devices.
2.2 The system shall be designed fault avoidant, as a minimum, by selecting high grade
components of proven quality and proper design of system electronics. Redundancy shall
be provided as a minimum, as per this specification to improve system availability and
reliability. Due consideration shall be given to the environmental conditions particularly for
field mounted subsystems, if specified in the job specification.
0 0
2.3 The system shall be able to operate satisfactorily from 15 C to 40 C and 0 ~ 95% non
condensing humidity range unless otherwise specified. Wherever required, the
components shall be tropicalised to suit Indian conditions
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2.4 The system shall be modular in construction and expandable in future by adding
additional modules which shall be easily accessible for maintenance and repair. The
modules shall preferably be suitable for inserting in 19 rack. The types of modules shall
be kept to minimum possible in order to have interchangeability and low spares
inventory.
2.5 The system shall be highly reliable and shall have well proven record of operating
satisfactorily in a hydrocarbon processing plant for a minimum of one year for a similar
application. Prototype system or instruments of experimental nature shall not be offered.
2.6 The PLC shall have a very high noise immunity in order to ensure safe and reliable
operation when subjected to electrical radio frequency interference and electro-magnetic
disturbances expected in a plant. The surge withstand capacity for input / output modules
shall be as per IEEE Standard 472.
2.7 The system shall be programmed in principle as per the logic diagrams enclosed with the
job specifications. However vendor shall prepare their own logic / ladder diagrams
depending upon the capability of the programmable logic controller offered by them.
Purchaser reserves the right to revise or review the logic diagram even after acceptance
of the offer.
2.8 The system shall have extensive set of self diagnostics hardware and software for easy
and fast maintenance of PLC. Routine checks should run automatically at frequent
intervals for identifying any fault in software or hardware. Diagnostics shall be required at
local as well as console level. Diagnostics shall be available upto the channel.
2.9 Pop up menu to be configured in DCS operator workstation to capture any degradation
of PLC.
2.10 Rack to rack connectivity shall be separate for separate legs of the QMR PLC
2.11 Separate power supply units shall be provided for individual I/O (input-output) rack and
processor unless otherwise specified in the job specifications. Suitable battery back-up
shall be provided to protect volatile memory. Redundant power supply distribution shall
be such that redundancy is maintained at all modules and even up to the channels for
field termination unit.
2.12 Operation of the PLC shall be completely unaffected by the momentary power loss of the
order of 20 milliseconds, unless otherwise specified. This feature shall be demonstrated
during FAT.
2.13 The scan time of programmable controller shall be of the order of 100 milliseconds
including spare I/O channels. Scan time of PLC is defined as the cycle time taken by the
system to read input, process input executing logic and update control output for all the
logics configured within the system. Other activities like diagnostics routines, output /
dump of data to peripherals, or any other activity which consume processor time shall
also be accounted while computing scan time.
In case any plant unit requires faster scan time, the same may be adopted for that
application.
2.14 Isolation shall be provided between programming panel and related subsystem if there is
any possibility of high voltage from 20.1 TFT being transmitted to other subsystems.
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2.15 On-line replacement of any module shall be possible in such a way that the removal and
addition of the module shall be possible without de-energizing the system. Further there
shall not be any interruption in the system while replacing a faulty module except for the
inputs / outputs which are being handled by that module. System degradation of any kind
is not acceptable.
2.16 Spares philosophy
2.16.1 Installed engineering spare modules of 20% shall be provided in input/output subsystem
for each type of module with a minimum of one module of each type to enhance the
system functional requirements. All installed spare shall be fully wired upto field
termination level.
2.16.2 In addition the system shall have the following minimum spare capability :
I/O racks of PLC shall have 10% usable spare slots for installing I/O modules of each
type in future. These racks shall be part of the offer.
The processor system shall have the capability to execute logics for additional I/Os
as per 2.16.1 and 2.16.2. In addition it shall be possible to extend memory by
additional 20% at a later stage.
Power supply modules shall be capable to take load of the spares as outlined above.
The PLC console shall have capacity to meet all requirements for the additional input
/ outputs as outlined above.
Whenever relays are used to interface process input / outputs with PLC, 20%
additional relays shall be provided. In addition, 20% spare space shall be provided in
cabinets to install 20% additional relays in future.
Vendor shall design all systems / racks based on the above. Additional terminals shall be
provided to enable termination of above spare I/Os and also to terminate spare cores of
existing multipair cables. This shall be adhered to under all circumstances.
2.16.3 Wherever possible, all equipment shall be standardized to ensure commonality of

spares, minimal training and greater economies as far as maintenance and additional
procurement is concerned
2.17 Paper, ribbon, printer heads and ink required for printer, copier, or any other consumable
item shall be supplied with the system required for minimum of six (6) months duration
after SAT. Any consumables required for system development, testing and
commissioning shall be provided by vendor and not included in the 6 month consumable
supply.
2.18 Safety barriers shall be provided by the vendor for intrinsically safe input/output circuits
wherever specified. In such cases, the system shall be designed intrinsically safe based
on entity concept. The barriers shall be certified by a statutory authority like BASEEFA,
CENELEC, FM, PTB, CMRI etc for the use in the area classification as specified
elsewhere in the job specification. The proper selection of the safety barriers shall
be the vendors total responsibility. The safety barriers shall not be zener type barriers.
2.19 No single mode failure shall affect the system whenever redundant system configuration
is specified.
2.20 Unless otherwise specified all electronic modules shall meet the requirements of
Environmental classification class G3 as per ISA-S 71.04
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2.21 The system as offered shall meet the requirement of Y2K compliance without any
modification, addition or replacement of any system hardware and software.
2.22 System configuration
Basic system configuration shall be as per the job specifications. However the system
shall consist of the following major subsystems :
2.22.1 Input / Output Subsystem
2.22.1.1 I/O devices interface with PLC shall be at I/O racks only. The I/O modules shall be
mounted in the I/O racks.
2.22.1.2 The maximum number of input / outputs per module shall be limited as follows :-
Sr. No. Type of Configuration No. of I/Os

1 DI 32
2 DO 16
3 AI 16
2.22.1.3 Each I/O shall be protected against reversal of polarity of the signal.
2.22.1.4 Each module shall have LED for each I/O channel to indicate the status of each input /
output.
2.22.1.5 Each input shall be provided with filters to filter out any noise in the input line or noise
because of input contact bouncing.
2.22.1.6 PLC inputs shall be provided with potential free/dry contacts unless otherwise specified.
2.22.1.7 The interrogation voltage to the input / output contact shall be powered from separate
power supply / supplies and shall not be a part of PLC unless otherwise specified. This
power supply shall be supplied at one point and shall be distributed by the vendor.
2.22.1.8 In case of triple / quadruple redundant system, if standard system architecture does not
allow for triplicate / quadruplicate signal conditioning circuits per I/O, then signals shall be
externally multiplied before connecting to I/O modules.
2.22.1.9 Output contacts from the PLC shall be potential free/dry contacts. Wet contacts /
powered contacts / TTL outputs etc. shall not be acceptable. Vendor must provide arc
suppression device for each output contact.
2.22.1.10 All output cards shall have output contact rating of 24 VDC 2 Amp inductive to drive
solenoid valves, MCC controls though interposing relays. Each output shall be short-
circuit proof and protected by fuse. Visual indication of fuse down must be provided for
each output.
2.22.1.11 PLC I/O cards shall have facility to detect wire open condition whenever normally open
inputs ( close on alarms ) are considered.
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2.22.1.12 In addition to digital input / output, PLC shall be able to cater for following types of I/Os
- Analog inputs:- 4-20 mA , 1-5 V DC , 0-10 V DC.
- Analog outputs:- 4-20 mA , 1-5 V DC , 0-10 V DC.
All I/O circuits shall be provided with galvanic isolation or optical isolation using isolation
barriers.
2.22.1.13 In case of triple / quadruple redundant system hot replacement of I/O modules shall be
provided. Additional slots must be provided in the I/O nest for hot replacement of these
modules. No output shall be affected while replacing these modules in either case. For all
modules, channel to channel isolation shall be provided.
2.22.1.14 All I/O cards shall have facility for sequential time stamping with 1 milisecond resolution.
2.22.1.15 Fail-safe DO cards shall have built-in SMOD (secondary means of De-energization), this
enables the watchdog and/or processor to de-energize the outputs in case of internal
fault.
2.22.2 Processor System
2.22.2.1 The processor system shall be TMR / QMR architecture. The processor shall have
capability to implement all the control functions required to implement the logic schemes
attached with the job specifications as Logic / Ladder diagram
2.22.2.2 The size of the memory shall be sufficient for storage of the program instruction required
by the logic schemes. Offer shall indicate the amount of memory occupied by the actual
program and spare capacity available for later program modifications or additions. A
minimum of 50% spare memory space shall be provided at the time of handover of the
system to Client
2.22.2.3 Memory shall be non-volatile. However, in case volatile memory is provided, battery
backup shall be provided for a minimum of 1 year to keep the stored program
intact. A battery drain indication shall be provided at least one week before the battery
gets drained. A potential free contact shall be provided for hardwired annunciation in the
control room.
2.22.2.4 Watchdog timer shall be a software device. The healthiness of processors shall be
continuously monitored by watchdog timer. Any hardware or software problem in the
processor subsystem including CPU, memory, power supply, communication interface
etc shall cause the watchdog timer to report processor failure.
2.22.2.5 Whenever dual processor is specified, redundancy shall be provided such that in case of
failure of the main processor, the standby processor shall take-over automatically. The
changeover shall be bumpless. Redundancy shall be provided for complete processor
subsystem including CPU, memory and power supply.
2.22.2.6 In case of triple redundant system all the three processors shall execute the same
instructions / programs and check their results and majority vote to correct any faulty
result. The faulty processor diagnostic shall be made available. Failure of a single
channel shall not affect the system. In case of quadruple modular redundant system, all
the 4 processors shall execute the same instructions / programs. The faulty processor
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diagnostic shall be made available. Failure of a single quad channel shall not affect the
system. In case multiprocessor configuration is offered, the processor must be able to
communicate with each other over the interconnecting data link. Vendor shall ensure that
system performance shall not degrade when such system is offered..
2.22.2.7 In case of failure of complete processor system i.e. both processors in case of dual
configuration and two or more in case triple / quadruple redundant system outputs
shall take fail safe state automatically unless otherwise specified in the job
specification.
2.22.2.8 In case multiprocessor configuration is offered, the processors must be able to

communicate with each other over the interconnecting data link. Vendor shall ensure that
system performance shall not degrade when such system is offered.
2.22.2.9 It shall be possible to generate the first out alarm by PLC in case where a group of
parameters are likely to trip the system.
2.22.2.10 TMR PLC functional configuration shall be 3-2-0 and for QMR PLC shall be 4-2-0.
2.22.3 PLC CONSOLE .
2.22.3.1 The PLC console shall be used for program storage, fault diagnostics and alarm
monitoring. It shall also be possible to use this for plant operation whenever specified.
For programming, a separate laptop shall be provided. It shall also be possible to have
the programming funtionality in the PC and all functionality of the PC on laptop by using
suitable passwords
2.22.3.2 The PC consists of a 19 colour monitor unless otherwise specified, one programming
keyboard, and operating keyboard whenever specified. The programming consoles shall
have latest hardware, operating system and windows based graphics user interface
(GUI). It shall include Ethernet connectivity, DVD compatible CD-RW drive, floppy drive,
SCSI port, 32 bit CPU with 600 MHz system clock, 128 MB RAM expandable to 256 MB
as a minimum.
2.22.3.3 PLC console when used for plant operation shall be supplied with dedicated operator
keyboard with a set of user configurable / assignable function keys. Even when touch-
screen is specified, the console in addition shall be supplied with operator keyboard
which shall have the same capability as the touch-screen as a minimum.
2.22.3.4 The keyboard shall preferably be touch sensitive sealed type easy to operate with each
key clearly identified. It shall be provided with a lock and key to prevent any unintentional
program modification. Key sequences shall be as short as practicable and the keyboard
layout shall be arranged so that the general flow of keying sequences shall be from left to
right, where practicable, major functions shall be accessed using a single key stroke.
2.22.3.5 All illegal entries shall be rejected by console and shall be identified by warning signal on
20.1 TFT.
2.22.3.6 Manual operation / forcing of any element connected to PLC shall be possible from
keyboard.
2.22.3.7 It shall be possible to modify, add or delete the application program on-line with
password protected access. System should have capability of logging the engineering
changes made along with detail of activities, user name and time stamp.
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2.22.3.8 PLC console 20.1 TFT shall display logic and / or ladder diagram indicating power flow
and shall show description and real time status of each contact. It shall also be possible
to display process alarms and diagnostic message as and when they appear. Further it
shall also be able to display I/O map in a user defined format.
2.22.3.9 Whenever PLC console is used for the operation of the plant, it shall be able to display
process, dynamic graphics, overview and group displays, real time and historical trends.
It shall be able to operate the plant i.e. start and stop rotating machinery, opening and
closing of valves etc from dynamic graphics and group displays. All such displays shall
be user configurable.
2.22.3.10 It shall be possible to print the ladder / logic diagram on the PLC printer. In addition,
printer shall also be able to print the following :
Diagnostic messages as and when they appear
Diagnostic reports on demand
Processor alarms related to PLC as and when they appear and alarm report
whenever initiated
Shutdown report as and when initiated
I/O map showing status of all inputs and corresponding outputs in a user defined
format
Screen print
2.22.3.11 The printer softwares for all printers shall be loaded in all operator consoles so that any
printer may be selected at any given time by any console. The log and alarm printers
shall be A3 132 column type with reliable paper feed mechanism for paper handling.
Screen displays shall be sent to any of the laser printers. The laser printers shall be
capable of printing 15 pages a minute and shall support paper sizes upto A3. Sufficient
memory shall be provided to support full page graphics printing.
2.22.3.12 In addition to self-diagnostic alarms, PLC console shall be provided with a common fault
alarm with potential free contact which shall be connected to the hardwired annunciator.
PLC self diagnostic alarms shall be mapped to DCS for alarming.
2.22.3.13 In addition a service unit or hand-held programming unit for trouble shooting and initial
check-ups from local level shall be quoted separately.
2.22.3.14 Where multiple process units are connected to the same PLC, a common workstation
shall be provided. These workstations shall display unit database for all units.
2.22.3.15 The operator stations shall have password access to various levels ranging from
operators, supervisors to engineering personnel.
2.22.4 Communication subsystem
2.22.4.1 The communication subsystem shall consist of communication processor with

communication ports / adaptors and cables for communication with processor and I/O sub-
systems.
2.22.4.2 Communication system shall be redundant.
2.22.4.3 In case of redundant communication subsystem, on the failure of the device, the
redundant device shall take-over automatically without interrupting the system operation.
Information about the failed device shall be displayed locally as well as on the PLC
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console. It shall be possible to manually switch-over the communication from main

bus/device to redundant bus/device without interrupting the PLC functions.
2.22.4.4 The mechanism used by the system for error check and control shall be transparent to
the application / information / programme. Error checking shall be done on all data
transfers by suitable codes.
2.22.4.5 The total load on any of the communication buses at any point of time shall not exceed
50%.
2.22.5 System power supplies
2.22.5.1 Programmable logic controller shall operate on uninterrupted power supply with following
specifications
Voltage 110 V + 10%
Frequency 50 Hz + 3%
2.22.5.2 Power supplies in the system shall be provided as follows :-

Each I/O rack shall be provided with separate power supply unless otherwise
specified in job specifications. Each power supply shall be sized to take full load of
the I/O rack. In case of triple / quadruple redundant system, each I/O rack signal
conditioning panel shall be provided with dual redundant power supply.
Processor subsystem shall be provided with separate power supply as a minimum
unless otherwise specified in job specifications. Failure of power supply for one
processor shall not affect the system operation / processor switchover.
In normal operation, the redundant power supply shall share the load. In case of
failure of one module the other power supply shall take the full load. Power supply
shall be sized taking into account the spare I/Os into account. Failure of power
supply module shall be alarmed to DCS through mapping from PLC
2.22.5.3 All power feeders shall be with an individual circuit breakers / Isolator and power on
indicator. All power supply bus bars and terminals shall have suitable removable insulating
covers. All power supply feeders shall be protected by robust transient suppression devices
within each cubicle or enclosure. Where the same PLC is used for multiple units, vendor
shall offer a facility wherein sequential unit wise power on can be carried out and overload
tripping circuits are arranged in such a manner to offer unit wise shutdown of the plant in
case of main power failure.
2.22.6 System loading
2.22.6.1 The contractor shall submit calculations and basis to determine the ability of equipment and
architecture of the system to meet all the requirements in this specification and at the same
time observe the maximum loadings defined in this para. Loading here refers to the use of
memory. CPU time and communication capacity. The loading shall consider the worst
case of high system activity. During this case, no degradation of system performance is
allowed. Maximum loadings on various sub-systems shall be as indicated in engineering
design basis.
2.23 Self diagnostic
2.23.1. The system shall have an extensive set of self-diagnostic routines which shall be able to
identify and provide information on the system failures upto channel level including
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redundant components and power supplies through detailed display pages and report print
outs.
2.23.2. At the local level, an individual LED shall identify failure of a module in any subsystem.
2.23.3. Self-diagnostics shall be provided to detect faults (which make the contacts permanently
close or open) in the input and output modules or input and output signal conditioning
modules in case of triple / quadruple modular redundant system whenever specified in the
job specifications. This may be achieved by automatically running the testing software at
cyclic intervals. The testing software cycle may be field adjustable by engineer. However,
the system performance shall not be degraded whenever testing feature is specified.
2.23.4. Testing softwares shall be capable of detecting faults in case of normally closed system as
well as in normally open system.
2.23.5. Feedback shall be provided internally in case of triple / quadruple redundant system from the
output voting logic system to detect any latent faults of the system.
2.23.6. No internal self diagnostics shall be capable of preventing or delaying normal system
operation and system availability. The self diagnostics shall be carried out with the main
purpose of reliability and integrity as paramount aims.
2.23.6.1. The minimum requirements for system diagnostics shall be as follows :-

Analog input diagnostics Sensor out of range, open or shorted loop, analog-to-digital
converter check.
Analog output diagnostics Open or shorted loop.
Configuration diagnostics Checking the compatibility and availability of selected I/O
hardware and software.
Memory diagnostics Checksum, parity check etc.
End-to-End CPU / memory diagnostics
Processor executes a test control or arithmetic algorithm, then compares results with
pre-stored answer.
Power system diagnostics Monitor the availability of supply voltage.
For all 2 out 3 voting logics, in addition to individual and voted alarm, contractor shall
provide a maintenance alarm indicating discrepancy shown by any of inputs.
The PLC system shall be able to generate a common alarm (High Priority) for PLC
diagnostics, power supply failure, fan failure, battery life over etc.
2.24. System software
2.24.1. The system software shall include all programs for the PLC and PLC console which are
required to perform all the PLC functions including communication, self diagnostics and shall
include separate SOE software. Any software supplied shall be of the latest version with long
term support from software vendor. It shall be responsibility of vendor to ensure software
protocol compatibility for third party systems and transfer of data between the same. The
PLC console operating system shall be Windows XP or latest version available.
2.24.2. When fully tested, the configuration software shall be stored in a central point non volatile
memory. Logic program shall be recorded on the floppy disk or cassettes, tape, two copies of
which shall be delivered with the system. All databases shall be field configurable and
expandable without software redesign.
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2.24.3. The PLC programming language for implementation of logic operation shall be based on
Ladder diagrams i.e. series parallel connection of relay contacts ( LD )

Functional block diagrams ( FB )
If a single PLC is used for multiple process units, then each logic sub system shall be
suitably grouped for I/Os, logic, diagnostic with proper identification.
2.24.4. Details of the diagnostic package and its related equipment and software shall be supplied
by the vendor with the offer. A list of additional diagnostic packages available including their
description and capabilities shall be provided as a separate quote.
2.24.5. Development software for the generation of various displays including dynamic graphics
shall be provided. Where the PLC console is the sole window to the Process, it shall have
the functionality as indicated in clause number 2.22.3 above.
2.24.6. System software for the report generation for reports like hourly on demand per shift daily
and weekly report shall be provided, whenever specified in job specifications in the user
defined format.
2.24.7. All system software including operating system software, network software and any other
proprietary software supplied shall be with suitable number of Licenses valid for the next 15
years. All updates / upgrades, software patches to fix bugs shall be provided free of cost for
above period.
2.25. Power supply distribution
2.25.1. Two feeders of 110 VAC, 110 VDC and 240 VAC power supply shall be made available at
one point. Further distribution of power supply shall be in vendors scope. Also, any other
voltage level required for operation of PLC shall be derived by vendor using above power
supplies.
2.25.2. The distribution network for interrogation voltage shall be designed such that a single fault in
any branch shall not cause trip of the logic other than where the fault has occurred.
2.25.3. Power distribution network must use bus bars of adequate capacity with DPDT (Double Pole
Double Throw) switches and HRC (high rupture capacity) fuses in each branch network.
Vendor may select circuit breaker if short circuit characteristics do not match the HRC fuse.
2.25.4. All cubicles lighting shall be on 240 V 50 Hz AC normal power supply.
2.26. PLC system cabinets
2.26.1. All cabinets shall be RITTAL make.
2.26.2. All PLC system cabinets shall be completely wired with all modules in place. Inside cabinet
wiring shall preferably be done using pre-fabricated cables.
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2.26.3. All the cabinets shall be free standing, enclosed type and shall be designed for bottom entry
of cables. Cabinet structure shall be sound and rigid and shall be provided with removable
lifting lugs to permit lifting of the cabinets
2.26.4. Cabinet shall be fabricated from cold rolled steel sheets of minimum 2 mm thickness suitably
reinforced to prevent warping and buckling. Doors shall be fabricated from cold rolled steel
sheet of minimum 1.6 mm thickness. Cabinets shall be thoroughly deburred and all sharp
edges shall be grounded smooth after fabrication.
2.26.5. Cabinet finish shall include sand blasting, grinding, chemical cleaning, surface finishing by
suitable filter and two coats of high grade lacquer with wet sanding between two coats. Three
coats of paint in the cabinet colour shall be given for non-glossy high satin finish. Colour of
the cabinets shall be as per job specification.
2.26.6. Each cabinet shall be maximum 2100 mm high (excluding 100 mm channel base). 1200 mm
wide and 800 mm deep in general. Construction shall be modular preferably to accommodate
19 standard electric racks. All cabinets shall be of same height. Maximum swing out for
pivoted card racks, doors and drawers shall be limited to 800 mm.
2.26.7. Cabinets shall be equipped with front and rear access doors. Doors shall be equipped with
lockable handles and concealed hinges with pull pins for easy door removal.
2.26.8. In order to remove dissipated heat effectively from cabinets, vent louvers backed by wire
mesh screen shall be provided in cabinet doors. Each cabinet shall be with internal
temperature device and cooling fans. An alarm shall be logged on the operator console in
case of excess temperature in any of the cabinets or cooling fan failure.
2.26.9. Illumination shall be provided for all cabinet by incandescent lamps, which shall be operated
by door switch.
2.26.10. Equipment within the cabinet shall be laid out in an accessible and logically segregated
manner. Cable glands shall be provided for incoming and outgoing cables to prevent
excessive stress on the individual terminals. All metal parts of the cabinet shall be electrically
continuous and shall be provided with a common grounding lug.
2.26.11. Each I/O module shall be provided with separate terminals for individual inputs and outputs.
All inter cubicle and internal signal wiring shall be done using minimum 1.0 mm2 stranded
copper conductor, and power wiring shall be done using minimum 1.5 mm2 stranded copper
conductor. All terminals shall be suitable for minimum 2.5 mm2 cables.
2.26.12. All cabling inside each panel shall follow a common colour coding for cables. The same shall
be based on the type of signals as listed below.
Digital Input
Digital Output
Analog Input
Analog Output
110V DC power supply
110V AC power supply
230V AC power supply
24V DC power supply
Earthing (Frame)
Earthing (IS Barrier)
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2.26.13. All panels shall be segregated based on type of signals. Also, IS and Non IS signals shall be
suitably segregated.
2.26.14. All cabinets shall be uniquely identified on the basis of unit, type of I/O and serial number.
Legend plates shall be made from SS 316 plate with characters 15mm high.
2.27 system software and database back-up
2.27.1 The system shall have an automatic and on demand data protection scheme for the
preservation of all data during a planned unplanned outage. The entire control software shall
be backed up including vendor software control database, user-built programs, source code
and data files.
2.27.2 Back-up copies produced on bulk devices shall be removable for remote storage . On line
backup shall not degrade system performance.
2.27.3 To correct from an outage, any component of the system must be able to be reloaded from
bulk. The contractor shall quote the maximum time required to reload the entire system for
backup bulk storage.
2.28 Earthing
2.28.1 Each cabinet, console and other equipment supplied as a part of PLC system shall be
provided with an earthing lug. All these earthing lugs shall be properly secured to the AC
mains earthing bus
2.28.2 All circuit grounds, shields and drain wires of control cables shall be connected to the system
ground bus, which shall be electrically isolated from AC mains earthing bus. This bus shall be
typically of 25 mm wide and 6 mm thick of copper.
2.28.3 All barriers, if used shall be securely grounded. Safety barrier ground wire shall be capable of
carrying a maximum fault level current of 0.5 A at 250 V r.m.s per barrier.
3.1 GENERAL
3.1.1 On the basis of guidelines specified in this specification, vendor shall submit their own testing,
installation, commissioning and acceptance procedure. For hardware, the procedure shall
include purpose of test, test definition of input, procedure, results, expected and acceptance
criteria. For software, it shall include details of the method, list of test sequence of execution,
results expected and acceptance criteria.
3.1.2 The testing and acceptance of the system shall be carried out on the mutually agreed
procedure and criteria based on these guidelines and vendor standard procedures.
3.2.1 Vendor shall demonstrate functional integrity of the system hardware and software. No
material or equipment shall be transported until all required tests have been successfully
completed and the material / equipment have been certified Ready for Shipment by
purchaser.
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3.2.2 Purchaser reserves the right to involve and satisfy himself at each and every stage of
testing. They shall be free to request specific tests on equipment considered necessary
by them, although not listed in this specification, but agreed as a part of factory
acceptance test procedure. The cost of performing all tests shall be borne by the vendor.
3.2.3 Vendor to note that acceptance of any equipment or the exemption of inspection / testing
shall in no way absolve the vendor of the responsibility for delivering the equipment
meeting all the specified requirements.
3.2.4 It shall be vendors responsibility to modify and/or replace any hardware or software if the
specified functions are not completely achieved satisfactorily during FAT.
3.2.5 Schedule of FAT shall be included in the Vendors proposal.
3.2.6 Vendor shall not replace any component / module / subsystem unless it has failed and a
log of such failures shall be maintained during FAT. If a malfunction of module /
component in a subsystem repeats, the test shall be terminated and vendor shall
replace the faulty component module. Thereafter test shall start all over again. If a
subsystem fails during FAT and is not repaired and made successfully operational within
4 hours of active repair time after the failure, the tests shall be suspended and restarted
all over again only after vendor has replaced the device into acceptable operational
condition.
3.2.7 Testing and FAT shall be carried out in two phases. The minimum requirements for
testing during these two phases shall be as follows :-
3.2.7.1 Under the first phase, vendor shall perform tests at his works to ensure that all
components function in accordance with the specification for each type of test. A test
report shall be submitted for purchaser review within two weeks of completion of this test.
All subsystem shall undergo a minimum of 30 days burn in period. Following tests shall
be performed by the vendor and reports shall be forwarded to purchaser.
Quality control test which shall be carried out to assure quality of all components and
modules. System pre-test which shall be of physical check of all modules, racks,
cabinets etc. System power-up test which shall test functionally all hardware and
software.
3.2.7.2 The second phase of testing shall systematically, fully and functionally test all hardware
and software in the presence of purchaser representatives. All subsystems shall be
interconnected to simulate, as close as possible the total integrated system. Following
minimum tests shall be carried out.
Visual and mechanical testing
High voltage and insulation testing
3.2.8 Functional testing
This shall include the simulation of each input and output to verify proper system
response. The testing as a minimum shall include :-
- Complete system configuration loading
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- Demonstration of all PLC system builder functions including additions / deletions of an

input/output, addition / deletion of a rung or an element in a rung generation of dynamic
graphics and other views, report generation etc.
- 100% checking of logics configured in the PLC by connecting switch/ lamp at input /
output.
- Checking of scan time.
- Checking of all PLC console displays, keyboard and touch-screen operation,
printer/hard copier function etc.
- System redundancy checks including correct change over of the backup unit in case of
failure of main unit.
- System diagnostic checking for all subsystems on local level as well as on
console, including checking of the testing software for I/O modules signal
conditioning modules, when specified.
- Checking of output status on processor failure.
- Checking of first-out alarm generation.
- Simulation of power failure and system restart auto boot-up of system configuration
and program after power restoration
3.2.9 Vendor shall notify the purchaser at least three (3) weeks prior to factory acceptance
test. In the event that representative arrives and the system is not ready for testing,
vendor shall be liable for back charges for any extra time and expense incurred.
3.3.1 Vendor shall offer the services of an installation team which would install the equipment
in the control room, lay the interconnecting cables inside control room, check-out, test
and commission the system.
3.3.2 Vendors responsibility at site shall include all activities necessary to be performed to
complete the job including ;
Receipt of hardware/software and checking completeness of supplies.
Installation of the system including free supply equipments if any.
Inter-cabinet cabling and termination.
Check out equipment installation.
Checking of interconnections, hardware and software configuration, overall
system functioning etc.
Loop checking
Commissioning and on-line debugging of the system
Involvement during plant commissioning and performance of final acceptance
test.
3.4 FIELD INSPECTION
3.4.1 All equipments shall be inspected thoroughly by vendor after its receipt at site for
completeness and proper functioning. Vendor must initiate the remedial action, in case
unsatisfactory operation of any item is observed, with intimation to Engineer-in-charge.
3.4.2 Vendor must document all observations including details of any malfunction observed.
Items / equipments requiring total replacement must document the reasons for the
same.
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3.5 LOOP CHECKING
3.5.1 Loop checking shall be carried out by vendor including checking the interconnections,
configuration and overall system functioning.
3.5.2 Vendor shall coordinate with the field contractor for smooth and proper loop checking.
Any discrepancy found during checking shall be brought to the notice of the Engineer-in-
charge. Complete loop checking shall be performed in his/her authorised
representatives presence.
3.6 SITE ACCEPTANCE TEST (SAT)
3.6.1 The purchaser shall provisionally takeover the system from vendor after system
acceptance test. System acceptance test shall be started only after the satisfactory
performance of loop checking and verification of records by Engineer-in-charge.
3.6.2 The system acceptance test shall be carried out in the presence of purchasers
representative and Engineer-in-charge or his authorised representative.
3.6.3 Vendor shall carry out the following functional tests, as a part of system acceptance test
as a minimum :-
Hardware verification as per final bill of material.
Visual and mechanical check-up for proper workmanship, identification, ferruling,
nameplates etc.
System configuration as per approved configuration diagram.
Demonstration of all system diagnostics.
Checking of correct change-over of redundant devices
Checking of proper functioning of all disc drives, alarm summary, printers etc.
3.7 PERFORMANCE TEST
The owner shall take over the system after satisfactory full functional performance test
for a period of 3 weeks.
During above period, any malfunctioning of the system components shall be replaced /
repaired as required free of cost. Once the system failure is detected, the acceptance
test shall start all over again from the beginning. The warranty period commences from
the day owner takes over the system.
4.0 GENERAL REQUIREMENTS
4.1 Vendor shall comply fully with the general requirements of PLC system including logistic
support services, documentation, warranty, maintenance contract and shipping
instructions.
4.2 Maintenance Contract

Vendor shall quote for maintenance contract after warranty period of two (2) years based
on per day rate for each category of personnel required. Personnel deployed shall have
thorough knowledge of the system and at least two yeas of experience on maintenance
of similar system. Any other conditions of contract required by vendor shall be explained
in the offer.
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4.3 Availability of System

Vendor shall confirm that support for supplied system hardware and software shall be
available for a period of 10 years from the date of commissioning.
4.4 Training
Bidder shall include the training of the engineering /operation/maintenance staff at the
system supervisor as well at site. The training shall include but will not be limited to the
following in general.
The different hardware components to be supplied by the Bidder.
Software training
Maintenance training on the individual instrument being supplied.
Training on the operation of the entire systems as per functional
requirement. Details of training plan for all categories will be divided
mutually at a later date.
4.5 Annual Maintenance Contract

Bidder shall quote separately for Annual Maintenance Contract for a period 5 years from
the date of commissioning.
5.0 SHIPPING
5.1 All the materials used for packing, wrapping, seals, moisture resistant barriers and
corrosion prevention shall be of recognised brands and shall conform to the best
standards for the articles which are packed.
5.2 Workmanship shall be in accordance with best commercial practices and requirements
of applicable specifications. There shall be no defects, imperfections or omissions, which
would tend to impair the protection offered by the package as a whole.
5.3 The packing shall be suitable for storing in tropical conditions, as specified in job
specifications. Shipment shall be thoroughly checked for completeness before final
packing. Vendor shall be responsible for any delay in installation or commissioning
schedule because of incomplete supply of equipment.
6.0 REJECTION
Vendor shall make his offer in detail with respect to ever item of the purchases
specifications. Any offer not conforming to this shall be summarily rejected.
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SPECIFICATION No.
SPECIFICATION FOR A133-00-6-82-0001 Rev. 1
HEALTH, SAFETY & ENVIRONMENT
MANAGEMENT AT DCU,CPCL Page 2 of 101
CHENNAI
TABLE OF CONTENTS
Section I Safety Management Program

0.0 Definitions
1.0 Purpose
2.0 Compliance
3.0 Objectives
4.0 Contractor Safety Policy and Assurance Plan
5.0 Site Safety Organisation
6.0 Roles and Responsibilities
7.0 Safety Meeting
8.0 Proactive Safety Monitoring
9.0 Site Safety Training and Competence of Employees
10.0 Safety Awareness and Promotional Activities
11.0 Documents and information to be submitted by Contractor
12.0 Incident Reporting
13.0 Site Emergency Response Action Plan
14.0 Site Access and Security Procedure
15.0 Permit to Work System
Section II - Occupational Health and Welfare Facilities

16.0 Welfare Facilities
17.0 Occupational Health Services
18.0 Sanitation and Hygiene Measures
Section III - Site Safety Program

19.0 Personal Protective Equipment (PPE)
20.0 Housekeeping
21.0 Safety Signs
22.0 Site Electricity
23.0 Form Work
24.0 Excavations
25.0 Hot Work
26.0 Fire Prevention and Control
27.0 Compressed Gases and Combustible Liquids
28.0 Working at height
29.0 Manual Handling
30.0 Sling and Lifting Gears (Rigging)
31.0 Lifting Appliances
32.0 Lifting Activities
33.0 Construction Vehicles
34.0 Construction Machineries
35.0 Noise
Format No. 8-00-0001-F1 Rev. 0

Copyright EIL All rights reserved
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TABLE OF CONTENTS
36.0 Confined Space

37.0 Radiography
38.0 Hand Tools
39.0 Demolitions
40.0 Temporary Structure/Fixtures
Section IV Liquidated Damages

Penalties for Violation/Non-Adherence of Safety Procedures and
41.0
Practices
42.0 Compensation in case of Accidents
Attachments
Attachment 1. Legal Obligations / Requirements for Construction
Attachment 2. Safety Assurance Plan
Attachment 3. Site Safety Organisation Chart
Attachment 4. Minutes of Meeting
Attachment 5. Field Safety Observation Report (SOR)
Attachment 6. SOR Summary Sheet
Attachment 7. Safe Plan of Action (SPA)
Attachment 8. General Inspection Report
Attachment 9. Routine Inspection Plan
Attachment 10. Safety Audit Checklist
Attachment 11. Safety Induction Checklist
Attachment 12. Tool Box Format
Attachment 13. Training Matrix
Attachment 14. Training Register
Attachment 15. Safety Update Board
Attachment 16. Weekly Safety Report
Attachment 17. Monthly Safety Report
Attachment 18. Incident and Investigation Report
Attachment 19. Incident Report Chain
Attachment 20. Contents of First-aid box
Attachment 21. IS Code for PPE
Attachment 22. PPE Issue Register
Attachment 23. PPE Stock Register
Attachment 24. DG Checklist
Attachment 25. Excavation Checklist
Attachment 26. Hot Work Activity Checklist
Attachment 27. Welding Set Checklist
Attachment 28. Gas Cutting Set Checklist
Attachment 29. Grinding Machine Checklist

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Attachments
Attachment 30. Fire Extinguisher Monthly Inspection
Attachment 31. Scaffolding Checklist
Attachment 32. Slings and Lifting Gear Register
Attachment 33. Wire Rope Sling Checklist
Attachment 34. Synthetic Web Sling Checklist
Attachment 35. Crane Register
Attachment 36. Mobile Crane Daily Inspection
Attachment 37. Monthly Mobile Crane Inspection
Attachment 38. Pre-Lift Checklist
Attachment 39. Construction Vehicle Checklist

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Section I Safety Management Program
0.0 Definitions
Owner : Chennai Petroleum Corporation Limited, Manali Refinery, Chennai
Consultant : Jacobs Engineering India Private Limited
Contractor : Person, Firm or Corporation to whom the work will be awarded by EIL.
LSTK Contractor: Engineers India Limited (EIL)
Shall : Mandatory requirement.
Should : Guideline that is strongly recommended.
May : Guideline that is to be considered.
Supervisor : Contractors engineer responsible for specific tasks.
1.0 Purpose
The field HSE specification set forth is the minimum requirements that shall be implemented
during the project execution. The contractors are required to implement these standards and any
additional requirements as per local laws and statutory requirements and best practices in industry
whichever are higher. Owner, consultant and EIL may issue further changing requirements from
time to time as the work progresses to fit changing site conditions, which will be binding on the
contractor.
The owner is fully committed for providing safe and healthy working conditions for all employees
working on the project and our goal is zero incidents in our operation. Safety is an overriding value
that the operation shall be conducted in such a manner that reasonably practicable measures are
taken to protect people not only in our employment but also others who may be affected by our
activities.
We believe that incidents are caused and eliminating the causes of incident can prevent them.
Safety is the responsibility of every employee but line management is ultimately responsible for the
implementation of safety requirements.
Everyone involved must be committed to achieving high standard of HSE Performance with proactive
approach at all levels in the organization with excellent teamwork.
All personnel should share a sense of empowerment on safety matters with an effective
communication system to facilitate the flow of safety information both up and down through the
organization
2.0 Compliances
All activities shall be in compliance with relevant local laws, statutory requirements, codes and
practices pertaining to health & safety of employees
2.1. Contractors or other third parties in the refinery shall abide by

Fire & Safety rules and regulations of the Refinery (Latest revision)
Security instruction issued by refinery management time to time
All requirements under the Factory Act 1948
The Contract Labour Act 1970
All requirements of Worker Compensation Act 1923 & ESIS Act including all amendments thereto.
Other statutory requirements shall also be applicable as mentioned.
Attachment 1: Legal Obligations / Requirements for Construction
2.2. The Contractors shall not employ minors (persons below the age of 18 years) in any part of the
refinery.
2.3. Contractor shall display notice at the conspicuous place showing the rates of wages of the workers,

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hours of work, wage periods, date of payment of wages, names and addresses of the Inspectors.
having jurisdiction and date of payment of unpaid wages, in English, Hindi and in the local language
understood by the majority of workers.
2.4. Contractors personnel shall abide by the applicable instructions as may be issued from time to time
to handle any emergency situations, such as explosion, fire, terrorist attacks, major accident, etc. In
the event of such emergencies, the Contractors personnel shall stop their work and proceed to a
safe designated place assembly point in the area of their work and inform the Engineer-in-Charge
immediately. If needed, they shall be safely evacuated.
2.5. Contractors vehicles, trucks, tractor, cranes and other portable equipments e.g. Air Compressor, DG
Set, Dewatering pumps etc. used inside Refinery premises (where Hydrocarbon is used as fuel) for
execution of the job must be mechanically sound and have an approved spark arrester and have
exhaust complying pollution norms. Idle running of those vehicles and equipments shall be avoided.
2.6. The Owner or the Engineer-in-charge or EIL may at any time require the Contractor to subject any
contract workman, to a medical examination, generally or in relation to specific jobs such as in
canteen, tank cleaning, work at height, etc.
2.7. Contractor shall not carry any work without having supervisor at site. If it is required to work
simultaneously in more than one location under the same contract, one supervisor must be put in
each of the locations. If a supervisor has to leave his site for any reason, he must stop his activities
for that period of time.
2.8. Female employee shall not be allowed to bring their child to workplace inside Refinery premises.
Contractor shall make suitable arrangement in case need, outside Refinery premises at his own cost.
2.9. The Contractor shall not be entitled to any extra or additional payment or other compensation for the
compliance with all applicable safety rules.
2.10. The requirement to comply with all applicable safety rules shall not entitle or justify the Contractor to
demand or claim any time or cost overrun.
2.11. The Contractor shall be solely responsible for any and all liability under the Workmens
Compensation Act, and other applicable laws with respect to all those engaged by the Contractor or
any sub-contractor.
2.12. In addition to this specification, contractor shall adhere to Health Safety Environment Procedure
(HSEP) of owner, consultant and EIL.
3.0 Objectives
3.1 General
The contractor shall practice safety leadership, demonstrate visible commitment to the project's
safety policy and strategic objectives, and provide resources to promote a culture that embraces and
accepts absolute safety behavior
Developing, signing, distributing, and emphasizing the safety policy at the outset of the project.
Leading and driving the project safety program in order to achieve a world class performance,
together with active participation at all levels with owner and consultant to ensure safe completion
of the project.
Implementing proactive monitoring system that provides feedback to ensure continuous
improvement in HSE performance.
Ensure compliance with all applicable laws, statutory requirements, codes of practices and
standards set forth.
In essence NO SAFETY NO WORK.

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3.2 Targets
The following Safety targets apply to the Project:
Injuries and Illness - Zero

Environmental Incidents - Zero
Property Damage - Zero
Vehicle Incidents - Zero
4.0 Contractors Safety Policy and Safety Assurance Plan

4.1 The contractor shall formulate a Safety & Health policy and shall be signed by authorised person.
The copy of the Safety & Health Policy shall be displayed at conspicuous places at work sites in
English, Hindi and a local language understood by the majority of construction workers.
4.2 The contractor shall submit copy of safety policy, HSE plan and safety assurance plan to
owner/consultant/ EIL in the standard form for implementation and monitoring of HSE requirements.
Attachment 2: Safety Assurance Plan
5.0 Site Safety Organisation

5.1 Contractor shall post a qualified and experienced Safety Manager and deploy Safety Engineers /
Officers, Supervisors and observers in every shift, to exclusively oversee and ensure compliance with
all applicable safety rules. Contractor shall notify the name of the safety manager, safety officer/
engineer and other safety personnel along with their bio-data to the owner /consultant and EIL for the
approval. Only on approval by the owner/consultant/ EIL, these personnel are authorised to work.
5.2 Qualifications of Safety Managers and Safety Engineer/officer shall not be less than as prescribed in
local regulations and the general requirements are described as under.
(a) A person shall not be eligible for appointment as Safety Officer unless he :
(i) Possesses a recognised degree in any branch of engineering or technology and has had practical
experience of working in factory in a supervisory capacity for a period of not less than 2 years; or a recognized
degree in physics or chemistry and has had practical experience of working in a factory in a supervisory
capacity for a period of not less than 5 years; or a recognised diploma in any branch of engineering or
technology and has had practical experience of working in a factory in a supervisory capacity for a period of
not less than 5 years.
(ii) Possesses a degree or diploma in industrial safety recognised by the State Government in addition to
possessing other qualification laid down in the said sub rule.
(iii) had adequate knowledge of the language spoken by majority of the workers in the region in which the
factory where he is to be appointed is situated.
(b) Notwithstanding the provision contained in clause (a), any person who:-
Possesses a recognised degree or diploma in engineering or technology and has had experience of not less
than 5 years in a department of the Central or Union Territory, State Government which deals with the
administration or the Factories Act! 1948; or
Possesses a recognised degree or diploma in engineering or technology and had experience of not less than
5 years, Full time, on training education consultancy, or research in the field of accident prevention in industry
or in any institution, shall also be eligible for appointment as a Safety Officer:

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5.3 Contractor shall submit site safety organization chart along with HSE plan.
Attachment 3: Site Safety Organisation Chart
5.4 Working hours per shift shall not exceed 12 hours per day.
5.5 Contractor shall appoint safety personnel as given below for every work shift:
Safety Observer : At all times minimum one observer for workers not exceeding 100 in numbers.
That means contractors are expected to deploy additional safety observers when
number of workers crosses beyond 100 and thereon.
Safety Supervisor: In addition to above, contractor shall depute one Safety Supervisor for every 250
workers.
Safety Engineer : In addition to above, one safety engineer/ officer for every 1000 workers.
Safety Manager : Minimum of one Safety Manager at all times required to be at site.
Requirement of Safety Personnel for every shift

No. of Workers
deployed Safety Engineer/
Safety Observer Safety Supervisor Safety Manager
Officer
1- 50
One
51-100
101-150 One
Two
151-200
201-250
Three
251-300 One
One
301-350
Four
351-400 Two
401-450
Five
451-500
Up to 1000 Ten Four
Up to 2000 Twenty Eight Two
5.6 In case any of the safety personnel leave the contractor the same shall be intimated to the owner/
Consultant/ EI L. The contractor shall recruit new personnel and fill up the vacancy.
6.0 Roles & Responsibilities

The contractor shall ensure that an employee of suitable seniority and authority with responsibility
for health and safety is always present on site during the course of the work, to supervise and
direct the work and to receive and implement instructions from the owner/ Consultant/ E IL s senior
representative.

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Contractor skilled workmen like riggers, scaffold erectors, welders, fitters, crane operators etc
should have sufficient past experience and skill on the relevant jobs. The electrician deployed
must have valid wireman License.
All supervisory staff and workmen shall be capable of following instructions and shall be made
aware of their responsibilities.
6.1 All Employees involved in project

Take reasonable care for the health and safety of him and other persons who may be affected by
his acts or omissions at work.
Co-operate with his management or others to enable compliance with statutory requirements.
Report to their immediate supervisor about hazardous situations and defects found in premises,
plant and equipment.
Avoid improvisation, which might entail risk.
Consider and suggest means of eliminating hazards.
Co-operate in maintaining a safe and healthy working environment.
Attend safety-training classes as and when organized.
Attend safety meetings if invited.
Participate in safety campaigns when organized.
Never intentionally or recklessly interfere with, or misuse, anything provided in the interests of
health, safety or welfare.
Draw to the attention of management /supervision improvements to health and safety which
appear to be necessary or advisable.
Immediately report any incident/ near misses to his/her supervisor.
Demonstrate leadership and commitment to HSE, setting a personal example at all times.
6.2 Contractors Construction Manager

He shall understand the owner/ Consultant/ EI Ls HSE requirements and the responsibility
allocated to each grade of supervision.
Understand and implement the contractual HSE requirements along with relevant Central / Local
legal and statutory regulations.
Assign clear responsibilities to achieve safety objectives and verify that sub-ordinates are
executing these responsibilities properly.
Ensure compliance of all the HSE policy and procedures.
Provide written method statements to establish safe work methods. (Explaining the sequence of
operations, provide outline potential hazards at each stage and identify safety measures to be
adopted).
Provide the resources necessary to maintain a safe and healthy work environment.
Locate storage areas, access and site office locations in line with owner/ Consultant/
EI L s requirements.
Ensure availability of all welfare, First -aid and sanitation facilities.
Enforce identified work permit procedures and requirements.
Check over work methods and precautions with supervision before work commences.
Shall lead the safety meetings and safety inspections/ audits and ensure safety deficiencies
identified are correct promptly.
Enhance safety awareness by promoting safety meetings, motivation programs, Trainings etc.
Ensure all incidents and near miss incidents are reported immediately and submit investigation
reports, participate in any other investigations as may require.
Set a personal example on site by adopting a safe working attitude.
6.3 Contractors Safety Personnel

He shall understand the owner/ Consultant/ E I Ls HSE requirements and advice management to
ensure
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Legal and contractual requirements affecting Health, Safety and Environmental issues.
Assist site management in identifying resources required to work safely.
Monitor the site activities to ensure only safe work methods are practiced at site, Health and
safety requirements are being observed, all welfare and first aid facilities are adequate and
properly maintained.
Inspect the work site and daily, report and correct unsafe conditions/ acts.
Ensure all persons have undergone safety induction training before engaging the on the job.
Check the provision and status of PPE requirements of the site.
Assist supervisor in preparing Safe Plan of Action (SPA).
Conducting investigation of all accidents and incidents at site, measures to prevent recurrence of
such incidents.
Facilitate, conduct and participate safety meetings, trainings, promotional activities at the site.
Initiate safety awareness and safety promotional activities
Review overall safety performance, record and analyse accident/ incidents and
Document and maintain all HSE statistics, reports and records.
Submit all documents related to HSE to owner, Consultant and E IL regularly.
6.4 Contractors Supervisory Personnel

Understand the owner/ Consultant/ EI L s HSE policy requirements and implement:
Organise work to the required safety standards to prevent injuries, damage to property and
environment.
Ensure all persons have undergone safety induction training before engaging the on the job.
Prepare and implement only safe and approved work methods, instruct and ensure compliance by
work force.
Enforce and comply with all work permit procedures.
Prior to assigning the days task inspect the work site, correct unsafe conditions if any and report
to site management to prevent recurrence.
Prepare Safe Plan of Action (SPA) and communicate the same to his workforce.
Communicate and ensure all identified hazards and preventive measures related to the task are
understood by the workforce.
Ensure all required safety resources are available and in good condition.
Inspect all scaffold, elevated platforms, fall and fire preventive/protective equipments involved in
the task,
Inspect all tools and equipments, safety guards, instruments are in good operating conditions.
Ensure required Personal Protective Equipments are available.
Plan and ensure a good housekeeping.
Monitor and control the task for unsafe acts and conditions.
Co ordinate task with other activities in the job site.
Ensure awareness of Emergency procedures, First aid, Fire fighting etc among the workforce.
Cooperate and implement instructions from Safety and Fire departments.
7.0 Safety Meetings

Effective communications raises safety awareness, and is vital to the successful implementation of
the Site Safety Plan. Objective of safety meeting is to improve the understanding of safety matters, to
obtain the support, co-operation and commitment of all interested parties.
7.1 Safety Kick-Off Meeting

On award of contract, a safety kick off meeting will be arranged and shall be attended by Contractor.
The agenda shall include
Type and nature of work.
Scope of work.
Contractor Safety Policy

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Contractors HSE plan.

Site Safety Organisation
Allowable working hours.
Legal requirements and documents to submit
Entry of Personnel and vehicle in to premises
Personnel Protective Equipment
Safety Management Programs
- Safety Induction
- Toolbox Talks
- Job Specific Training
- Safety Observation Report (SOR)
- Safe Plan of Action (SPA)
- Safety Inspections and Colour Coding Program
- Monthly Safety Audit
Reporting of incidents.
Permit System - administration and requirements.
Plant and equipment and test certificates
Safety Promotional Activities.
Interfaces with other contractors.
Any other specific anticipated hazards related to the work scope.
Emergency Response Action Plan
Welfare facilities for workers
Work Stoppages and Disciplinary Actions
7.2 Weekly Safety Meetings

Contractors Site Manager, Contractors Safety Managers/officers, Contractors Discipline Heads shall
attend weekly safety meeting with consultant / EILs site management team. At these meetings
previous week safety performance would be analyzed and the activities planned for the forthcoming
week would be reviewed.
Coordinator Consultants Safety manager
Contractors/ EIL RCM
Contractors/EIL Safety Manager
Contractors/ EIL discipline heads
Members Consultants RCM
Consultants Safety Representatives

Consultants discipline head
Owners representative
7.2.1 Weekly meeting in weekdays shall be predetermined with mutual agreement between contractor and
owner/consultant.
7.3 Monthly Safety Committee Meeting

7.3.1 In order to ensure better communication and coordination for realising safety targets, the project shall
establish an independent safety committee comprising of Owner Representative, Consultants
Construction Manager, Consultants Safety Manager, and Consultants Discipline Heads, Contractors
Site Manager, Contractors Safety Managers/officers, Contractors Discipline Heads and workers
representatives.

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Chairman Owners Representative

Secretary Owners Safety Manager
Consultants RCM
Consultants Safety Representatives
Consultants discipline head
Members Contractor/EIL RCM
Contractor /EIL Safety Representatives
Contractors/EIL discipline head
Workers Representative
7.3.2 Site safety committee meeting shall be conducted at least once in a month. The agenda shall include
Review of previous minutes
Review of site safety performance
Monthly safety statistics
Contractors safety performance
Challenges ahead
SOR trend
Safety inspection & Audit reports
Issues by owner/ Consultant/ E IL
7.3.3 Contractor/EIL shall send circular to all safety committee members about the date and venue of
monthly safety committee meeting at least seven days prior to the day of meeting.
7.4 The Minutes of the meeting shall be prepared and sent to all members within 1 working day
preferably by mail/fax followed by hardcopy. Safety Committee meeting minutes shall also be
displayed in the notice board for wider publicity to all concerned.
Attachment 4: Minutes of Meeting
8.0 Pro-Active Safety Monitoring

Contractor shall implement proactive safety monitoring programs that provides feedback to ensure
continuous improvement in safety performance and compliances.
8.1 Safety Observation Report (SOR)

8.11 The SOR is used as a tool for supervisors to record good safety practices unsafe acts/conditions and
the steps taken (immediately and as follow-up) to correct the unsafe practices and recommendation
to prevent its recurrence.
8.12 It is everyones responsibility to take immediate corrective action if any unsafe act/ conditions are
observed.
8.13 Contractors job supervisor is responsible to close-out the SOR by taking corrective action during
follow-up action.
8.14 SOR shall be submitted to consultant and it shall be summarized periodically for effective tracking, to
analyse the trend and identify frequently occurring unsafe act/ conditions for improved safety
implementation.
Attachment 5: Safety Observation Report (SOR)
Attachment 6: Safety Observation Report Summary Sheet

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8.2 Method Statement

Contractors shall submit method statements for each work to owner/ Consultant/ E IL at least
seven days prior to the commencement of the work. The method statement shall detail:
The job to be undertaken
The steps of activities required completing the job.
The individual trades/disciplines involved in the activity.
Plant, equipment, tools to be used in the activity.
Any hazardous substances/chemicals to be used along with their MSDS.
A detailed description of how the work will be done including control measures and procedures to
complete each activity and the overall job safely.
Compliance with the procedure on the work method statement and relevancy to current operations
shall be monitored on a daily basis and also shall be discussed on safety meetings.
8.3 Safe Plan of Action (SPA)
8.31 The SPA is the primary tool used at site to identify and plan to mitigate safety hazards. This form
shall be completed by the contractors supervisor along with crew before starting a new activity and
kept at the work place for ready reference.
8.32 The SPA has sections for the employees to:

State the task to be performed
Location of the task to be performed
Safety hazards anticipated
Steps to be taken to prevent the risks identified
Equipment, tools, or materials needed for protection against the hazard and to perform the work
safely.
Authorisation by reviewing and approving personnel
The name(s) of the Supervisor(s) for each activity.
The name of the person in overall charge of the job.
Duration of the job.
8.33 It is the responsibility of the supervisor to ensure that all resources (equipment, tools, materials etc)
identified through SPA are implemented and all the steps identified to prevent the hazards are
implemented while executing the job.
8.34 It is the responsibility of the job supervisor to communicate the SPA to all workmen involved in that
specific task
8.35 A copy of SPA shall be displayed proximity to the actual works location in Hindi /vernacular language
& English.
Attachment 7: Safe Plan of Action (SPA)
8.4 Safety Inspections

The purpose of safety inspection is to identify any variation in construction activities and operations,
machineries, plant and equipments for ensuring an activity whether it is executed in accordance to a
general set of safety rules.
All equipments, machineries, tools, slings, lifting gears, lifting appliances involved in site shall be
inspected periodically.
Monthly colour coding program shall be implemented by the contractor and after the periodical
inspection, stickers for the corresponding month shall be pasted. Documents related to the inspection
shall be maintained and submitted to owner/ Consultant/ EI L regularly.

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Month Colour code

January & July Yellow
February & August Orange

March & September Pink
April & October Green
May & November Red
June & December Blue
8.41 General Inspection (Safety Walk Around)

General inspections shall be performed at predetermined intervals and the inspection shall involve
contractors RCM and contractors safety manager, owner/ Consultant/ E I Ls representatives.
Attachment 8: General Inspection Format
8.42 Routine Inspections

Routine inspections referred to the inspection of work site, equipment, temporary structures, work
activities etc.
Job specific inspections are performed on activities without a predetermined date. Competent
supervisors usually perform inspections for ensuring an activity whether it is executed in accordance
to a general set of rules.
Contractor shall inspect all equipments, tools etc initially before putting those into the service.
Contractor shall formulate the required checklist for all activities and equipments. As a minimum,
contractor shall conduct inspection as per the attachment.
Attachment 9: Routine Inspection Plan
8.5 Safety Audit

Safety audits are mandatory. The purpose of safety audit is to monitor and assess the effectiveness
of the site safety plan at workplace. It helps to develop the safety procedures further if the existing
procedures are found un-satisfactory. It assesses potential risk, liabilities and the degree of
compliance of construction safety plan and its supplementary procedures and programs against
applicable and current safety legislation regulations and requirements of the owner/ Consultant/ EI L.
Contractors construction manager holds the ultimate responsibility in ensuring implementation of

safety audit program during the construction work.
8.5.1 Monthly Safety Audit

Monthly Safety Audit shall be performed once in a month with prior notice. It shall be organised by
consultants safety manager with representatives from owner and contractor with a pre-determined
format.
These audits will play a vital role in assessing the Contractors Safety performance rating.
Based on the audit team observation, the evaluator shall allot the score based on the compliance
observed of the requirement and summarise the overall scoring of the audit.
The audit findings along with the recommended corrective actions with target date shall be circulated
to the respective contractors. The contractor should complete the recommended corrective actions
and submit the corrective action report.
The date for the audit shall be agreed by the owner/ Consultant/ E I L and

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contractor.
Attachment 10: Safety Audit Checklist
9.0 Site Safety Training and Competence of Employees

Contractor must ensure that his employees are adequately trained and experienced to carry out
their work safely. Training should continue throughout the project and should include regular
toolbox discussions.
Contractor must also ensure that specific hazards likely to be experienced on the site are notified
to their workforce together with any precautions to be taken and local rules to be observed.
Where particularly severe or unusual hazards arise, consultant reserves the right at no additional
cost to request contractors employees to attend safety training and instruction sessions, whether
carried out on site or externally.
Contractor shall provide a dedicated training room for conducting training for their workers.
9.1 Initial site orientation / safety induction and ID cards

9.11 All personnel working on the site shall be required to attend a safety induction briefing before
commencing work. Safety induction shall cover all topics included in the attached checklist.
Attachment 11: Safety Induction
9.12 The contractor shall conduct a site visit for his new employees in groups of less than 25 to familiarize
the new employees with essential services, their work place, and general site layout.
9.13 It is the responsibility of the contractor to familiarize all new personnel to the project on the actual
location of assembly points, fire alarm points, first-aid center, welfare facilities and other important
locations.
9.14 Contractors are responsible for arranging site safety induction for their workmen and they shall
inform consultants safety representative at least one day in advance.
9.15 Induction card duly stamped as Safety Inducted and the date of induction by contractor shall be
issued after the completion of Induction.
9.2 Toolbox Talks

Contractor shall conduct job specific and weekly tool box talks to encourage two way
communications with the employees.
Contractor shall maintain records of Toolbox Talks and shall be submitted to Consultant on regular
basis.
Attachment 12: Tool Box Talk
9.21 Job specific tool box talk

Contractors task supervisor shall conduct job specific toolbox talks (SPA) for all workers before
commencement of their job.
Topics shall include hazards and safety precautions as identified in the SPA.
9.22 Weekly tool box talk

Contractors safety manager shall conduct weekly tool box talk preferably on Monday at the start of
the shift.
Duration of talk shall not be less than 15 minutes.
Topics may be the current site safety issues that shall be agreed between the contractor,
owner/ Consultant/ EI L
9.3 Training from Owner

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Contractors and their supervisory staff shall undergo a one-day training programme annually from
owner on Safe Working Practices in the Refinery Premises so as to familiarize themselves with the
safety rules, regulations and practices. Contractor shall be in possession of valid safety training
badge while working in the Refinery premises.
The Contractors shall ensure that their supervisors must undergo Fire & Safety Training &
subsequent Test at Fire Station before starting the job. All contractors must disclose to CLM Cell the
name of supervisors and arrange safety training at Refinery Fire Station, before obtaining a gate
pass. CISF will issue the gate pass meant for supervisor, only after getting the confirmation from Fire
& Safety. It is the duty of supervisor to train his work force in Fire & Safety on regular basis. The
violation of this will be viewed seriously.
9.4 Site safety training

Contractor is responsible for site safety awareness training for all personnel working in his areas.
Training includes
Personal Protective Equipment Scaffold

Housekeeping Fall prevention and protection
Work permit Hot work
First-aid Heavy lifting and Rigging
H2S Fire prevention and protection
Mock drill including fire rescue, evacuation etc Electrical Safety

Excavation Hand and power tools
Manual handling Confined Space Entry
Driving Safety Pre-commissioning Safety
Working at Height Lock-out and Tag-out
Completion of specific hazard training is mandatory before working on such tasks. A list of all trained
persons shall be maintained at site.
The contractor shall prepare the training calendar for safety activities and submit to owner/
Consultant/ EI L on monthly basis.
Attachment 13: Safety Training Matrix
Contractor shall maintain records of training register and copy shall be submitted to owner/
Consultant/ EI L after completion of training program
Attachment 14: Training Register
9.5 Safety Hand Book

The contractor shall ensure that the workmen working with him comply with safety rules mentioned in
the Safety booklet for Contractor and their employee. Booklet can be had free of cost from owners
Fire & Safety Dept.
10.0 Safety Awareness and Promotional Activities

In order to develop safety consciousness and awareness amongst the employees, the contractor site
management shall organize suitable Safety campaigns, Safety competitions and Safety rewards.
10.1 Safety Posters

The contractor shall take every effort to communicate the safety measures through displaying

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posters, banners and sign boards around the work site.

Posters should be in Hindi, English and other suitable language deemed appropriate.
Posters should be replaced at least once in a month to maintain its effectiveness.
10.2 Safety Update Board

Contractor shall display safety statistics board at conspicuous locations such as site, contractor site
office; workers rest shed etc and shall be updated on regular basis.
Attachment 15: Safety Update Board
10.3 Safety Notice Board

Contractor shall provide a dedicated notice board for display of safety alerts, safety shares or any
other safety related notices for awareness among work force.
10.4 Safety Campaigns

Contractor may organize monthly/weekly safety campaigns by on different safety themes to maintain
the focus on the hazards involved in the activities.
10.5 Safety Competitions

Contractors may plan for various safety competitions to motivate employees to take active part in
safety program.
10.6 Awards and Recognitions

Construction site safety awards programs may be instituted with focus on remarkable achievements
and contributions towards safety.
Contractor shall formulate safety reward program for individuals safety performance excellence as
Supervisor of the Month
Worker of the Month
10.7 Important days to observe

Contractor should observe the following important days related to Health, Safety and Environment by
displaying banners, badges, distributing pamphlets, competitions etc
4th March - National Safety Day
14th April - Fire Safety Day
5th June - World Environment Day
9th July - Occupational Health day
11.0 Documents and Information to be submitted by Contractor

11.1 Apart from safety policy, safety plan, safety organisation chart, safety assurance plan contractor shall
also submit the documents as required.
11.2 Contractor shall submit Man Power Report on daily basis at least by 10.00 am every day.
11.3 Contractor shall submit Weekly Safety Report every Monday as per the approved format. The data
shall be from Monday to Sunday.
11.4 Contractor shall submit the listed supporting documents along with the weekly safety report.
Safety Induction
Tool box Talks
Safety Observation Report (SOR)
Safety Observation Summary Sheet
Safety inspection reports
Safety Audit Report (if any)
Safe Plan of Action (SPA) of each activity.
Method statements

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Safety training and mock drill records

Incident and Investigation Report (if any)
Attachment 16: Weekly Safety Report
11.5 Contractor shall submit Monthly Safety Report as per the approved format
Attachment 17: Monthly Safety Report
Test Certificates for lifting tools and tackles, lifting gear, lifting equipment and appliances.
Test certificates of air receivers.
Information relating to hazardous materials used and their MSDS.
Employers liability insurance certificate.
Copies of all Statutory Registers maintained by the contractor when asked for.
11.6 Display of Safety Instructions

The Contractor shall display a Safety Policy at a prominent place at his site office and each work
spot.
At all work sites, contractor has to display a board containing following information:-
Name of the Contractor;
Name of the work; Work Order No.;
Job site warning instruction;
Emergency Telephone Number;
Do's and don'ts on safety and security;
Working under the Department;
OWNER site in-charge name;
Permit No. & Validity period.

12.1 Any incident at site how slight they are or which entails a person reporting to hospital or leaving site
for treatment shall be verbally reported immediately to owner/ Consultant/ EI Ls representative. This
will enable the owner/ Consultant/ EI L to reach to the scene of incident / dangerous occurrences to
monitor/assist any rescue work and/or start conducting the investigation process so that the
evidences are not lost.
12.2 The return date of injured workmen back to the work shall be reported to owner/ Consultant/ EI L
promptly.
12.3 Written reports of all incidents and dangerous occurrences shall be submitted within 6 hours as per
format attached
Attachment 18: Incident and Investigation Report
12.4 Contractor shall ensure that any incident that occurs is fully investigated to find root cause and
preventive measures are adopted to prevent its reoccurrence. owner/ Consultant/ EI L shall have a
right to conduct independent inquiry of the incident.
12.5 Near misses and minor incidents should also be investigated by the Contractor as soon as possible
as they are signals that there are inadequacies in the safety management system.
12.6 Incident reporting chain and emergency contact numbers shall be displayed at conspicuous locations
at site and contractor offices.
Attachment 19: Incident Reporting Chain and Emergency Contact Numbers
13.0 Site Emergency Response Action Plan
13.1 A detailed site emergency procedure shall be worked out and communicated to all employees at site.

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Necessary arrangements shall be made to deal with such emergency situations. An emergency
response team will be formed to tackle such situations.
13.2 The contractor shall ensure that an Emergency Response Plan is prepared to deal with emergencies
such as
Fire and explosion
Collapse of lifting appliances and transport equipment
Collapse of building, sheds or structure etc.
Gas leakage or spillage of dangerous goods or chemicals
Excavation collapse
Fall of person from height
13.3 The following shall be considered to establish emergency procedures.

Make a list of available emergency services and confirm their communication channels.
Set up emergency response teams.
Ensure that supervisors clearly understand their responsibility and role in the site emergency
procedures.
Designate first aid and provide medical supplies and other material and equipment that may be
required for emergency use.
Determine emergency evacuation routes for work areas and construction site.
Make sure that all personnel clearly understand emergency warning siren signals or other warning
signals used by owner.
Designate a supervisor to conduct a head count and give instructions to evacuees as necessary.
Post-emergency information for each work area on the site.
13.4 Contractor shall conduct an onsite emergency mock drill once in every month for all his workers.
13.5 Bombs, Unattended Baggages/Objects

The following actions shall be taken by the contractor and his employees/workmen about Bombs,
Unattended baggage / Objects lying in secluded places in the Plant.
On noticing any bomb/ unattended baggage or object lying in the plant area, they should
immediately inform the CISF control room on Telephone No.3685 & 3660 and OWNER Fire
Control Room No. 3630 & 3663.
They should not touch the object or try to open the baggage or fiddle with the wires or battery if
found attached to the object.
They should move away to a safety distance of approximate 300 m. without creating any panic.
In case of unattended baggage, they should help CISF personnel in identifying the claimant.
They should not move to the area unless clearance is given by security personnel.
Dos & Donts in case of Bomb/Unattended baggage lying secluded places in the Plant.
Sl. Sl.
Dos Donts
No. No.
1. On noticing any bomb or unattended 1. Do not touch the bomb / unattended
baggage, in form CISF Control Room baggage.
by quickest possible means or on 2. Do not lift any attended baggage
Intercom Telephone No. 3685 / 3660
and OWNER Fire Control Room on 3. Do not go very close to the object
101 / 3630 / 3663.
2. Move away from the bomb/unattended 4. Do not create panic.
baggage.
3. Help security personnel in identifying 5. Do not fiddle with wires or battery if
unattended baggage. found attached with any object.

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4. Help ladies and injured person during 6. Do not open any unattended
evacuation process from the affected baggage.
area.
5. Move back to your place of work after 7. Do not try to defuse any bomb or
clearance has been given by CISF. explosive material
14.0 Site Access and Security Procedures

14.1 Site Entry Permit Personnel and Machinery
Refinery is an operational area, therefore, contractor and his employee shall observe all fire &
safety regulations of the refinery and shall so organise his work as not to interfere with the running
of the Refinery in any manner whatsoever. The contractor shall ensure that their staff/workmen
carry with them valid passes/work permits etc for proper identification inside the battery area.
Contractor shall arrange to apply for and secure valid gate passes for the entry and exit of his
men, materials and equipment, including those of the sub-contractors, from the concerned
authorities of the Owner.
The contractor shall ensure that their workmen/ supervisors shall not move to other places other
than their work premises without proper permission / authorisation.
The contractor shall ensure verification of antecedents of the labourers/ supervisors from Polices/
other officials before they are engaged by him. No person having adverse antecedent shall be
employed by the contractor. The contractor shall be held responsible for all the acts carried out by
his workmen.
Access to the site must be at all times via recognized roadways and footpaths. Personnel must
not access to construction areas through unauthorized areas. Anyone found disregarding this rule
would be subject to disciplinary action.
Contractor shall prepare and display the workers and vehicle site movement chart. The same
shall be communicated to all workmen in the site.
Persons without proper PPE shall be restricted at gate by security personnel. Entry to the site will
be permitted with PPE only.
Contractor must obtain this permit prior to the start up of the job, column, vessels, tanks or any
enclosed area where the chemicals or hazardous materials is either used or stored into it. It is the
contractors duty to see that daily, the above permits are obtained from the area-in-charge till the
completion of the job. All points stipulated in the permit must be strictly complied with.
14.2 Gate Pass/ ID Card

The Contractor shall make his own arrangements of Gate Pass with photo for his employees as
prescribed and instructed by the Security dept. i.e. CISF, and Contract Labour Management Cell
(CLM) at his own cost, each gate pass has to be endorsed by the Security Officer of the Refinery
before the pass be used by any employee. In case of termination of the service of any of his
employee during the contractual period, the contractor shall have to surrender the Gate Pass
issued to the employees to the Security Dept. At the end of the project all the gate passes
endorsed by the Security Dept. for use of the contractors employees shall have to be returned.
Gate pass shall be issued only after completing the site orientation / induction and local
statutory regulation formalities.
Separate entry passes shall be issued for visitors. Visitor passes will be valid only for a day
(Normal working hours) and at entry gate visitor shall undergo site safety instructions to be
followed during the visit and shall be provided with required PPE.
14.4 Working in Night

Contractor shall arrange necessary arrangement for working at night. The authorisation for
working at night shall be obtained from owner/ Consultant/ E IL.
Responsible person shall be assigned as in-charge and it shall be informed to owner/ Consultant/
EI L.
Contractor shall arrange Necessary lighting, emergency vehicle (emergency vehicle shall be
arranged by EIL) and emergency DG.
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14.5 Prohibited Items and Activities

Gambling, fooling on the work, horseplay, mock fighting or fighting is strictly forbidden in the
Refinery premises Project area.
Fooling on the job, mock fighting or fighting within the Refinery premises will not be tolerated.
Gambling within the Refinery premises is strictly forbidden.
Entering the Refinery premises while in possession of weapons such as knives & gun etc. is
prohibited.
Contractor personnel shall not pick up quarrel or get into arguments with Refinery personnel or
act in any misunderstanding, such problems should be referred to appropriate Refinery personnel.
Working under influence of alcohol/ narcotics and entering Refinery premises while in the
influence of alcohol/ narcotics is strictly forbidden. The contractor should ensure compliance of
above by him and all his workmen.
Contractors are prohibited from using Cellular phones within the Refinery premises, except to the
extent permitted by the Owner by special or general order / instruction.
Carrying Match Boxes / Lighters and No Smoking

Carrying / Striking of matches, lighters inside the Owners premises or smoking within the refinery,
tank farm or dyke limits are strictly prohibited. Owners regulatory officials shall be entitled to
forthwith remove, using force if necessary, anyone violating the No Smoking and other fire safety
rules.
Any contractors employee who is found smoking or in the possession of matchbox or lighter or
any other means of ignition in a prohibited area will be turned out from the premises of the
Refinery. Suitable action as decided by the Management will also be taken against the
contractor/contractors employees.
Unsafe Practices: Any unsafe practices or disregard of normal safe working practices by contractor
personnel when pointed out by company personnel shall be immediately corrected.
14.6 Disciplinary Actions

Contractor shall implement a disciplinary action policy whereby contractor and sub-contractors
employees, found violating safety rules.
15.0 Permit to Work System

15.1 A permit to work system is a safety strategy designed to protect personnel and plant and which
consists of an organized and predefined safety procedure. It forms a clear record of all foreseeable
hazards, which have been considered in advance of the construction operations.
15.2 The contractor shall not commence the job without the valid permit for the area and for the job.
Clearance shall be obtained from the area-in-charge and shift engineer
15.3 The following is the list of some of the activities, which would require permit, and list may change
depending upon work situation.
Working at Height
Excavations
Lifting Operations
Hot Work
Electrical Works (Isolation & Energisation)
Confined Spaces
Radiography
High Pressure test
Commissioning of equipment
15.4 Before starting any work, contractor shall apply at least one day ahead for fire & safety permit for
excavation, electrical, gas welding and cutting work to Engineer-in-Charge of work/ works who in turn

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will arrange for such permits. The contractor shall take all the precautions given in the permit before
starting of the work to the full satisfaction of the Engineer-in-Charge of the sections. On account of
operational problem it is possible that the clearance and permit may get delayed for which the
contractor shall not ask for the idle charges. Fire equipment such as fire extinguishers, fire hoses,
control type nozzles, personal protective equipment, Blow man air apparatus etc required for safety
precautions are to be arranged by contractor himself. However in case of emergency on
authorization from Engineer-in-Charge those items will be issued from the Refinerys Fire Station on
chargeable basis and shall be returned after completion of the work / works in working conditions, to
the full satisfaction of the Fire & Safety Officer. In case of any damage to the fire & safety equipments
issued or used by the contractor, the contractor shall bear the cost of such damage in full and the
same will be recovered from his bills.
15.5 Safety measures stipulated in the respective Work Permits shall be strictly complied at all times when
within the premises of the Owner.
15.6 Owner/EIL reserves the right to cancel a work permit without assigning reasons. When called
upon to stop the work by the Engineer-in-charge/EIL, the Contractor shall immediately cease to
continue the work. Before re-commencement, fresh work permit must be obtained.
15.7 The Engineer-in-Charge/EIL reserves the right to terminate the contract and forfeit any or all
amounts due to him in case he finds that the precautions written on the permit are not strictly
adhered to by the Contractor.
15.8 Permit to work shall be valid for a shift (8 Hours) only. However, Engineer may extend the permit to a
maximum of another 4 hours if necessary.
15.9 A copy Permit to Work shall be displayed, during its validity, in a conspicuous location in close
proximity to the actual works location to which it applies.
15.10 Hot work Permit

The entire job is to be carried out within the running unit of Refinery. The Contractor shall take all
necessary safety precautions and obtain required certificates/ fire permits / safety/ work permits etc.
from the competent authority before carrying out any hot works during the execution of the entire
works covered by this tender.
A hot work permit issued by the concerned department or area-in-charge must cover any work
carried out within Refinery. In addition a clearance must be obtained from the concerned
departments officer or supervisor prior to commencement of any job. A hot permit is required for:
Any work involving open flames, spark such as welding, gas cutting, soldering, grinding, concrete
breaking, use of hurricane lamps and internal combustion driving vehicles / Radiography / Crane
lifting / Vessel entry.
Sand blasting, Trucks, Jeeps, Cranes, Lifts, Cars or any kind of vehicle driven by an internal
combustion engine or by batteries
Use of gasoline, diesel or electrical power engines or tools.
Entry of vehicles inside battery limits of process area within tank dykes and adjacent to pump
houses and loading gantries etc.
While carrying out the hot job, the contractor and his workmen must ensure the following safety
measures and job should be carried with
Valid hot job permit,
Availability of tested and proper fire extinguisher at the work places
Provision of running fire water hose at work place.

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Section II - Occupational Health and Welfare Facilities
16.0 Welfare Facilities

The owner may provide certain facilities. However the contractors shall provide drinking water,
required number of toilet for male and female (centralized toilet for male and female shall be arranged
by EIL at site), washing facilities and rest shelters in suitable locations as per statutory regulations.
16.1 Drinking water

16.11 The contractor shall make in every worksite, effective arrangements to provide sufficient supply of
wholesome drinking water. Quality of the drinking water shall conform to the requirements of national
standards on Public Health.
16.12 While locating these drinking water facilities due care shall be taken so that these are easily
accessible within a distance of 200m from the place of work for all workers at all location of work
sites.
16.13 All such points shall be legible marked Drinking Water in a language understood by a majority of the
workmen employed and shall be situated within six meters of any washing places, urinals or latrines.
16.2 Latrine and urinals (Centralized toilet shall be arranged by EIL at site)
16.21 EIL shall provide sufficient latrine seat and urinal facility in the worksite.
16.22 When women are employed, separate latrine and urinals accommodation shall be provided by EIL.
16.23 Notice shall be displayed outside each block of latrines or urinals a containing therein "For Men
Only" or "For Women Only", where both male and female workers are employed, written in the
language understood by the majority of such workers.
16.3 Canteen
16.31 In every workplace wherein not less than 250 workers are ordinarily employed the contractor shall
provide an adequate canteen.
16.32 The charges for food stuff shall be based on no profit no loss basis. The price list of all items shall
be conspicuously displayed in such canteen.
16.33 Building of the canteen shall be situated at the distance not less than fifteen point two meters from
any latrine or urinal or any source of dust, smoke or obnoxious fumes.
16.34 Waste water from canteen shall be carried away in suitable covered drains and shall not be allowed
to accumulate in the surroundings of canteen
16.4 Centralized toilet for male and female shall be provided at site by EIL on behalf of Contractor.
17.0 Occupational Health Services

The owner/EIL at project site shall provide a centralized first-aid center for the treatment of minor
injuries and illness. However all major injuries and illness cases shall be referred to the Hospitals and
contractor shall make his own arrangement for such treatment as required.
EIL shall provide stretcher and shall be readily available in an emergency.
Centralized First Aid centre along with Stretcher and Emergency vehicle shall be provided at
site by EIL on behalf of Contractor.
The contractor shall maintain injury record. A separate first-aid register shall be maintained and it
shall be submitted to owner/ Consultant/ EI L on regular basis.
17.1 First Aid Box

The contractor shall provide sufficient number of First-aid box for providing First-aid to the injured

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workers. Every First-aid box is distinctly marked First-aid and is equipped with the articles specified
in Attachment
Attachment 20: Contents of First-Aid box
17.2 Hospital Tie-up and Emergency vehicle

17.2.1Contractors shall require to tie-up with the hospitals located in the neighbourhood for attending
medical emergencies.
17.2.2 Emergency vehicle shall be arranged by EIL during all working hours for the purpose.
18.0 Sanitation and Hygiene Measures

18.1 Prevention of mosquito breeding
Empty cans, oil drums, packing and other receptacles, which may retain water shall be deposited
at a central collection point and shall be removed from the site regularly.
Still waters shall be treated at least once every week with oil in order to prevent mosquito
breeding.
Drainages shall be cleaned regularly.
The contractor at periodic interval shall arrange to prevent mosquito breeding by fumigation /
spraying of insecticides.
18.2 Prevention of snake bite

Contractor shall remove weeds from site regularly to keep away the snakes.

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Section III - Site Safety Program

19.1 The contractor shall provide all required PPE to his employees & workers, which are duly inspected
and approved by the owner/ Consultant/ EI L. NO PPE ZONE would be identified separately.
All PPE provided by the contractor shall confirm to Bureau of Indian Standards (BIS).
Attachment 21: Bureau of Indian Standards for PPE
Copy of Manufacturers test certificates of PPE used shall be submitted to owner/ Consultant/ EI L.
19.2 The contractor shall:

Maintain records of issue and replacement of PPE.
Maintain 10% PPE stock of total requirement available at their store and stock record.
Issue PPE to worker free of cost.
Maintain all personal protective equipment in good working condition.
Periodically check and replace all defective / broken personal protective equipment.
Contractor shall submit PPE issue register and PPE stock record to owner/ Consultant/ EI L on
regular intervals.
Attachment 22: PPE Issue Register
Attachment 23: PPE Stock Register
19.3 As a minimum, every worker shall wear safety shoes, safety helmet and safety goggles at project
site.
Depending upon the job requirement other PPE shall used.
Head Protection Safety Helmet
Foot Protection - steel toe cap shoes, steel toe cap gumboot
Eye Protection - Goggles, Helmet mounted face shield
Hand Protection - Gloves
Respiratory Protection - Nose mask, Self Contained Breathing Apparatus
Hearing Protection - Ear plugs, Ear muffs
Personal Fall Protection - Full body harness with double lanyard, Rope-grab fall arrester, etc
Body Protection - Full body apron
19.3.1Head Protection
Safety helmet shall be worn by all persons at all times on project site. It shall consist of
suspension cradle and chin strap.
All persons on the project site shall wear chin strap at all time.
Logo of corresponding main contractor shall be affixed on the safety helmet.
Damaged helmet shall not be used and should be discarded from the site immediately.
19.3.2Foot Protection
All personnel shall wear suitable safety footwear with steel toe cap at all times while on the project
site.
19.3.3Eye/Face Protection
Contractor shall provide suitable eye/face protectors where there is a potential of injury to the
eyes and face from dust, flying particles, molten metal, chemicals, fumes or vapors, light radiation

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or combination of these.
Operation Hazards Eye Protectors
General site use Dust, flying particles Safety goggles (Plain)

Sparks, harmful rays,
Welding goggles (Black Shade) -
Gas Cutting molten metal, flying
eyecup type
particles.
Sparks, intense rays, molten
Electric (Arc) welding Welders hood mounted on helmet
metal
Grinding Flying particles Face shield mounted on helmet
Chipping goggles (Plain) eyecup
Chipping Flying particles
type
Chemical resistant goggles and face
Chemical handling Splash, acid burns, fumes
shield.
Contractor shall inspect the goggles used by workmen and shall replace the defective goggles
immediately.
Eye protection for Helpers exposed to light radiation from welding, gas cutting activity shall be
provided with black shaded welding goggles.
19.3.4Hand Protection
Contractor shall choose and use suitable gloves for the task.
Protection Level
Hand protector Sharp Activity
Heat Chemical Electricity
objects
Cotton dot type Inspection work, Climbing
Medium Poor Poor Poor
glove Ladders.
Leather & cloth
Good Medium Poor Poor Scaffolding
type glove
Leather riggers Hot work, Rigging, Manual
Good Good Poor Poor
Gloves Handling.
Rubber moulded For use with Chemicals &
Poor Medium Good Good
gloves Acids
Rubber Gloves Poor Poor Poor Good Electrical works
In addition to above, gloves shall be used by personnel involved in works with possibility of the
risk from abrasion, cutting, tearing, chemical, or other burn, infection.
19.3.5Respiratory Protection
19.3.5.1 Respiratory protective equipment to be used in confined space and activity involving any
chemicals shall be as advised by owners Engineer-in-Charge / Fire & Safety Dept.
19.3.5.2 Supplied Air Respirators and Self Contained Breathing Apparatus (SCBA) used for working in
hazardous atmosphere shall be advised by owners Engineer-in-Charge / Fire & Safety
Department. The same shall confirm to BIS and shall be approved by owner/ Consultant/ E IL.
19.3.5.3 Contractor shall organise practical demonstration training on the methodology to use SCBA or
Supplied Air Respirators in consultation with owner/ Consultant/ E IL.
19.3.5.4 Air Purifying Respirators

Contractor shall use appropriate particulate filter respirators like dust mask depending upon the
fineness of particulates to filter.
Personnel involved in housekeeping, handling cement, insulation material etc shall use suitable

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dust mask.
Contractor shall use chemical cartridge respirators while performing outdoor spray painting.
19.3.6Hearing Protection
Hearing protection shall be worn by personnel involved in works in areas of high noise levels, or
when working with equipment that generate high noise levels.
Hearing protection can be of an external cup-type protector normally ear muff which fits over
the outside of the ear, or plug-type, usually disposable type ear plugs made of compressible
foam, which fits inside the ear.
Disposable ear plugs shall be of one time use and shall be disposed properly.
19.3.7Personal Fall Protection

Full body safety harness shall be required when working two meters or above. It shall be fitted
with double lanyard and the maximum length of the lanyard shall be not greater than 1.8 m.
The lanyard shall be fitted with shock absorber and anchoring hook shall be of scaffold type snap
hook.
Full body safety harness fitted with shock absorber shall be used while working 3 m or above.
19.3.8Body Protection
Full body apron suitable for the task such as hot work, chemical handling shall be used.
Contractor personnel shall not wear loose clothing while working around moving or rotating
equipment.
20.0 Housekeeping
20.1 Contractor shall maintain very high standard of housekeeping at all times.
Keep the site neat and tidy. Keep adequate number of skips / waste bins.
Keep the access clear of all obstructions.
Remove the nails or bend them down from the wooden scrap and remove them from job site.
Store the material in an orderly manner.
20.2 The contractor shall on daily basis keep the premises and surrounding area free from accumulation
of waste materials or rubbish caused by activities.
20.3 At the completion of days work contractor shall remove these materials to avoid Slip/ Trip hazards
and provide safe areas for movement of all workers and supervisors.
20.4 Empty gas cylinders shall be removed from the site and shall send back to the contractors store.
22.5 Contractor should establish regular maintenance program of sweeping and hosing to minimise
accumulation of dirt and dust in such areas.
20.6 If the Contractor does not clear the area after the completion of work, the same shall be got done by
owner /EIL and recoveries shall be made from the bills of the Contractor at double the rate at which
the owner /EIL has got it done.
20.7 On completion of the job the contractor shall remove all his construction material, tools etc. and
remove all temporary constructions and leave the job site thoroughly cleaned up and ready for use. A
job will not be considered completed until all surplus material, scrape and debris / rubbish are
removed from the job site.
20.8 When required contractors should suspend other operations and do housekeeping.
20.9 Waste Disposal

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Waste generated at site shall be segregated at source and disposed off in accordance with
environmental control regulations and municipality rules. Consultant shall be informed of procedure
followed by the contractor before disposal.
20.9.1Scrap yard shall be identified and waste shall be disposed temporarily at designated scarp yard.
Scrap yard shall be barricaded and shall be clearly marked as Scrap Yard in English and other local
languages.
22.9.2All receptacles shall be constructed of metal or other suitable types of containers of non-flammable
materials. Cardboard, wooden boxes or crates and similar types of containers shall not be used for
the collection of combustible waste.
22.9.3Skips containing combustible waste should be strategically placed to ensure fire does not spread in
the case of combustion within a skip.
22.9.4Contractor shall maintain routine housekeeping inspection record and shall be submitted to
owner/consultant/ EIL.
21.0 Safety Signs

Contractor shall post safety signs which give a general safety message in workplaces to draw
attention rapidly to the objects and situation affecting health and safety.
21.1 Colours of safety signs, dimension and layout shall confirm to IS 9457:2005
Red : Prohibition signs
Yellow : Warning signs
Green : Mandatory action signs
Blue : Safe condition signs
21.2 Bands
The band colour for indicating hazard location shall be the combination of Yellow and Black.
The band colour for indicating prohibition shall be the combination of Red and White.
The band colour for indicating mandatory action shall be the combination of Blue and White.
The band colour for indicating safe condition shall be the combination of Green and White.
21.3 Tags
Contractor shall implement tag system for scaffold, LOTO and unsafe equipment.
22.0 Site Electricity

22.1 Competency
The contractor shall appoint a competent person on site who will be responsible for the control of
all electrical systems.
All maintenance and repairs of electrical system shall carried-out qualified and authorised
electricians only.
22.2 Power Supply

If the owners supply electricity, it will be provided at one point, which would be determined by the
owner. The supply would be of 230V, 50Hz, and single phase or of 415/ 433V, 50Hz, three phase.
Power distribution beyond this point shall be through armoured cable only. No deviation on this
would be permitted. The provision of all connections and equipment required beyond this point shall
be responsibility of the contractor.
If the electricity supply is in contractor scope, the contractor shall assess required electrical loads and
shall install required capacity diesel generators for power supply.

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The contractor shall submit electrical Single Line Diagram (SLD), schematic diagram and the details
of the equipment for all temporary electrical installation to the owner/consultant/ EIL.
22.3 Diesel Generator (DG)

The contractor shall install only acoustic DG. It shall confirm to national standards.
The DG shall be placed on firm base and shall be protected from water logging.
The noise level from DG shall not exceed 85dbA.
The DG shall be barricaded to restrict any unauthorised entry.
The body of the DG and main electrical panel shall be properly grounded.
DGs Exhaust shall be fitted with spark arrestor.
Barrel shall be kept on spill tray while transferring diesel to DG. Any diesel spillage around DG
shall be cleaned immediately.
Diesel barrels irrespective of empty or full shall not be stored near DG.
Adequate fire extinguishers and sand buckets shall be provided.
Rubber mat shall be provided for main electrical panel.
22.3.1Contractor shall display the following details near the DG.

Name with photograph and contact number of authorised person to operate the DG
Single Line Diagram (SLD)
Safety signs
Cardio Pulmonary Resuscitation (CRP) and electric shock first-aid treatment chart.
Location of nearest first-aid box availability.
List of emergency services contact numbers.
22.3.2Contractor shall inspect DG periodically and the record shall be submitted to owner/consultant/ EIL.
Attachment 24: Diesel Generator checklist
22.4 Distribution System

Contractor shall ensure that all distribution board (DB) used in the site shall be of IP type which
specification confirms to national standards.
The contractor shall provide sufficient ELCB (maintain sensitivity 30 mA) / RCCB for all the
equipments (including Portable equipments), electrical switchboards, distribution panels etc. to
prevent electrical shocks to the workers
Earth Leakage Circuit Breaker (ELCB) should be provided on all distribution boards and main
switchboards. Single switch multiple socket system would not be permitted.
Rating of fuses and circuit breakers used for the protection of circuits should be coordinate with
equipment power ratings. Use of makeshift wires or conductors as fuse wire is strictly prohibited.
Protection against lightning shall be ensured to all equipment kept in open at sites.
22.5 Cables
Periodic check shall be carried out for defective cables, cracked or perished insulation, loose
joints in conduits, damaged fuse boxes and switchboards, loose pins, faulty sockets and defective
earth wire.
Kinking, twisting, binding or crushing of cables shall be avoided all the time. No electrical
equipments shall be left open or unsecured at the end of the days work.
All power distribution cables should be taken overhead with sufficient headroom.
Cabling passing under the walk way and across way for transport and mobile equipment shall be
laid in ducts at a minimum depth of 0.6 meters.
All switch boards, extension boards, etc. should be protected from rain and water. No water
logging should be allowed around switchboards.
22.6 Plugs, Sockets and Couplers

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The contractor shall ensure plugs; sockets and couplers used shall be splash proof type. The
minimum degree of Ingress Protection should be of IP44 in accordance with national standards.
Plugs and fittings used shall be of the weatherproof type and they should be colour coded in
accordance with the internationally recognised standards
110 volts: Yellow.

240 volts: Blue.
415 volts: Red.
No loose connections or tapped joints shall be allowed any where in the work site, office area, stores
and other areas. Proper cable connectors as per national standards shall only be used to connect
cables
Plugs shall be used to connect with sockets. Inserting the leads into the sockets shall be strictly
prohibited.
22.7 Lighting
The contractor shall provide sufficient lighting at site, of the right type and at the right place.
A far as possible contractor shall provide flood lighting to cover maximum work area.
The access and storage yard shall be well illuminated.
Luminaries should be robust and water proof especially at the point of the cable entry.
Hand held lamps used shall be of 115V and suitably guarded to protect from any mechanical
damage.
Light fitting for hazardous environment shall be of flame proof type which specifications shall
confirm to national standards.
Contractor shall use only 24V lamp in to confined space It shall be guarded and of flame proof
type.
22.8 Power Tools

Power tools include grinder, Drilling machine, Jack Hammer and Concrete breaker etc
The contractor shall ensure all portable power tools do not exceed 125 volts rating and free from
defects and properly grounded.
Rotating tools shall be switched off and held until rotation has completely stopped.
Tools must be disconnected before changing bits, blades, cutters or wheels.
Electrical power hand tools shall be of double insulated type.
All tools shall be used with extension cords which are as short as possible.
Drilling of large holes shall be done stage by stage by using small bore drills and gradually
increasing the drill bit size.
Contractors shall provide suitable storage with suitable racks and bins for storing tools and
equipment.
The contractors qualified electrician shall inspect and tag electrical power hand tools regularly.
The tag shall display name, signature of the individual inspecting the tool, date of inspection.
The contractor shall keep, on site, a register of all electrical power hand tools in use giving all
relevant details about the tool and its inspection.
No electrical powered hand tool shall be used other than it is tagged with a current
INSPECTION tag.
All electrical leads must be connected to the power source through standard industrial
waterproofed plugs and sockets, which shall be in good condition.
While working at higher elevation, adequate precaution to be taken to ensure that they do not fall
down.
22.9 Lock-Out and Tag-Out (LOTO)

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Contractor shall form a LOTO procedure and shall be implemented during any maintenance,
repair, pre-commissioning and commissioning activities.
The equipment shall be isolated from energy sources before carrying any maintenance work.
LOTO register shall be maintained and shall be controlled by a designated person.
Contractor shall be responsible for arranging locks for locking the feeders or panel boards.
All locks shall be neatly labelled for easy identification and the keys of the locks shall be
maintained by the designated person.
22.10 Earthing
Contractor shall ensure all earthing shall confirm to IS 3043:1987
Body of electrically operated tools, equipments, distribution board, electrical panel etc shall be
grounded properly.
Earth pit shall be clearly marked and earth resistance shall be measured on monthly basis and
register shall be maintained by contractor.
23.0 Form Work

Contractor shall ensure no workers shall be allowed to work above vertically protruded reinforcing
steel unless it has been bent over or capped.
Reinforcing steel for wall, pier, column and similar vertical form work structures shall be guyed
and supported to prevent collapse and to guard against possible wind pressure.
Pump concrete or similar system using discharge pipe shall be provided with pipe supports.
Compressed air hose in discharge pipe systems shall be provided with positive fail-safe joint
connectors to prevent separation of section when pressurised.
Banks man shall be deployed for backing the transit mixer and wheel stopper shall be paced.
Form work an shoring shall be designed, erected, supported, braced and maintained so that it will
safety support all vertical and lateral loads that may be imposed during concrete pouring.
No persons shall be allowed closed to the shoring during pour operation.
Scaffolds used for supporting Form Work should be constructed on a firm ground with a base
plate. The staging should as per IS 3696. Staging should be inspected frequently even after
completion of concrete work, or after completion of intended use.
24.0 Excavations
24.1 The contractor shall obtain work permit from owner/consultant/ EIL before starting excavation
24.2 Contractor shall prepare a method statement by considering the following factors
Nature & type of the soil
Weather and moisture conditions
Underground utilities
Methodology adopted to avoid cave-in
Depth and width of excavation
Duration of the excavation job
Proximity of other structures, services
Dewatering systems
24.3 Contractor shall stabilise the sides of an excavation by designing the shoring, if the depth is 4 metre
or more and which shall be approved by owner/consultant/ EIL.
24.4 All excavations and trenches depth of 0.60 m or more shall be hard barricaded.
The hard barricade shall be made of steel pipes of minimum 40 NB.
The hard barricade shall have hand rail at 1100mm and mid rail at 550 mm and the spacing
between two vertical members should not be more than 1000 mm.
The hard barricade shall withstand a lateral load of 100 kg.
The hard barricade shall be provided at least 1.0 meter away from the edge of the excavation.

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24.5 Excavations and trenches depth less than 600 mm shall be cordoned off and suitable sign boards
warning tapes posted.
24.6 Access shall be provided by mean of portable ladder or ramp if the depth is more than 1.5m.
24.7 Portable ladders shall be provided at intervals of not more than 15 m, depending on the number of
workmen present.
24.8 All excavated materials shall be deposited minimum 1.5 m away from the edge of the excavation.
24.9 Excavating equipments and vehicle shall be operated 2.0 m away from excavated area.
Attachment 25: Excavation Checklist
25.0 Hot Work

Any work involving open flame/ spark shall be considered as hot work.
All hot work involved equipments and fitting shall confirm to relevant IS Standards and the
manufacturers test certificate shall be submitted to owner/consultant/ EIL.
Contractor shall obtain hot work permit from owner/ consultant prior to the commencement of the
job.
Fire watcher shall be engaged for each hot work activity and shall be competent in using fire
extinguishers
Work area beneath or adjacent to hot works shall be made free from combustible materials, and
cordoned-off to prevent personnel being injured by welding spatters.
Barriers or screens shall be erected whenever necessary to protect the workmen working near by.
Suitable safety signs & notices shall be displayed near the hot work area.
Contractor shall use non asbestos fire blankets to avoid falling of spatters. Manufacturers test
certificate shall be submitted to owner/consultant/ EIL.
Fire extinguisher shall always be carried with each welding set, preferably a dry chemical powder
type.
After hot work, contractor shall ensure a good housekeeping by sweeping the work area, stacking
the materials, winding the cables/ hoses and placing the equipments properly.
Appropriate PPE mentioned in clause 19.0 shall be used depending up on the hot work activity.
Attachment 26: Hot Work Activity Checklist
25.1 Welding Activity
25.1.1As far as possible D.C. Generator / Rectifiers should be used in preference to A.C. Transformer sets.
25.1.2The contractor shall get welding transformer certified by the owner/consultant/ EIL Electrical Engineer
before start of work and shall obtain a certificate valid for a period of three months renewable after
every three months.
25.1.3A copy of the certificate shall be displayed on respective welding sets.
25.1.4The contractor shall ensure

The welding transformer is kept away from any wet area and shall be located close to work site.
The body of the welding transformer shall be properly earthed.
The length of supply cable to welding transformer shall not exceed 5 m.
The size of the cable used shall be proportional to the voltage supply.
Damaged supply and lead cables are not used.
Lugs shall be used for connecting the lead and return cables with welding transformer.
The welding transformer shall have separate on/ off switch.
The electrode holder handle shall be of non metallic body.

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Grounding from welding return connection shall be done only on work piece. Return connection
shall not be grounded with scaffold member, pipe racks or pipes containing flammable liquid or
gases.
Used electrode shall be collected and shall be disposed properly.
25.1.5Periodic Inspection shall be carried on the welding transformer and the record shall be submitted to
owner/consultant/ EIL
Attachment 27: Welding Set Checklist
25.2 Gas Cutting Activity

The contractor shall ensure that
All gas cutting set shall be inspected prior to entry into the site
All gas cutting sets shall be kept at upright position and fastened in the trolley.
Cylinder valve key shall be made available all the time along with the cylinder when on use.
Domestic type LPG (14KG) shall not be used at the site.
Hose clamp shall be used to connect hoses firmly in both sides of cylinders and torch.
Approved type Non-return valve shall be fixed at torch end and Flashback arrester shall be fixed
at cylinder end.
All gas cylinders shall be fixed with pressure regulator and double head dial gauges.
Hoses used shall be free from any damage. Soap solution test shall be carried-out on the entire
length of hoses to check any leak.
Hoses quality shall confirm BIS. Also Red hose shall be for fuel gas and blue hose for oxygen.
Cutting torch nozzles shall be cleaned before commencing the job to avoid any backfire.
Cutting torch showing any physical damage shall be immediately replaced.
The torch shall be ignited by friction lighter. Igniting by match-box and welding arc is strictly
prohibited.
Gas cylinders shall not be placed beneath the hot work area.
Material Safety Data Sheet (MSDS) of gas cylinders shall be displayed at store yard.
Empty/ full cylinders shall be handled by the means of trolley.
Valve protection cap shall be fitted on the cylinder while shifting and storing.
When handling oxygen cylinders, ensure hands, clothes, gloves are free from oil, dirt, grit and
grease. Under no circumstances oil shall be allowed to contaminate a cylinder containing oxygen.
Periodic Inspection shall be carried on the gas cutting set and the record shall be submitted to
Attachment 28: Gas Cutting Set Checklist
25.3 Grinding/ Cutting Activity

Grinding/ cutting activity shall be always carried out by trained and experienced person.
Only reinforced resin-bonded or resin-bonded abrasive wheels must be used in portable grinding
machines.
Grinding wheels should be stored in dry place and shall avoid direct contact of heat. Wet or
soaked grinding wheels shall not be used.
Wheels shall not be used at any time beyond their expiry date.
The RPM of grinding/ cutting wheel should be equal or greater than the machine spindle RPM.
Grinding Wheels should be segregated size wise to avoid wrong selection of the wheel. Grinding
wheel fitted shall be of suitable size for the grinding machine.
Power supply cable used shall be of rated current carrying capacity with plug-top and shall be free
from damages.
Supply shall be routed through ELCB.
Machine selected shall be of non-metallic body. Body earthing shall be ensured the in case of
metallic body.
All grinding machine shall be fitted with Dead-Man switch and this shall not be bypassed any time.

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All grinding/ cutting machines shall be guarded.

Check shall be done for any abnormal sound and/or vibration.
Grinding wheel without manufacturers specification showing size, speed and expiry date shall not
in used.
Portable grinding machine shall not be used as bench grinder. Small work piece shall be fixed on
bench vice.
Proper spanner shall be used for fixing grinding wheel with the machine.
Machine shall be put OFF from the main switch when not in use.
Grinding activity shall not be carried out in confined space without a valid work permit.
Periodic Inspection shall be carried on the grinding/cutting machine and the record shall be
submitted to owner/consultant/ EIL.
Attachment 29: Grinding Machine Checklist
26.0 Fire Prevention and Control

26.1 The contractor shall take every precaution and use all reasonable means to prevent an outbreak of
fire and shall tender immediate assistance in case of fire. Any outbreak of fire in or near the
workplace shall immediately be reported to the owner/consultant/ EIL.
26.2 The contractors shall provide adequate number of well-maintained fire extinguishers at each work
area.
26.3 Extinguishers should be sited in such a way that it is not necessary to travel more than 15 meters
from the site of the fire to reach the extinguishers. The location of fire extinguishers shall be clearly
marked by sign boards.
26.4 Contractor shall provide fire extinguishers as per IS 2190:1992
Type of occupancy Recommended scale of equipment to be installed

One 4.5 kg capacity carbon dioxide extinguisher for every 100
Office, Computer installations, 2
m of floor area or part thereof with minimum of
record rooms,
two extinguishers so located as to be available within 10 m
2
5 kg capacity dry powder extinguisher for every 600 m area
Workshops, painting shops,
with minimum of four extinguishers per compartment.
generator rooms
Extinguishers should be available within 15 m radius.
Flammable liquid stores, 2
5 kg capacity dry powder extinguisher for every 600 m area
storage in drums and cans in
with minimum of four extinguishers per compartment.
open, paints and varnishes
Extinguishers should be available within 15 m radius.
godown.
One 10 kg dry powder extinguisher or 6.8 kg carbon dioxide
2
extinguisher for 100 m of floor area or part thereof,
Storage area of LPG and other
with minimum of one extinguishers of the same type for
industrial gases.
every compartment; extinguisher should be available within a
radius of
26.5 The contractor shall ensure that workmen are trained in the use of fire extinguishers, understands the
basics of fire fighting and train the workmen to become familiar with such Fire Fighting Procedures
26.6 Fire drills should be held at regular intervals to ensure personnel are familiar with the location, of
Assembly Point and response expected of them in case of emergency.
26.7 Smoking on site is strictly prohibited. No Smoking signboards shall be displayed at prominent
location including stores/ storage places.
26.8 Care of flammable materials, oily rags, waste etc. shall not be left lying around or allowed to
accumulate. Covered metal skips should be used for disposal of flammable waste.

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26.9 If hot work operations are to be carried out, non-flammable screens and blankets shall be used to
confine sparks hot metal or slag. A fire extinguisher should also be readily available.
26.10 Chemicals and other such goods should be stored in stable racks properly labelled. Mutually
reactive chemicals should be kept away from each other. Storage place should have proper
ventilation.
26.11 Fire extinguishers shall be Periodically Inspected and the record shall be submitted to
Attachment 30 Fire Extinguisher Checklist
27.0 Compressed Gases and Combustible Liquids

27.1 Compressed Gases
Contractor shall ensure that
Handling and Storage of gas cylinder shall comply Gas cylinder rules 2003.
Oxygen cylinders and fuel gas cylinders shall be stored separately, at least 6.6 meters apart or
separated by a fire proof, 1.6 meters high partition.
Flammable substances shall not be stored within 15 m of cylinder storage areas.
Valve protection caps over the cylinder shall be provided in storage yard as well as while not in
use.
All compressed gas cylinders shall be used, stored and transported in an upright position.
Compressed gas storage facilities shall be positioned at a sufficient distance from work area,
offices and roads in such a manner as not to cause a hazard to employees, facilities and/or other
contractors.
Cylinders should be stored in suitably designed racks, which must have chains so that any
number of cylinders can be securely and safely stored.
Signs indicating the contents with separate storage for full or empty shall be displayed.
Warning signs must be posted - DANGER - HIGHLY FLAMMABLE - NO SMOKING and NO
NAKED FLAME.
Fire extinguisher shall be provided within accessible distance and adequate quantity and shall
confirm IS 2190:1992.
Oxygen cylinder shall be separated from other combustible gas, oil or grease.
27.2 Combustible Liquids

Contractor shall ensure that
The handling and storage of combustible liquids shall comply The Petroleum Act, 1934 and
Rules 1976
Flammable and combustible liquids must be stored in a metal storage cabinet with a prominent
sign boards FLAMMABLE - NO SMOKING and NO NAKED FLAME.
The area should be well ventilated and free from flammable material
Fire extinguisher shall be provided within accessible distance and adequate quantity and shall
confirm IS 2190:1992.
28.0 Work at Height

Work involving above 1.8m from ground level that include all work activities where there is a need
to control the risk of falling which is able to cause personal injury.
It includes working on scaffolds, access and egress through ladder and working near unprotected
excavation.
The contractor shall ensure that work at height is carried out only when the weather conditions do
not endanger the safety of persons involved in the work.
Life line shall be installed and full body safety harness with double lanyard of 1.8m with shock
absorber and scaffold type snap hook shall be used to ensure 100% protection.
Fall protection devices shall be secured to an anchorage point or a structural member which can
support a minimum dead weight 2450kg.
Ladders shall be only used as access for ascending and descending. Using scaffold member as
access is strictly prohibited.

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No loose materials shall be kept on working platform and shall be kept on baskets.
Safety net shall be used for all height works, where ever feasible.
28.1 Scaffolds
Scaffolding shall be properly designed and erected, with its intended use, where additional,
anticipated loads are to be applied; the structure shall be redesigned and modified accordingly. All
scaffolding material shall be as per relevant IS specification.
Light Duty Scaffold

Distribution load on platform is 0.75 KN/sq.m. (Maximum bay length 2.7 m)
Medium duty scaffold
Heavy duty scaffold
Bamboo and wooden scaffolding is prohibited. Only steel pipe scaffold shall be permitted.
Return cable of welding machine shall not be connected with scaffolds member.
Scaffold shall be inspected every week or after any adverse weather condition like rain, cyclone
etc.
Scaffold inspection record shall be submitted to owner/consultant/ EIL immediately after inspection.
28.1.1Scaffold Erection
Scaffold shall be erected by competent scaffold erectors under the supervision of competent
supervisor.
Scaffold shall be erected with a factor of safety not less than 4.
Survey for all underground utility systems such pipe line shall be identified and possible worst
scenario shall be assessed before erecting the scaffold.
Scaffold should be vertical and plumb.
The footing shall be placed on levelled and firm ground capable of carrying indented load without
settling or displacement.
Base plate shall be provided at a size of 150 mm X 150mm and thickness of not less than 6mm.
Uses of concrete blocks, barrels, boxes, loose bricks as supports are strictly prohibited.
The height of the scaffold shall not be more than four times of its minimum base dimension unless
guy ropes, ties or braces are used.
Scaffold having more than 10 m height shall be secured with fixed structure for stability at every 8
m.
Vertical member shall be connected with horizontal members using right angle type clamp.
Only bracing may be connected with vertical member using swivel clamp.
Landing platform shall be provided at every 9m. Platform shall not be extended beyond 150 mm
from the end.
Platform shall be made of minimum 2 gratings (at least 46 cm) and fastened properly
Hand rail shall be provided at a height of 1100mm, mid rail at 600mm and toe board width shall be
150mm.
Scaffold shall be braced at all four sides.
Access shall be provided by means of portable ladder and it is the duty of supervisor to provide
safe access. It shall be immediately installed after the completion of second level horizontal or 6
m.
Ladders shall be extended at least 3 rungs from platform.
Full body harness with double lanyards fitted with shock absorbers with scaffold type snap hooks
shall be worn by scaffold erectors.
The completed scaffolding shall be inspected and certified by scaffolding supervisor and engineer
using scaffold.
After completion of scaffold inspection if safe, green tag shall be displayed near the access
ladder. If scaffold found unsafe, red tag shall be displayed near access ladder.

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Attachment 31: Scaffolding Checklist
28.1.2Scaffold Dismantling
Scaffold shall be dismantled by scaffolders under the supervision of competent supervisor.
Area shall be cordoned-off before commencement of scaffold dismantling.
Warning/ notice board shall be displayed as Scaffold Dismantling under progress Shall be
displayed in Hindi, English or vernacular languages.
Dismantling shall be from top to bottom plan wise.
Bracing shall be removed first and then all horizontal members in one plane.
After reaching to second last horizontal plane, first bracing of 3 m from ground level plane shall be
installed. Then the horizontal members from second level shall be removed.
Loose members shall be segregated and shall be collected in boxes and shall be lowered
properly.
Loose scaffold member shall be lowered down by rope and not by using men chain or throwing.
While dismantling or erecting scaffold spanner shall be used with proper string in hand to avoid
any fall.
28.1.3Mobile Scaffolds
Mobile scaffold shall be used on a level and smooth surface only.
The minimum base dimensions for mobile scaffolds used internally and externally shall be 3.5 and
3.0 times respectively.
If the tower is exposed to movement or exposed to more than light winds, physical ties shall be
used.
Mobile tower scaffolds shall have wheels fitted at base with a locking device.
Mobile scaffold shall not be moved by carrying any workmen or loose materials.
28.1.4Ladders and Staircases

Ladders shall be of good construction, sound material and made as per standard specifications.
Wooden ladders shall not be permitted at site.
Portable single ladder length shall not exceed 9m.
The space between two rungs shall not be more than 300mm.
The width between side rails in portable ladder shall not be less than 0.45m.
Ladder shall use only after inspection and approval from owner/consultant/ EIL.
Ladders shall be checked for defects such as worn and missing rungs, loose tie rods, and split or
frayed feet. Defective ladder shall be removed from service immediately.
Ladder shall be installed on level surface and shall be tied properly at the top.
Solid footing shall be provided if the ladders are placed on loose soil.
0
Ladder shall be placed at angle of 75 .
Ladder shall be extended at least 1m from the landing platform.
Three point contacts shall be made while ascending and descending the ladder.
No load shall be carried while ascending and descending the ladder. Load shall be pulled or
lowered by ropes by means of pulley.
Ladders are a means of access, and they should not be used as working platforms.
Ladders shall not be placed in front of the door or in the path of moving object unless it guarded.
While ascending and descending should be facing towards the ladder
Portable ladder used shall be of anti slip base.
29.0 Manual Handling

The contractor shall ensure that no worker lifts by hand or carries overhead or over his back or
shoulders any material, article, tool or appliances exceeding in weight as said below.
Adult man : 55 Kg
Adult woman : 30 Kg
Capability of worker for manual material handling should be considered in before assigning the task.

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Contractor shall train the workmen on safe lifting posture.

Whenever load-handling operations are essential, consideration should be given to the use of
mechanical handling, like use of lifting appliances or fork lifts. The contractors should consider the
use of such mechanical aids at the planning stage of their activities.
30.0 Slings and Lifting Gears (Rigging)

30.1 General
Slings include wire rope slings, synthetic web slings, chain slings and metal mesh sling. Lifting gears
include block, hook and shackles.
The contractor shall offer his slings and lifting gears for inspection and approval of
owner/consultant/ EIL before putting it in to the job.
Contractor shall submit manufacturers test certificate and test certificates from Govt. approved
certifying authorities for all of his lifting gear and slings.
Lifting gear in use shall be thoroughly examined once at least in every twelve months by a competent
person.
The Safe Working Load (SWL) and manufacturers serial numbers shall be clearly marked on the
slings and the lifting gears, either by tagging, stamping, engraving or embossing. These markings on
lifting gears and slings shall be inspected and a register shall be maintained.
If SWL and manufacturers serial numbers is not clearly marked, those slings and lifting gears shall
be prohibited to use.
Attachment 32: Slings and Lifting Gear Register
30.2 Wire Rope Sling

Contractor shall use wire rope sling made with suitable thimble to eye splices and loops of ropes for
the attachment of hooks, rings and other such parts.
Contractor shall not use homemade (hand spliced) wire rope slings made of at site.
Wire rope slings made of wire rope clips (bull dog clips) shall not be used at site.
All wire ropes shall be properly handled and stored to avoid any damage.
Contractor shall discard all damaged sling if there are
Ten random broken wire ropes in one lay
Four broken wires in one strand of a rope lay.
Severe localised abrasion or scraping
Kinking, crushing, bird-caging or other damage causing distortion.
Deformed or excessively worn
Severe corrosion and evidence of heat damage.
Attachment 33: Monthly Wire Rope Inspection Checklist
30.3 Chain Sling

SWL of all attached fittings (hooks, rings, shackles, etc) to chain slings shall be equal to the SWL of
chain sling.
Using of onsite welding repaired chain slings is strictly prohibited and shall be discarded immediately.
Chain slings of bent links, cracked welds and excessive wear shall be discarded immediately from
site.
30.4 Synthetic Webbing Slings

Synthetic webbing slings are manufactured from woven manmade fibre. These slings shall not be
subjected to point loading, sharp edged objects and non vertical lifting.

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Attachment 33: Monthly Web Sling Inspection Checklist
30.5 Hooks
Hooks shall be fitted with safety latch on hook opening so that slings cannot be displaced.
Loads shall be applied only in the part designed to take them, Point load shall be avoided as point
load results in overstressing the hook causing it to break.
0
The hook shall be removed from the service if there is a visible crack and if it is twisted 10 out of
place.
30.6 Shackles
Contractor shall use the correct pin for each shackle. Rebar, mild steel bolts are not acceptable
replacement for shackle pin.
30.7 Spreader Beam

SWL and serial number of all spreader beams shall be clearly marked. Test certificates from Govt.
approved certifying authorities shall be submitted to owner/consultant/ EIL.
Register of spreader beam shall be maintained by contractor and same shall be submitted to
31.0 Lifting Appliances

31.1 General
Lifting appliances means mobile cranes, derricks, tower cranes, overhead cranes, chain pulley
blocks, forklift, strand jacks, hydraulic jacks etc.
All lifting appliances including all parts and gears thereof, whether fixed or movable shall be
thoroughly tested and examined by a competent person at least once in a year or after it has
undergone any alterations or repairs liable to affect its strength or stability. Within the validity, if the
lifting appliances are shifted to a new site, re-examination by the same competent person for
ensuring its safety shall also be done.
Contractor shall maintain list of lifting appliances, lifting appliances maintenance register and shall be
submitted to owner/consultant/ EIL on regular basis.
The contractor shall not employ any person to drive or operate lifting appliances unless he is above
twenty-one years of age and possesses a valid heavy transport vehicle driving licence as per Motor
Vehicle Act and Rules.
The operator shall possess the knowledge of the inherent risks involved in the operation of lifting
appliances.
The operator shall be is medically examined and the report shall be submitted to owner/consultant/
EIL.
The laminated photocopies of test certificates issued by competent person, the operators photo,
manufacturers load chart shall be displayed in the operator cabin.
Safe Working Load (SWL) shall be clearly displayed on lifting appliances.
Hooks shall be fitted with safety latch on hook opening so that slings cannot be displaced.
Lifting appliances shall be periodically inspected and reports shall be submitted to owner/consultant/
EIL.
Attachment 35: Crane Register
31.2 Hydraulic Mobile Crane

All alarms and signals like safe load indicators (SLI), boom angle indicators, boom extension
indicators, over lift boom alarm, swing alarm, hydraulic safety valves, mechanical radius

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indicators, etc. shall be periodically examined and maintained always in working condition.
Boom shall be free from bents, cracks, rust, flaking or cracked paint, bulges, greases etc.
Hydraulic pipes any fittings shall be free from any leak.
The operator cabin shall have wind shield, wipers etc. The wind shield shall be clean ad free from
cracks.
Fire extinguisher shall be provided at operator cabin.
Attachment 36: Daily Crane Inspection by Operator
Attachment 37: Monthly Crane Inspection
31.3 Chain Pulley Blocks

The contractor shall ensure the strength of the structure to withstand the load before hanging
chain pulley block.
Chain pulley block shall have safety latch.
Loads in excess of SWL shall not be lifted or lowered.
The hand and load chains shall hand freely without any twist or knots.
Chain pulley blocks are designed for lifting the loads vertically and shall not be used to pull the
loads horizontally.
31.4 Tower Cranes

The instructions of the manufacturer of a tower crane and standard safe practices regarding such
crane are followed while operating or using such crane.
No person other than the operator trained and capable to work at heights are employed to operate
tower cranes
The ground on which a tower crane stands has adequate bearing capacity;
Bases for tower cranes and trucks for rail-mounted tower cranes are firm and levelled and such
cranes are erected at a reasonably safe distance from excavations and are operated within
gradient limits as specified by the manufacturer of such cranes;
Tower cranes are sited where there is a clear space available for erection, operation and
dismantling.
Tower cranes are sited in such a way that the loads on such cranes are not handled over any
occupied premises, public thoroughfares, railways or near power cables, other than construction
works for which such cranes are used;
Where two or more tower cranes are sited and operated, every care is taken to ensure positive
and proper communication between operators of tower cranes to avoid any dangerous
occurrences.
32.0 Lifting Activity

32.1 Lifting of Material
Contractor shall designate a rigging co-ordinator who shall have adequate knowledge, skill,
experience, qualification and training who shall successfully demonstrate to solve problems related to
safe crane operation. This rigging co-ordinator shall prepare a rigging plan, supervise and control all
lifting activities.
Contractor shall submit a detailed method statement/ rigging plan for critical and heavy lift by
considering following
Rigging sketch
Details of the crane
Rated capacity of crane
List of rigging hardware
Rated capacity of rigging components
Weight of the rigging gear
Weight of the load
Total weight of the lift (Weight of the rigging gear + Weight of the load)
Dimension of the load
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Crane Radius
Boom Length
Safe working limits of the crane as per load chart
Ground and site condition
Placement of crane
Swing radius
Sling angles
Hand signal and necessary communication to be used.
Contractor shall submit all manufactures operator manual, third party test certificate to
Before beginning any crane operation the supervisor and operator shall complete the pre-lifting
checklist. The same shall be submitted to owner/consultant/ EIL.
Attachment 38: Per-Lift Checklist
The outrigger of the crane shall be fully extended prior to the lift and shall be padded on firm base.
The operator shall have valid operator license.
Lifting activity shall not be carried out when wind velocities is 25km/hr or greater or during other
adverse condition.
Sufficient clearance shall be maintained while working near over head power lines
Up to 250,000 volts at least six meter clearance shall be maintained.
Above 250,000 volts at least 7.5 meter clearance shall be maintained.
Contractor shall deploy only the riggers having sufficient knowledge, experience and skill.
A trial lift shall be carried out, raising the load a short distance above its pick-up point, to check the
stability of the crane, and the efficiency of the brakes.
Tagline shall be used to control the load swing.
Crane boom swing radius shall be barricaded and safety sign boards shall be displayed.
Signal man shall be provided with retro-reflective jacket and he is the only authorised person to give
signal to the operator.
No person shall move beneath the load and travel on the load.
32.2 Lifting of Personnel

Contractor shall avoid lifting of personnel by crane. The preference shall be scaffold. If the nature
of job demands, then such lift shall be authorized by owner.
The suspended personnel basket shall be limited to a capacity of six persons.
Suspended personnel basket and attaching device shall be designed with factor of safety greater
than five.
Suspended personnel basket shall have name plate specifying the weight of the empty basket,
maximum number of allowed persons and rated capacity of personnel basket.
Personnel lifting basket shall be tested by third party competent person and the test certificate
shall be submitted to owner/consultant/ EIL.
Personnel lifting basket shall have hand rail at 1100mm, mid rail at 550mm and toe guard width
shall be of 150mm.
A trail lift without personnel shall be carried with maximum anticipated load. The taril lift shall be
from ground level to the location to which the basket to be lifted.
Lifting activity shall not be carried out when wind velocities is 25km/hr or greater or during other
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adverse condition.
Suitable anchor points shall be provided in the basket and personnel being lifted shall anchor their
full body safety harness to the anchor points.
The crane operator shall not leave the cabin after personnel are lifted. In case of emergency, all
personnel shall be lowered to ground and leave the cabin.
33.0 Construction Vehicle

33.1 Dumpers, trailers, trucks, excavators, transit mixers, road rollers, tractors piling rigs, cranes, tipper,
lorry loaders, skip wagons, crawler tractors, scrapers, graders, tankers etc are considered as
construction vehicles.
33.2 The contractors shall provide a list of vehicles needed to be used at site and formulate a procedure
relating to construction vehicle inspection, operation and maintenance. It must be consistent with the
manufacturer's recommendations and consultants requirements.
Contractor's construction vehicles are to be periodically inspected and maintained according to pre-
determined schedule. Records of all inspection and maintenance shall be maintained and submitted
to owner/consultant/ EIL on regular basis.
Vehicle maintenance or repairing work shall not be carried out inside the construction site.
33.3 Operators entering site shall be instructed to follow the safe system of work adopted on site. These
shall be preferably, written instructions showing the relevant site rules, the site layout, delivery areas,
speed limits, etc.
33.4 All vehicle operators shall undergo medical fitness test, audiometric test and vision check test. The
medical certificates of those operators shall be submitted to owner/consultant/ EIL.
33.5 Vehicle operator shall possess valid driving license.
33.6 All construction vehicles shall have

RC and Pollution under Control (PUC) certificate
Exhaust shall be fitted with flame arrestor.
Horn, mirrors, head and tail lights, indicators, reflectors etc.
Parking brake and brake light
First Aid kit
Fire extinguishers
All Vehicles shall be fitted with audible reverse alarms and maintained in good working condition.
Reversing shall be done only when there is adequate rear view visibility and under the directions of a
banksman.
All vehicles shall be equipped with wind shields and wipers. Cracked or broken wind shields shall be
replaced.
33.7 At start of each shift operator shall check oil, fuel, water and hydraulic levels, that all gauges are
working and the vehicle is functioning smoothly.
33.8 The maximum speed limit on the construction site is 20-km/ hr. The maximum speed limit in work
areas is 15-km/ hr.
Personnel must not be transported while standing on the bed of trucks or trailers or on material
handling / earth mounting equipment or they shall not be allowed to sit on doors.
Material extending from vehicle bed shall be indicated with red flag.
The latch on the dumper skips shall be in working order and release mechanism shall function
smoothly.
The operators shall turn-off the engine and remove the ignition key before leaving the vehicle.
Before moving the vehicle operator shall walk around it to see the area is clear. No one shall be
allowed to sit or lie around or beneath the vehicle.

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Wheel stopper shall be provided to while parked at slopes, place near any excavations etc.
33.9 Parking and Vehicle movement in Refinery Premises

Vehicles shall be parked only in designated areas. No vehicle shall be parked opposite fire
hydrants or at the intersection of roads or within 10 meters of any road corner or in front of the
Fire Station.
Vehicle shall not be parked, in any manner that will block emergency services, bends, building
exits and walkways etc.
No vehicles should enter into any operating area without valid fire permit followed by a safety
clearance from the area-in-charge (this includes process areas, tank farms and loading racks).
The contractors shall prominently display the name of their company on all the vehicles including
tractor trolleys, trucks, open jeeps, cranes which are allowed by the owner to enter inside the
Refinery for carrying out the job. The display board shall be put on front and rear side of each of
the vehicle.
Photocopy of the vehicle gate pass along with the drivers photo shall be pasted on the
windscreen for display. Driver shall keep valid driving license along with him
Attachment 39: Construction Vehicle
34.0 Construction Machinery

The contractor shall ensure at the construction site all motors, cogwheels, chains and friction
gearing, flywheels, shafting, dangerous and moving parts of machinery are guarded. The guard of
dangerous part of machinery is not removed while such machinery is in motion or in use.
34.1 Air receivers / compressors
Contractor shall ensure that air receivers/ compressors shall be
In good condition and properly maintained.
Individually identified and marked with their safe working pressure.
Be accompanied by a valid test certificate.
Fitted with a properly set pressure relief valve.
Examined and the pressure relief valve tested by an independent examiner at yearly intervals.
A register containing relevant details about the air receivers, compressors shall be maintained at
site such as identification numbers, dates of inspections, pressure ratings etc.
All compressed air fittings shall be wired and/or restrained to prevent them from whipping should
the coupling separate.
Only hose clamps designed for compressed air service shall be used. Worm drive (jubilee) clips
are not acceptable.
35.0 Noise
Noise must be kept to a minimum at all times and must not exceed acceptable and/or any work
activity which is likely to expose any employee on site to a noise level of 85 db(A) or above,
assessments should be carried out. In such circumstances, the contractor must keep stocks of
ear defenders or other suitable hearing protection and issue to the workmen who are exposed to
the higher levels of noise.
The Contractor shall ensure that noise generated from all powered mechanical equipment shall
be effectively reduced using the most modern techniques available including but not limited to
silencers and mufflers.
The Contractor shall construct acoustic screens or enclosures around any parts of the works from
which excessive noise may be generated.
Grinders, Cutters, Jack Hammer (pneumatic drills), Engine driven plant and the like, all give off
levels of noise that is harmful.
Earplugs and earmuffs are the commonest form of hearing protection to be used.

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36.0 Confined Space

36.1 General
A confined space is large enough and so configured that an employee can bodily enter and perform
assigned work, has limited or restricted means for entry or exit and is not designed for continuous
employee occupancy.
A person passes through an opening into a confined space and is considered to have occurred as
soon as any part of the entrant's body breaks the plane of an opening into the space is confined
space entry.
The danger may be as a direct result of a process being undertaken by persons in confined space
and the activities such as spray painting, use of cleaning fluids (solvents), hot work, abrasive
blasting, arc air gouging were considered as dangerous activities.
The hazards involved are asphyxiation, fire and explosion, oxygen enrichment or deficiency, dust and
fumes, electrocution, heat exhaustion.
36.2 Preparation
Contractor shall prepare method statement and submit to owner/consultant/ EIL for review at least
seven days prior to the commencement of the activity. Method statement for work in confined space
shall address the following as minimum.
Work scope and methodology
Nominated supervisors for obtaining permit to work and overall controller of the work activity.
Nominated stand by persons
Tools and equipments to be used
Explosion proof fittings
Flame proof lighting arrangement including emergency lighting
Ventilation arrangement
Access
Fire safety and fire extinguisher requirements
First-aid facilities
Rescue procedure and availability of equipment/ resource for rescue
36.3 Authorization
Nominated supervisor is a competent construction engineer who has adequate knowledge, skill,
experience and familiarity about working in confined space.
Contractors nominated supervisor shall ensure that workmen and other supervisors employed for
work in confined space are trained and competent in performing such task before signing the work
permit.
All entry into confined spaces shall be controlled by means of a permit to work and this shall be
obtained from owner/consultant/ EIL.
No new activity shall be introduced in to a confined space without permission and signed approval of
permit to work from owner/consultant/ EIL.
36.4 Access
Clear and safe access shall be maintained continuously while workers are in confined space.
Ladder shall be of suitable size and length.
Adequate lighting shall be provided at all access and egress points.
36.5 Communication
Effective communication shall be maintained between personnel in confined space and outside by
combination of visual/ voice or portable radio.
36.6 Ventilation
Contractor shall check the oxygen level and confined space entry shall only be permitted if level of
oxygen by volume is in between 19.5 percent to 23.5 percent.
The oxygen level shall be surveyed at regular interval while any task is performed in confined space.
The oxygen level survey details shall be maintained in log register.
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Exhaust fan or other mechanical means shall be used to bring Lower Explosive Limit (LEL) 0% or
toxic gas below Threshold Limit Value (TLV). Also Self Contained Breathing Apparatus (SCBA) shall
be used if necessary.
Whenever spray painting is carried out in confined space, forced ventilation shall be provided to
avoid any accumulation of flammable vapours.
36.7 Electrical Safety

Electrical hand tools to be used in confined space shall be inspected for good working condition, free
from defects, double insulated cables, connections through ELCB and valid test and inspection
stickers.
Contractor shall use only 24V lamp. Lamp shall be suitably guarded
All electrical fittings shall be of Flame proof and confirm to national standards
36.8 Fire Safety

All combustible materials shall be removed wherever possible before performing any hot work.
Fire protection equipments such as fire extinguishers or fire hoses shall be kept at the work area.
A fire watcher shall be deputed whenever hot work is carried out in confined space.
Compressed gas cylinders shall not be taken into confined space under any circumstance.
Gas cutting torch/ electric arc welding torch shall be removed from confined space during any
interval/break and as soon as the job is completed.
36.9 Emergency Rescue

Stand by person shall be deployed at the entrance of confined space to assist in rescue if any.
Stand by person shall be trained in rescue and his duties include evacuation of all entrants in
confined space. Also communicate for any emergency services and assist in rescue.
Stand by person shall be familiar with all possible hazards in confined space and remain outside
confined space entry until relived by another stand by person.
Rescue equipments such as full body safety harness, tripod, lifelines, Self Contained Breathing
Apparatus (SCBA), stretchers, Man basket, crane shall be kept readily available.
37.0 Radiography
Radiography camera must be operated only by licensed radiographers certified by BARC under
the direct supervision of site-in-charge.
Contractor shall submit list of competent persons involved in radiography at least seven days prior
to the commencement of the job.
Contractor shall submit a list of authorised person involved in radiography associated works such
as isolation of sources, radiation survey meter surveyor, area cordon-off crew.
Field radiography shall be carried out during night time where there is no occupancy around.
All radioactive sources must be clearly identified with its strength of the source, activity at different
levels. A warning label should be displayed indicating Danger Radioactive Material.
The area shall be cordoned-off whenever radiography is carried out and the distance to be
cordoned-off is determined by the type and strength of radiation source to be used, the type of
exposure given, nature of occupancy and the total exposure time per week.
The radiation levels along the cordon should be monitored by suitable and calibrated radiation
survey meter to confirm the cordon-off distance is adequate.
Everyone involved in field radiography activity shall wear personnel monitoring badges.
Radiation warning symbols shall be conspicuously posted along the cordon in English, Hindi and
vernacular languages. It shall be readable from a distance of 7 m under normal illumination.
All safeguards should be implemented to ensure that workmen are not crossing the barricades.
The boundary of cordon on all sides shall be adequately illuminated throughout the duration of
radiography.
Red warning lights must be posted at night along boundary of cordon and especially at the point
of entry.
38.0 Hand tools

Contractor shall ensure that all hand tools used shall be of correct type, size and weight for the job.
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Hand tools used for electrical operations shall be properly insulated and shall be non-conductive
type.
Screwdrivers used shall correct size of tip to fit the slot of the screw.
Screw drivers shall not be carried in pockets of clothing.
Hammers handles shall be made of smooth timber. Hammer head should be secured to wooden
handles with proper wedges.
Chisels edges shall be kept sharp all the time. The original shape and angle shall be maintained.
The chisel should be handled by tongs. Holding chisel by hand while chipping shall be avoided.
Shovel blade shall not be allowed to become blunt, turned, split or jagged.
Only spanners and adjustable wrenches shall be used. Improvised extension of spanners may
cause shearing of bolt and slip of tool.
The ordinary wrenches shall not struck by hammer.
Pipe wrenches should be large enough for the job. It should not be struck with hammer nor, shall
be used as hammer.
Pliers used for electrical works shall be fitted with insulated handle.
The hacksaw blade to cut shall be set in hacksaw frame. The teeth shall point forward direction
and sufficient tension should be applied to ensure the blade is maintained rigid.
39.0 Demolition
Prior to the commencement of any demolition work and also during the process of demolition
contractor shall follow the following additional precautionary steps shall be observed.
All roads and open areas adjacent to the particular site shall either be closed or suitably
controlled.
All underground / overground power / telephone cables or water / sewerage lines in the vicinity of
the particular site shall be either suitably diverted or made non-functional for the duration of the
demolition activity.
All practical steps shall be taken to prevent danger to persons employed from risk of fire or
explosion or flooding. No floor, roof or other part of the building shall be overloaded with debris or
materials as to render it unsafe.
40.0 Temporary Structure/Fixtures

Before erecting temporary shelters like sheds anywhere within the Refinery premises, written
permission of the Engineer-in-charge be obtained.
Temporary fixtures like sheds, tents, etc. shall be erected in conforming with normal safety
standards. Thatched roof to such fixtures will not be permitted.
Temporary piping, hose connections and electrical wiring must be laid in such manner that they
do not cause tripping or hitting hazard
Temporary sheds can be constructed only for the storing of the material / site office. It should not
be used for any other purpose.
However, for all jobs having value more than Rs. One crore, no temporary sheds shall be allowed
for office / stores of the contractor and instead the contractor shall arrange for portal cabin for site
office / stores.
Following information shall be clearly written on the shed:- Name of the contractor; Work Order
No.; Working under the Department; Name of the Engineer-in-charge; Permit No. & it's validity
period.
The shed shall be made of safe construction material and good aesthetic view. The shed shall be
made strictly at the authorised location and size.
All windows shall be either of wire mesh or glass.
Company has the right to open or break the door at any time to inspect the shed.
After completion of the job shed must be demolished within 10 days and area must be cleaned.
All precautions should be taken to ensure that any temporary electrics wiring used within the
Refinery will not cause sparks or shock

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Section IV Liquidated Damages
41.0 Penalties for Violation/Non-Adherence of Safety Procedures and Practices

41.1 The contractor has to follow all Safety, Health and Environment rules & regulations of the Refinery. In
case of non-compliance of any of these rules and regulations by contractor or his employees, the
contractor shall be held responsible. If any violation or non-fulfilment of these Safety, Health and
Environment rules and regulation is observed by Refinery authorities during checking at any time, a
penalty of Rs. 5000.00 (Rs. Five Thousand Only) shall be imposed on the contractor for each
occasion of non-compliance to these rules and regulations by him or his employees. The decision of
Refinery authorities shall be final and binding on to the contractor in this regard. The amount of
penalties so imposed shall be recovered from the next R.A. Bill of the work or any other dues payable
to the contractor by Refinery
Event Penalty
Absence of Resident / safety Engineer of Contractor in

Rs 1000 per meeting
EIL/OWNERs safety meeting
Failure to have regular site safety Inspection (by contractors
Rs 1000 / week
themselves) every week
Failure to conduct Health / Safety / Environment (HSE)
meetings by Contractor at site (in-house) and maintain Rs 1000/month
records
Failure to submit HSE reports/check Lists, etc., by 5th of Rs 1000 /month and Rs 100 / day
every month to EIL/OWNER for further delay
Working without clearance Rs 5000/occasion
Hot work without proper Clearance / permit Rs 10000 / occasion
For not providing shoring / strutting / proper slope and not
keeping the excavated earth at least 1.5M away from the Rs 5000 / occasion
excavated area
41.2 In case the violation / non-compliance of above Safety, Health & Environment rules results in results
in any Physical Injury or Fatal Accident, an additional penalty as given below shall also be imposed
on to the Contractor:
41.3 For any reportable physical injury as per Indian Factories Act - 1948: Additional penalty of 0.5 % of
the contract value subject to a maximum of Rs.2,00,000 (Rs. Two Lakhs Only) per injury in addition
to the penalty of Rs.5000 as per 41.2 above
41.4 For Fatal accident: Additional penalty of 1 % of the contract value subject to a maximum of
Rs.10,00,000 (Rs. Ten Lakhs Only) per fatality in addition to the penalty of Rs.5000 as per 41.2
above.
42.0 Compensation in case of Accidents

In case of any accidents/injury of a contractor's workmen, the contractor shall pay a suitable
compensation (subjected to the minimum compensation as mentioned below) to the affected person /
his family members in the presence of Engineer-in-charge and in consultation with Chief Medical
Officer of the Refinery. The said compensation shall depend on the seriousness of injury, etc, and
shall be in addition to the hospitalization / treatment charges and Group Insurance Amount payable
to the effected person. The following are the minimum compensation shall be paid to the affected
person / his family as stated above:

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42.1 In case of fatal accidents: Rs.1.0 lacs (Rs. One Lakhs) within 5 days of accident.
42.2 In case of loss of both the limbs (hand / legs/eyes/ ears) : Rs.50,000/- (Rs. Fifty Thousand ) within 1
week.
42.3 In case of loss of one limb (hand / legs/eyes/ ears) : Rs.25,000/- (Rs. Twenty Five Thousand ) within
1 week.
42.4 In case of any injury not specified above, Rs.1000/- (Rs. One Thousand) to Rs.5000/- (Rs. Five
Thousand) as directed by Engineer-in-charge within 1 week.

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LEGAL OBLIGATIONS / REQUIREMENTS FOR CONSTRUCTION
Factories Act, 1948,

Minimum Wages Act, 1948 and Rules 1950
Employees Provident Fund & Miscellaneous Provisions Act, 1952.
Contract Labour Act, 1970 and Rules 1971
Weekly Holidays Act, 1942.
Fatal Incidents Act, 1855.
Personal Injuries (Compensation Insurance) Act, 1963.
Workman Compensation Act, 1923 along with allied Rules
The Public Liability Insurance Act 1991 and Rules 1991
Child Labour (Prohibitions & Regulations) Act, 1986 and Rules 1950
Indian Electricity Act 2003 and Rules 1956
Motor Vehicles Act as amended in 1994 and The Central Motor Vehicles Rules, 1989.
The Petroleum Act, 1934 and Rules 1976
Gas Cylinder Rules, 2003
Environment Protection Act, 1986 and Rules 1986
Air (Prevention and control of Pollution) Act, 1981
Water (Prevention and Control of Pollution) Act, 1974
The Noise Pollution (Regulation & Control) Rules, 2000
Manufacture, Storage & Import of Hazardous Chemicals Rules, 1989
The Hazardous Waste (Management & Handling) Rules, 1989
Hazardous Waste Management Rules 1989 (as amended in 1999)
Building and other Construction Workers Act, 1996.

Page 144 of 564
SPECIFICATION No.
HEALTH, SAFETY & ENVIRONMENT MANAGEMENT AT Page 51 of 101
DCU,CPCL CHENNAI
HSE ASSURANCE PLAN
SR ACTIVITY FREQUENCY EXTENT OF CHECKING REMARKS
NO OPERATING CHECKING SUB CONTRACTOR LSTK CONSULTANT

/OWNER
Area Engr Safety Supervisor Safety Officer CONTRACTO
R
1. HSE Policy Communicate to all Once in the Review Contractor to submit.

working at Project site. beginning. implementation
As applicable system
2. Safety committee Through meetings at To be formed consisting Owner, Consultant, Contractor / Sub Contractor and Representatives of workers.
predefined interval.
3. Training (Induction and For everyone As per Training Requirement in HSE Manual Entry passes to be issued only
Periodic) after induction
4. Reporting
4.1 Safety Statistics Monthly Monthly NA NA Monthly Monthly
4.2 Weekly First Aid and Weekly Weekly W Weekly Once a Week R
Illness Reports
4.3 Labour Report with Work Daily Daily Daily Daily Daily R Summary at the end of
hours month
4.4 Incident Reports As applicable As NA W W R

applicable
4.5 Investigation Reports As applicable As NA W W R

applicable

Page 145 of 564
SPECIFICATION No.
DCU,CPCL CHENNAI
HSE ASSURANCE PLAN


/OWNER
Area Engr Safety Safety Officer CONTRACTOR
Supervisor
5. Statutory requirements Regular Once in 3 NA NA Monthly R Once in Quarter

(Registration, Records of months
Payment, Licenses)
6. Facilities
i. First Aid Regular R NA W R R Once in a Month
ii. Emergency care services Advance R NA Daily Periodic S Once in a Month

(Doctor, Ambulance) arrangement.
iii. Medical examination (Pre & Regular Periodic N.A. N.A. Periodic S Once in a Month
Periodic)
iv. Temporary accommodation In the beginning R N.A. R R R R
v. Drinking Water tank Filling everyday, Through R N.A. R S R

cleaning once a Records
week
vi. Urinals & Latrines Daily sweeping R N.A. R R R R If applicable

arrangement.

Page 146 of 564
SPECIFICATION No.
DCU,CPCL CHENNAI
HSE ASSURANCE PLAN


/OWNER
Area Engr Safety Safety Officer CONTRACTOR
Supervisor
vii. Septic tank/disposal system In the beginning S N.A. W R R R If applicable
viii. Mosquito control Once a week, Through records N.A W R R R If applicable

disinfecting
arrangement
ix. Crches for Children below Required if 50 or R N.A Daily Monthly R R

6 yrs. more females
employed at site
x. Canteen Required if more R N.A. Daily Monthly R R If applicable

than 250 workers
are employed.
xi. Waste disposal Daily R N.A. Daily monthly R R
7. Fire fighting system S Once in a month N.A. W R R R
8. Traffic rules Daily Daily N.A. W R R R
9. Use of PPE Daily Daily By all, regular basis.

Page 147 of 564
SPECIFICATION No.
DCU,CPCL CHENNAI
HSE ASSURANCE PLAN

NO
OPERATING CHECKING SUB CONTRACTOR LSTK CONSULTANT
CONTRACTOR /OWNER
Area Engr Safety Safety Officer
Supervisor
10. Work permit system S W W R R As applicable
11. Safety publicity Continuous Periodic N.A. N.A. W R
12. Excavation S NB W W R R S
13. Cutouts/openings S NB W W R R S
14. Barricading S Daily W W R R
15. Scaffolds S Regularly W W W R
16. Ladders S Regularly R R R R
17. Welding/cutting M/C S Once in 3 W W W R S
months
18. Elect. Hand tools & S Once in 3 W W R R
Distribution Boards month
19. Mechanical Equipment S Once in 6 W W Rw R S
months
20. LOAD TESTS FOR Heavy lifts W N.A. Rw Rw S Formal procedure
required for heavy lifts
Legends: W Witness
Rw Review of Sub-Contractors document
R Random verification
S Surveillance
NA Not applicable

Page 148 of 564
SPECIFICATION No.
DCU,CPCL CHENNAI
Site Safety Organisation Chart

Owner
Owners/PMCs Project Owner/PMCsSafety Representative
/PMC Representative
EIL
Resident Construction Manager
Safety officer
Resident Construction Manager

Contractor
Safety Manager
Safety Engineer
Safety Supervisor Safety Supervisor Safety Supervisor
Safety Observer Safety Observer Safety Observer Safety Observer Safety Observer

Page 149 of 564
SPECIFICATION No.
DCU,CPCL CHENNAI
Client: Weekly Safety Meeting

Safety Committee
Project:
Meeting
Project Number Meeting Number:
Confirmation of Meeting Telephone Talk

Date Held : Location :
Date Issued : Recorded by:
Issued By : Distribution:
Subject:
Participants:
Client Consultant Contractor/
EIL
Agreed date
Sl. Target
Remarks in Previous Action by
No Date
meeting

Page 150 of 564
SPECIFICATION No.
DCU,CPCL CHENNAI

Page 151 of 564 Copyright EIL All rights reserved
SPECIFICATION No.
A133-00-6-82-0001 Rev. 1
SPECIFICATION FOR
HEALTH, SAFETY & ENVIRONMENT MANAGEMENT AT DCU,CPCL CHENNAI Page 58 of 101
SAFETY OBSERVATION REPORT (SOR) SUMMARY SHEET
Project Contractor Date From: To:
P - Positive; AR - At Risk: UA - Unsafe Act; UC - Unsafe Condition; LB - Lack of Belief; LT - Lack of Training; LI - Lack of Interest; LR - Lack of Resource; C - Closed; O-Open
SOR
Direct
Observation Indirect Cause SOR SOR Status Closed
Date Time Observer Location Description Cause Corrective Action
category on
P AR UA UC LB LT LI LR C O
Contractors RCM Name Contractors Safety Manager Name

Signature Signature
Date Date
1.7.7.1

Page 152 of 564
SPECIFICATION No.
A133-00-6-82-0001 Rev. 1
SPECIFICATION FOR
Safe Plan of Action
Contractor Date: From: To: Doc no:

Activity/ Task Work area/ location Rev 0
Job description:
PPE Required
Full body double lanyard Hand gloves
Helmet Safety shoes/ Gumboot Safety goggles
safety harness
Nose mask Ear plug Hard hat with welding Shield Grinding visors/ face shield Others
Safety Devices
Caution tape/ Barricading Sign/Display boards Fluorescent jackets Lifeline/Fall Arrestor Safety net
pipes
Flash back Arrestor Fire extinguisher Fire blanket Warning lights
Others
Steps of Activity/Task Hazard/Reaction to Change Safe Plan Resources
Description Performer (Team members) Approved by Reviewed by

Name
Signature
Company
Date
The signature of the supervisor confirms the completion of the hazard assessment and Safe Plan of Action by the crew.
Supervisors Signature: Date

Instructions: 1. Write name of job or task in space provided. 2. Conduct walk-through survey of work area. 3. Write the steps of the task in a safe sequence. 4. List all possible hazards involved in each step and
reaction to change. 5. In the Safe Plan column, state actions that will be taken to prevent the hazards or injury from reaction to change. 6. In Resources column, list equipment, tools, etc. needed to do the job. 8. Ask
each team member, who helped develop and will use this SPA, to sign in spaces provided. 9. Review the SPA at the end of the task for improvements.
Work shall stop when conditions change, the job changes, or a deficiency in the plan is discovered, and the current SPA will be modified or a new SPA created.

Page 153 of 564
SPECIFICATION No.
DCU,CPCL CHENNAI
General Inspection Report (Safety Walk Around)

Project Contractor
Location Date Time
Name of team members involved in inspection

Sl.No Observation Hazard Identified Corrective Action Remarks
Signature of team members
Contractor shall complete the corrective action and submit the compliance report to EIL/ owner/consultant

Page 154 of 564
SPECIFICATION No.
A133-00-6-82-0001 Rev. 1
SPECIFICATION FOR
Attachment 9

Page 155 of 564
SPECIFICATION No.
A133-00-6-82-0001 Rev. 1
SPECIFICATION FOR
Attachment 9

Page 156 of 564
SPECIFICATION No.
A133-00-6-82-0001 Rev. 1
SPECIFICATION FOR
Monthly Safety Audit Checklist

Page 1 of 6
Project Date Location
Contractor Audit No. Audit Team members:
Sl. Possible Obtained

Description Observation
No Points Score
A Training 20
1 Induction training given to all new joining workers 5
2 Toolbox talks conducted frequently 5
3 Fire drill & site specific training conducted frequently 5
4 Records maintained for all training given at site? 5
B Personal Protective Equipment 25
5 PPE issue and inspection register maintained? 5
6 Compliance of safety shoes, safety goggles and helmets 5
7 Full body safety harness (lanyard length - 1.8 m) anchored 5
8 Welding shield & grinding visor mounted helmet used 5
9 Other necessary PPEs 5
C House Keeping 35
10 Clear walkways are maintained without any obstructions? 5
11 All materials are stacked properly? 5
12 Waste materials/ scraps dumped properly at identified areas? 5
13 Electrical cables are properly routed to prevent trip hazards or 5
damages due to vehicle movement
14 Nails or other sharp objects being removed or bent? 5
15 Clear walkways are maintained without any obstructions? 5
16 Scrap yard identified at site and waste disposed from site 5
regularly

Page 157 of 564
SPECIFICATION No.
A133-00-6-82-0001 Rev. 1
SPECIFICATION FOR
Page 2 of 6


No Score Score
D Work at height 20
17 Edge protection & floor opening protection provided? 5
18 Fully planked working platform with handrails, mid rails & toe- 5
guards with secured access ladder extending 1 m from
19 Fall arrestors, lifelines & safety nets in use wherever 5
necessary?
20 Ensuring everyone anchoring the safety harness when 5
exposed to a fall of 2m and above
E Scaffolds & ladders 40
21 Scaffold designed & erected by trained personnel 5
22 Scaffolding checklist prepared and displayed? Scaffold 5

tags displayed?
23 Scaffold erected on a level surface with base plate / sole plate? 5
23 Appropriate scaffold materials are used & installed 5

properly with necessary supports and back ties wherever
Staging for shuttering is designed for loads like worker movement,
25 5
impact loads and other incidental loads during various construction
26 Dismantling of scaffolds done under proper supervision? 5
Are all materials properly lowered?
27 Ladders in use are without defects? Positioned in a safe angle 5
and secured properly?
28 Mobile scaffolds are used with proper lock system 5
and appropriate access to the working platform?
F Excavation 20
29 Sloping/ benching or shoring maintained 5
30 Adequate barricading provided for the pit/trench 5
31 Access ladder in place where work is carried out 5
32 Excavated earth removed or deposited 1.5 m away 5

Page 158 of 564
SPECIFICATION No.
A133-00-6-82-0001 Rev. 1
SPECIFICATION FOR
Page 3 of 6

No Score Score
G Electrical 50
33 Electrical Inspection register maintained? 5

34 All power tools are inspected and tagged? 5
35 Does cabling provide sufficient headroom? 5
36 Electrical connections are free of insulation damages, 5
joints and provided with plug tops
36 All electrical connections are taken through ELCB (30 mA) 5
37 Proper earthing for main panel & body earhting for DBs? 5
38 All DBs are provided with a rain protection canopy? 5
39 Adequate safety provisions at panel room? 5
40 Is there enough number of first-aiders having knowledge of 5
CPR for electrocution?
41 DG inspected and maintained 5
H Vehicle movement 30
42 All vehicles installed with reverse horns 5
43 Authorised driver/ operator with a valid driving license 5
is engaged?
44 Vehicle operators given adequate training on speed limit, 5
overloading & site rules
45 Spark arrestors available? 5
46 Banksman available for controlling the vehicle movement? 5
47 Maintenance record and inspection record maintained 5

Page 159 of 564
SPECIFICATION No.
A133-00-6-82-0001 Rev. 1
SPECIFICATION FOR
Page 4 of 6


No Score Score
I Welding, gas cutting and grinding 50
48 Adequate PPEs are provided and used? 5
49 Earth connectors are securely connected to the job and not to 5
the adjoining structure or scaffold?
Welding cable used is maintained in good condition without any cut or
50 open/ tapped joints? Gas cutting hose is without any crack/ damage?
5
51 Flash Back Arrestors installed in the cutting set (both at 5

cylinder end and torch end)
52 Cylinder storage area clearly identified for fuel gas 5
and oxygen? Not exposed to sunlight kept in upright position
53 Cylinder keys are always available on acetylene cylinders? 5
Double pressure gauges are in working condition?
54 Grinding machine are with proper guards? 5
55 Grinding wheel used of proper RPM rating as marked on the 5
grinding machine?
56 Grinding wheel is without any crack or deformation 5
on circumference?
57 Adequate precaution taken to prevent the hazards from 5
hot spatters and sparks
J Rigging 30
58 Inspection and test certificate records maintained for all lifting 5
tools and tackles, hydras and cranes?
59 SWL & date of testing are visibly marked/ painted on all lifting 5
tools/ tackles and equipments?
60 Crane operators are trained, qualified, and have valid license. 5
61 All rigging tools and lifting equipment are in good 5

condition, properly inspected and have current certification.
62 Tag lines are used appropriately. 5
63 Cranes are set up properly including extended outrigger pads. 5

Page 160 of 564
SPECIFICATION No.
A133-00-6-82-0001 Rev. 1
SPECIFICATION FOR
Page 5 of 6


No Score Score
11 Other 55
64 SPAs are prepared and displayed at site? 5
65 Emergency response plan established at site and 5
communicated to all. Assembly point identified?
66 Adequate First aid facilities maintained. First Aid 5
register maintained at site?
Confined space works are carried out with a valid authorized permit
67 and is the permit displayed? All requirements specified in the 5
permit are fulfilled before confined space entry?
68 Fire Extinguishers in place for all hot works 5
Are illumination levels at workplace and passage ways
69 adequate? Sufficient lighting arrangements are made for night 5
works?
70 Sign boards and caution boards are kept wherever necessary? 5
71 All rotary parts of machinery are properly guarded? 5
73 Restrooms are made & well maintained. Designated place for 5
drinking water & clearly labeled
74 Participation of execution engineers in implementation of safety 5
program
75 Safety awareness and promotional activity 5
Safety Performance Rating Indicator (Score %) Contractor's Safety Performance

GOOD 90 100 % No of points attended
SATISFACTORY 76 89 % Possible Score
UNACCEPTABLE < 75 % Scores Obtained
Score %

Page 161 of 564
SPECIFICATION No.
A133-00-6-82-0001 Rev. 1
SPECIFICATION FOR
Page 6 of 6
Sl. Responsible Completion

Observation Corrective Action Target date
No Person date
Contractors RCM Endorsement

Date
Note: Contractor shall complete the corrective action and submit the sheet to EIL/Consultant/Owner.

Page 162 of 564
SPECIFICATION No.
HEALTH, SAFETY & ENVIRONMENT MANAGEMENT Page 69 of 101
AT DCU,CPCL CHENNAI
Safety Induction Induction Number

Project Name Project Number
Contractor Date of Induction
Inductee Name Designation
Age Blood Group Experience in Role:
1.0 Introduction about site
2.0 Safety Policy of Owner, Consultant & Contractor
3.0 Alcohol policy, Drugs, No smoking
4.0 Gate pass procedure
5.0 First aid facilities
6.0 Emergency procedure
8.0 Welfare facilities
9.0 Personal Hygiene
10.0 Good housekeeping
11.0 Fire preventions and protections
12.0 Safe Plan of Action (SPA)
14.0 Working at height (Ladders, Scaffolding, Safety harness)
15.0 Fall prevention and protection (Open edges, floor cut outs)
16.0 Safe use of hand and power tools
17.0 Material handling
18.0 Electrical safety
19.0 Gas cutting, welding and Gas Cylinders
20.0 Traffic rules
21.0 Movement on site

Your Health - should the Company and your work colleagues know about your health? Are you
taking specially prescribed medication? Are you epileptic or diabetic, or do you have a heart problem/
disease? If we all know - we can help if you become ill, if we don't know, any help may be too late.
Name of Inductor Name of Inductee

Signature Signature/ Thumb Impression
Date Emergency Contact Number

Page 163 of 564
SPECIFICATION No.
A133-00-6-82-0001 Rev. 1
SPECIFICATION FOR
Safety Induction Attendance Register (Required only for two or more attendees)
Date of Induction: Total Number of Attendees: Induction Number:
Emergency Signature/
Gate Pass Blood Experience
Sl.No Full Name Designation Age Contractor Permanent Address Contact Thumb
Number Group in Role
Number impression

Page 164 of 564
SPECIFICATION No.
AT DCU,CPCL CHENNAI

Page 165 of 564
SPECIFICATION No.
AT DCU,CPCL CHENNAI

Page 166 of 564
SPECIFICATION No.
HEALTH, SAFETY & ENVIRONMENT Page 73 of 101
MANAGEMENT AT DCU,CPCL CHENNAI
Safety Training Matrix

Project Number Project Name
Contractor Training Matrix for the Month of
Supervisor
Electrician
Strength
Bar binder
Operators
Carpenter
Planned
Unskilled
Scaffold
operato
Sl.No Training Topic
Grinder
Vehicle
Painter
erector
Welder
worker
Rigger
Mason
mover
Date
Crane
Earth
Fitter
1. Safety Induction
2. Personal Protective Equipment
3. Housekeeping
4. Work permit
5. First-aid
6. H2S
7. Mock drill
8. Excavation
9. Manual handling
10. Driving Safety
11. Working at Height
12. Scaffold
13. Hot work
14. Heavy lifting and Rigging
15. Fire prevention and protection
16. Electrical Safety
17. Hand and power tools
18. Confined Space Entry
19. Pre-commissioning Safety
20. Lock-out and Tag-out
Contractors Endorsement Date

Page 167 of 564
SPECIFICATION No.
HEALTH, SAFETY &
ENVIRONMENT MANAGEMENT Page 74 of 101
AT DCU,CPCL CHENNAI
Attendance Register for Safety Training

Project Project No
Contractor Topic
Date Location
Time Conducted by
Signature/ Thumb
Sl.No Name Designation Organisation
Impression
1
10
11
12
13
14
15
16
17
Facultys Signature
Date
1.

Page 168 of 564
SPECIFICATION No.
A133-00-6-82-0001 Rev.1
SPECIFICATION FOR

Page 169 of 564
SPECIFICATION No.
Weekly Safety Report
Project Name Name of the Contractor

Project Started on Report Number
Report for the period From to
Descriptio For the Week Cumulative
Work Hours
Average Strength (Staff + Workmen)
Total Recordable Incident Rate (TRIR)
Performance Indicators
Fatal
Injuries & Illness
Recordable
Medical Aid
Incidents
Days away from work

Restricted Workday case
First-aid case
Near miss
Property Damage
Environmental Damage
Motor Vehicle Incident
Brief description of the incident during the week (if any):
Safety Metrics
Safety Induction
Tool Box Talks
Safety Training
Positive SOR
Other SOR
Safety Inspection
Safety Audit
Safe Plan of Action (SPA)
Safety Meeting
Contractors RCM endorsement Contractors Safety Manager Endorsement

Date of Submission
Remarks: Contractor shall submit supporting documents along with weekly safety report.

Page 170 of 564
SPECIFICATION No.
MONTHLY HEALTH, SAFETY & ENVIRONMENT (HSE) REPORT
Actual work start Date: Project: For the Month of

Name of the Contractor Name of Work Report No
Job No : Status as on
Contractor in consultation with EIL shall generate the reports through web based package (www.eil.co.in/conthse)
UPTO THIS
ITEM CUMULATIVE
PREVIOUS MONTH
1) Average number of Staff & Workmen
2) Man-hours worked
3) Number of Induction programmes conducted
4) Number of HSE meetings organized at site
5) Number of HSE awareness programmes conducted at site
6) Number of Tool Box Talks conducted
7) Number of Lost Time Accidents (LTA) Fatal
Other LTA
8) Number of Loss Time Injuries (LTI) Fatalities
Other LTI
9) Number of Non-Loss Time Accidents
10) Number of First Aid Cases
11) Number of Near Miss Incidents
12) No. of unsafe acts/ practices detected
13) No. of disciplinary actions taken against staff/ workmen
14) Man-days lost due to accidents
15) LTA Free man-hours i.e. LTA free man-hours counted from the Last
LTA (enter date: .)
16) Frequency Rate (No. of LTA per 2 lacs man-hours worked)
17) Severity Rate (No. of man days lost per 2 lacs man-hours worked)
18) Loss Time Injury Frequency (No. of LTI per 2 lacs man-hours
19) No. of activities for which Job Safety Analysis (JSA) completed
20) No. of incentives/ awards given
21) No. of occasions on which penalty imposed by EIL/ Owner
22) No. of Audits conducted
23) No. of pending NCs in above Audits
24) Compensation cases raised with Insurance
25) Compensation cases resolved and paid to workmen
26) Whether workmen compensation policy taken Yes No
27) Whether workmen compensation policy is valid Yes No
28) Whether workmen registered under ESI Act, as applicable Yes No
Remarks, if any
Date: Prepared by Safety Officer Approved by Site Head / Resident Construction Manager
(Signature and Name) (Signature and Name)
To : - OWNER & RCM EIL (2 copies)
Page 171 of 564

SPECIFICATION No.

Page 172 of 564
SPECIFICATION No.

Page 173 of 564
SPECIFICATION No.

Page 174 of 564
SPECIFICATION No.
Incident Reporting Chain and Emergency Contact Numbers
Project: Contractor:
Incident (First Witness)
Immediate Supervisor
Contractors RCM Emergency Services

(Name and Contact Number to be updated) (First-aid centre, Fire Services)
Consultants RCM
(Name and Contact Number to be updated)
Head Office Client

(Name and Contact Number to be updated)
Emergency Contact Numbers

Services Name Contact Number Remarks
Medical Centre (To be updated) (To be updated)
Ambulance (To be updated) (To be updated)
Hospital (To be updated) (To be updated) Tie-up Nearest
Fire Station (To be updated) (To be updated)

Project Security (To be updated) (To be updated)
Police Station (To be updated) (To be updated)
Consultants Safety Department (To be updated) (To be updated)
Contractors RCM (To be updated) (To be updated)
Contractors Safety Manager (To be updated) (To be updated)
Contractors First-aid centre (To be updated) (To be updated)
Consultant RCM (To be updated) (To be updated)
Client (To be updated) (To be updated)
Note:
First witness shall attend the injured person.
Supervisor shall inform emergency services and also the contractors RCM.
All incidents and near miss incidents shall be reported immediately.
Detail report shall be submitted within 24 hours irrespective of Sundays and holidays if any.

Page 175 of 564
SPECIFICATION No.
CONTENTS OF A FIRST-AID
BOX
A sufficient number of eye wash bottles filled with distilled water or suitable liquid clearly indicated
by a distinctive sign which shall be visible at all times.
4 per cent xylocaine eye drops, and boric acid eye drops and soda by carbonate eye drops.
Twenty-four small sterilised dressings.
Twelve medium size sterilised dressings.
Twelve large size sterilised dressing.
Twelve large size sterilised burn dressings.
Twelve (fifteen cm) packets of sterilised cotton wool.
(Two hundred ml) bottle of certimide solution (1 per cent) or suitable antiseptic solution.
One (two hundred ml) bottle of mercurochrome (2 per cent) solution in water.
One (one hundred twenty ml) bottle of salvolatile having the doses and mode of administration
indicated on the label.
One pair of scissors.
One roll of adhesive plaster (six cm X one metre).
Two rolls of adhesive plaster (two cms X one metre).
Twelve pieces of sterilised eye pads in separate sealed packets.
A bottle containing hundred tablets (each of three hundred twenty-five mg) of aspirin or any
other analgesic.
Twelve roller bandages ten cms wide.
Twelve roller bandages five cms wide.
One tourniquet.
A supply of suitable splints.
Three packets of safety pins.
Kidney tray.
A snake bite lancet.
One (thirty ml) bottle containing potassium permanganate crystals.
One copy of first-aid leaflet issued by the Directorate General.
Six triangular bandages.
Two pairs of suitable, sterilised, latex hand gloves.

Page 176 of 564
SPECIFICATION No.
Bureau of Indian Standards for PPE
IS : 1179 - 1967 Equipment for eye and face protection during welding.
IS : 1989 -1986 (Part - I & III) Leather safety boots and shoes.
IS : 2925 -1984 Industrial Safety Helmets.
IS : 3521 - 1983 Industrial Safety belts and harness.
IS : 3778 -1975 Rubber knee boots.
IS : 4770 -1968 Rubber gloves for electrical purposes.
IS : 5424 - 1969 Rubber mats for electrical purposes.
IS : 5557 -1969 Industrial and Safety rubber knee boots.
IS : 5983 -1978 Eye protectors.
Code of practice for selections, care and repair of Safety

IS : 6519 -1971
footwear.
IS : 6994 -1973 (Part - I) Industrial Safety Gloves.
Guide for selection of industrial safety equipment for

IS : 8519 - 1977
body protection.
Guide for selection of industrial safety equipment for eye,
IS : 8520 - 1977
face and ear protection.
Code of practice for maintenance and care of industrial
IS : 8990 - 1978
safety clothing.
IS : 9167 - 1979 Eye protectors.
Recommendations for the selection, use and

IS : 9623 - 1980
maintenance of respiratory protective devices.
Guide for selection of industrial safety equipment for
IS : 10667 - 1983
protection of fool and leg.
IS : 11226 -1985 Leather Safety footwear having direct moulding sole.

Page 177 of 564
SPECIFICATION No.
HEALTH, SAFETY & ENVIRONMENT MANAGEMENT AT DCU,CPCL Page 84 of 101
CHENNAI
Project: Contractor
Personal Protective Equipment Issue Register
Personal Protective Equipment Signature/

Date of ID Card Inducted
Sl.No Name Discipline Safety Safety Safety Safety Hand Other Thumb Remarks
Issue No on
Helmet Goggles Shoe Harness Gloves PPE Impression

Page 178 of 564
SPECIFICATION No.
AT DCU,CPCL CHENNAI
Personal Protective Equipment & Safety Equipments Stock Register
Date as on: Contractor:

PPE Quantity
Available in Unit Remarks
Items Procured Issued
Stock
Safety Shoes
Size 6 Pair
Size 7 Pair
Size 8 Pair
Size 9 Pair
Size 10 Pair
Gum Boot Pair
Safety Helmet No
Safety Goggles No
Hand Gloves Pair
Ear Muff No
Ear Plug No
Nose Mask No
Full Body Harness No
Fall Arrestor System No
Life Line No
Welders Hood No
Grinder Visor No
Fire Blanket No
Fire Extinguisher No
Caution Tapes Meter
Name of Stores In-charge Name of Safety Manager

Signature Signature
Date Date

Page 179 of 564
SPECIFICATION No.
AT DCU,CPCL CHENNAI
Diesel Generator Set Checklist
Project Contractor
Inspection Date : Inspected By:
Location: DG ID:
DG Rating Output Current
Sl.No Particulars Observations Remarks
1 Whether DG is acoustic type

Does proper access exists for DG &
2
Unauthorized entry restricted
3 Whether body & Neutral is earthed
Condition of control panel
Are the doors lockable?
4 Is the termination of I/C cable done properly
with proper size of lugs?
Are the I/C & O/G terminals fixed and tighten
5 Whether voltmeters, Ammeter are working
6 Whether DG panel has MCCB with proper rating
7 Whether Single Line Diagram displayed
8 Is their any spillage around DG
9 Whether fire extinguishers are provided
CRP chart & Danger sign board displayed in
10
English and local languages
Information such as authorized operator details,
11
nearest first aid kit availability displayed
12 Sound level is within limit
Is the spark arrestor in good condition and fixed
13
properly?
Is the emergency stop push button function
14
properly
15 Current months color coded stickers fixed
Name of Electrical Engineer

Signature
Date

Page 180 of 564
SPECIFICATION No.
AT DCU,CPCL CHENNAI
Excavation Checklist
Project Contractor
Description of work: Dimension of the pit/ trench:
Sl. Day Mon Tue Wed Thu Fri Sat Sun
ITEMS
No Date
A) Before excavation
1 Excavation permit no -
Underground/ overhead facilities present are:
2
3 Underground cable detection done?
Has the exact location of excavation been
4
marked?
Has the operator possess a valid operating
5
license?
6 Whether SPA Prepared and displayed on site
The area to be excavated and hazards are clearly
7
communicated to the operator & the helper?
B) After excavation
Has adequate sloping maintained to prevent soil
8
collapse?
9 Any adjoining structure nearby?
10 Shoring / Sloping required?
Has the excavated pit hard barricaded (if
11
depth>0 6m) else soft barricaded?
12 Warning signs displayed?
Excavated earth stored 1m away from edge of
13
barrication?
14 Vehicle movement restricted?
Access/ egress ladder placed every 15m interval,
15
based on no of workmen?
16 Dewatering required?
Walkovers/ passageway provided at necessary
17
places?
18 Sufficient illumination inside the pit at all times?
Signature
Remarks: ( 3) good / YES, ( X ) Poor / NO. If No, Please indicate in the comments column.
Date: Comments

Page 181 of 564
SPECIFICATION No.
AT DCU,CPCL CHENNAI
Hot Work Activity Checklist

Project Contractor
Description of work: Hot work permit no:

Sl. Day Mon Tue Wed Thu Fri Sat Sun
ITEMS
No Date
The work area has been barricaded and warning
1
signs displayed?
The work area has been made free from
2
combustible/flammable materials?
The sparks / radiation from the hot work have
3
been adequately contained?
Flammable wastes are disposed in a covered
4
container?
Are adequate number of well-maintained fire
extinguishers and fire blankets, provided at each
5
work area and all workers /supervisors in the work
area are aware of its location?
Fire extinguishers regularly inspected and kept at
6
designated places with clear access?
Are fire hydrant system, fire hose and foam
7
system in ready during critical works?
The contractor has been briefed on all the
8
necessary safety requirements?
Appropriate PPE/ protective clothing has been
9
provided for the job?
10 Tools and machineries to be used are inspected?
11 Fire watcher deployed?
Any hazardous work carried out nearby
12
simultaneously?
13 Gas Monitoring required? Yes (Y) No (N)
Are chances of flammable vapour cloud formation
14 at nearby area or likely to occur during the course
of work? eg: Spray painting?
All workers are trained in the use of fire
15 extinguishers, fire fighting procedure and
emergency response?
16 Whether SPA Prepared and Displayed on site?
17 Any other Fire prevention required?
Signature
Note: Fire Watcher to standby 15 mins after work completed
Remarks: ( 3) good / YES, ( X ) Poor / NO. If No, Please indicate in the comments column.
Date: Comments

Page 182 of 564
SPECIFICATION No.
AT DCU,CPCL CHENNAI
ARC WELDING MACHINE CHECKLIST

Project Contractor:
Site supervisor: Welding m/c ID
Date: Location
No Items Observation Remarks
A WELDING SETS
1 Connections are proper and effectively insulated.
2 ON / OFF switch in good working condition?
3 Voltmeter/ Ammeter connected & working properly?
4 Regulator working properly
5 Welding machine completely covered and no loose
connections?
6 Good earthing and grounding.(Double earthing)
7 Wheels freely rotating?
Compatible Fire extinguisher available for the welding set
8
B CABLE AND JOINTS
1 Supply cable's length exceeding 5m?
2 Connection taken through ELCBs?
Welding cables of proper rating and in proper
3
condition without any damages?
4 Connecting lugs tightened properly?
5 Well insulated and no exposed parts?
6 Size of cable used are proportional to voltage supply
Return earth cable of sufficient length? Are electrical
7
conductors prohibited from being used to complete
8 Any overloading, whereby cables become hot?
9 Any contact with oil / sharp edges or water?
Are cables properly placed to prevent tripping
10
hazards?
C ELECTRODE HOLDERS
Electrode holders used are in good working
1
condition?
2 Properly insulated and no exposed metal parts?
Holders are kept dried and properly hung up after use?
3
4 Not in contact with metal parts.

5 Electrodes are detached after welding.
Name of Electrical Manager Name of Safety Manager
Signature Signature
Format No.Page
8-00-0001-F1
183 of 564 Rev. 0
SPECIFICATION No.
AT DCU,CPCL CHENNAI
Gas Cutting Set Checklist

Project Contractor:
Site supervisor: Gas cutting set ID
Date: Location

A GAS CYCLINDERS
Cylinders used are in upright and secured position,
1
tied with chain and used in a trolley?
Cylinders protected from direct fire, sparks or
2
excessive heat?
3 Double pressure gauges in working condition?
Cylinder valves, regulators, hoses are free from
4
oil/grease?
Any leakage observed after doing Soap solution/
5
leakage test?
Cylinders are kept away from live electric cables or
6
ground wires.
Empty and full cylinders are properly separated and
7
marked?
Oxygen and fuel cylinders kept separately in a
8
designated storage shed?
B REGULATORS / HOSES / TORCHES
Regulators and torches are in sound working
1
condition?
Any leakage observed after doing Soap solution/
2
leakage test?
Hoses are free of any tape or wrapping materials
3
used for plugging leaks?
4 Proper connections are used for fastening?
5 All gas hoses are secured with clips at both ends?
6 Are regulators, hoses & fittings free from oil &

grease?
7 Any kinked or tangled hoses?
8 Hoses protected from being run-over?
Are approved flash back arrestors installed at both
9
cylinder and torch ends?
C OTHERS
1 Cylinder keys readily available on cylinder?
2 Proper lighter is used to light the torch?
3 Fire extinguisher & fire blanket readily available?
Name of Safety Manager

Signature
Format No.Page
8-00-0001-F1
184 of 564 Rev. 0
SPECIFICATION No.
AT DCU,CPCL CHENNAI
Grinding Machine Checklist

Project Contractor:
Site supervisor: Machine ID
Date: Location

A GRINDING MACHINE
1 Any physical damages to the machine?
2 RPM punched/ marked?
3 Guard in place?
4 Double insulated body?
5 Proper size spanner/ key in place?
6 Electrical connection done properly?
7 Is Dead man provided with machine and in working
condition?
8 Handles tightly placed?
B GRINDING WHEEL
1 Appropriate selection of abrasive wheel?
2 Within expiry date?
3 RPM, size and type of the wheel marked?
4 Any cracks/ damps observed in the wheel?
5 Properly stored after use?
Grinding and cutting wheel stored & used
6
accordingly?
C CABLES & CONNECTIONS
1 Cable in proper condition without any damages?
2 Cable with plug tops?
3 Connection used through ELCBS?
Cables routed properly without obstructing the
4
passage ways?
Name of Safety Manager
Signature

Page 185 of 564
SPECIFICATION No.
AT DCU,CPCL CHENNAI
Fire Extinguisher Monthly Inspection
Project
Contractor:
Inspected by:
Visual Inspection
Sl.NO Date Identification No. Result Location Date of Refill Date of Expiry
OK NOT OK
Checklist for Inspection

Located in its designated place
No obstruction to access or visibility
Operating instructions on the extinguisher label legible and facing outward
Seals and tamper indicators not broken or missing
Determine fullness by weighing
Examine for obvious physical damage, corrosion, leakage or clogged nozzle
Pressure gauge reading or indicator in the operative range or position.
Comments/Remarks
Name of the Inspector

Signature
Date

Page 186 of 564
SPECIFICATION No.
AT DCU,CPCL CHENNAI

Page 187 of 564
SPECIFICATION No.
CHENNAI
Slings and Lifting Gear Register

Project Contractor
Inspected by: Date: Signature:
Manufacturers Date into service Remarks

Sl.No Type of Sling Type of Gear SWL Diameter Length
Serial Number

Page 188 of 564
SPECIFICATION No.
CHENNAI
Monthly Wire Rope Inspection Report

Project Contractor Inspection for the Month
Inspected by: Date: Signature: Colour Code for Month:
Excess Wear Kinking , Bird-
Diameter 4 Broken 10 random broken
Sl. Manufacturers Location Thimble of 1/3 caging,
SWL Length Wires in 1 wire ropes in one Remarks
No Serial Number of Sling available diameter in Serious
Size Rope Lay lay
outside wires Corrosion

Page 189 of 564
SPECIFICATION No.
CHENNAI
Monthly Synthetic Web Sling Periodic Inspection Report

Project Contractor Inspection for the Month
Inspected by: Date: Signature: Colour Code for Month:
Worn or Slings
Sl. Manufacturers Location Chemical Tears, Snags, Slings Properly
SWL Length Broken Properly Remarks
No Serial Number of Sling Burns Holes or Cuts Stored
Stitches Tagged

Page 190 of 564
SPECIFICATION No.
CHENNAI
Crane Register
Project Contractor
Third Party
Capacity Certificate Date into service Remarks
Sl.No Crane Type Manufacturer Model Year Current Owner
Rating (SWL) Reference
Number
Name of Contractors P& M Manager Name of Contractors Safety Manager

Signature Signature
Date Date

Page 191 of 564
SPECIFICATION No.
CHENNAI

Page 192 of 564
SPECIFICATION No.
AT DCU,CPCL CHENNAI
Mobile Crane Inspection
Date Time
Contractor Make
Owner Operator
Load Rating Registration No
Sl.No Description Observation Hazards Identified Remedial Measure

Condition of wire rope
1
(Visual Inspection)
2 Safety latch
3 Tyres Condition
4 Reverse horn
5 Limit Switch
Operator
6 License
Competency Certificate
7 Certificate from third party

8 Hook Condition
9 SWL Marked
10 Load Chart Displayed
11 Any oil leakage
12 Wind Screen
13 Out Riggers
Name of Contractors P&M Manager Name of Contractors Safety Manager
Signature Signature
Date Date
1.7.7.1

Page 193 of 564
SPECIFICATION No.
AT DCU,CPCL CHENNAI
Pre-Lift Checklist
Project: Date:
Contractor
Lift Description:
Yes No
1. Crane Operator minimum qualification requirements?
2. Lift calculations and rigging plan completed?
3. Are all required approvals/permits signed?
4. Crane inspections up to date (Monthly/Daily)?
5. Weather conditions and wind speed acceptable?
6. Has the stability of the ground been assured?
7. Matting and/or outrigger pads inspected and approved?
8. Electrical equipment and power lines at required distance?
9. Rigging inspected for defects?
10. Connecting/disconnecting means have been developed?
11. Have the safety precautions been reviewed?
12. The total lifted weight is below 95% of crane capacity capacity?
13. Signal person(s) assigned?
14. Safe Plan of Action (SPA) Completed?
15. Pre-Lift Meeting/SPA talk held?
16. Hoist area & load path cleared of non-essential personnel?
17. Crane set up per the lift plan (radius, configuration, etc)?
18. Rigging equipment and tag line(s) installed per plan?

19. Emergency/Contingency plan in place for power failure, plant upset,
power line contact, lifting over operating equipment, etc.
Name of rigging coordinator:
Signature: Date:

Page 194 of 564
SPECIFICATION No.
AT DCU,CPCL CHENNAI
Checklist for Construction Vehicles

Date of Inspection Inspected by
Registration No. Make
Driver Name License type
License No License valid up to
PUC Certificate No and Valid up to RC No and Valid up to
3. Sl.No Description Observation Remarks
1. Operator with valid driving permit

Banks man/Helper available to guide the
2
vehicle in construction area
2 Condition of headlights
Condition of indicators
a) Front indicators
3
b) Rear indicators
c) Side indicators
4 Condition of back lights
5 Condition of side lights
7 wipers in good working condition
8 Condition of side mirrors
9 Reverse horn
11 Are all breaking arrangements satisfactory?
12 Condition of tyres
15 Anchoring points &anchoring accessories
16 Spark arrestor fitted
17 Any fuel leakage
18 Wedges availability as wheel stoppers
19 Fire extinguisher availability
Whether parking brake and brake light in
20
working condition
Name of Contractors RCM Name of Contractors Safety Manager

Signature Signature
Date Date
Format No. 8-00-0001-F1

Page 195 of 564 Rev. 0
SAFETY MEASURES FOR STANDARD No.
alf-ar_Jek ENGINEERS
kVieg INDIA LIMITED ELECTRICAL INSTALLATIONS 7-51-0332 Rev. 2
r222.. ofnok: Unde, tnkir70)
DURING CONSTRUCTION Page 1 of 2
ELECTRICAL POWER IS THE MAINSTAY OF ANY CONSTRUCTION ACTIVITY. AT THE SAME TIME IT REQUIRES
UTMOST CARE IN IT'S UTILISATION TO AVOID ACCIDENTS DUE TO ELECTRICAL SHOCK, FIRE INCIDENTS OR
ELECTRIC SHORT CIRCUITS. EXPOSURE OF ELECTRICAL INSTALLATION TO ADVERSE ENVIRONMENTAL
CONDITIONS INCREASE THE RISK OF SUCH ACCIDENTS. HENCE IT IS NECESSARY TO TAKE EXTRA
PRECAUTIONS FOR SUCH INSTALLATIONS TO ENSURE SAFETY OF PERSONNEL AND EQUIPMENT. THIS
STANDARD ADDRESSES THE SAFETY MEASURES REQUIRED TO BE ADOPTED FOR THE ELECTRICAL
INSTALLATIONS BY ALL CONTRACTORS DURING CONSTRUCTION PHASE.
ALL ELECTRICAL CONNECTIONS/WORK FOR ELECTRICAL INSTALLATIONS SHALL BE CARRIED OUT AS PER
PROVISIONS OF THE LATEST REVISION OF THE FOLLOWING CODES AND STANDARDS IN ADDITION TO THE
REQUIREMENTS OF STATUTORY AUTHORITIES AND IE RULES:
OISDSTD-173 : FIRE PREVENTION AND PROTECTION SYSTEM FOR ELECTRICAL INSTALLATIONS.
SP-30 (BIS) : NATIONAL ELECTRIC CODE.
THE INSTALLATION SHALL HAVE APPROVAL FROM CONCERNED STATUTORY AUTHORITIES.
ALL ELECTRICAL CONNECTIONS SHALL BE DONE BY AN ELECTRICIAN WITH VALID LICENCE AND TO THE
SATISFACTION OF ENGINEERINCHARGE.
ONE COMPETENT LICENCED ELECTRICIAN SHALL BE MADE AVAILABLE BY CONTRACTOR AT SITE ROUND
THE CLOCK TO ATTEND TO THE NORMAL/EMERGENCY JOBS.
ALL SWITCH BOARDS/WELDING MACHINES SHALL BE KEPT IN WELL VENTILATED & COVERED SHED.
THE SHED SHALL BE ELEVATED TO AVOID WATER LOGGING. NO FLAMMABLE MATERIALS SHALL BE
USED FOR CONSTRUCTING THE SHED. ALSO FLAMMABLE MATERIALS SHALL NOT BE STORED IN AND
AROUND ELECTRICAL EQUIPMENT/SWITCHBOARD. ADEQUATE CLEARANCES AND OPERATIONAL SPACE
SHALL BE PROVIDED AROUND THE EQUIPMENT.
FIRE EXTINGUISHERS AND INSULATING MATS SHALL BE PROVIDED IN ALL POWER DISTRIBUTION CENTERS.
TEMPORARY ELECTRICAL EQUIPMENT SHALL NOT BE EMPLOYED IN HAZARDOUS AREAS WITHOUT OBTAINING
SAFETY PERMIT.
PROPER HOUSE KEEPING SHALL BE DONE AROUND THE ELECTRICAL INSTALLATIONS.
ALL TEMPORARY INSTALLATIONS SHALL BE TESTED BEFORE ENERGISING, TO ENSURE PROPER

EARTHING, BONDING, SUITABILITY OF PROTECTION SYSTEM, ADEQUACY OF FEEDERS/CABLES ETC.
ALL WELDERS SHALL USE HAND GLOVES IRRESPECTIVE OF HOLDER VOLTAGE.

MULTILINGUAL (ENGLISH, HINDI AND LOCAL LANGUAGE) CAUTION BOARDS, SHOCK TREATMENT CHARTS
AND INSTRUCTION PLATE CONTAINING LOCATION OF ISOLATION POINT FOR INCOMING SUPPLY, NAME
& TELEPHONE NO. OF CONTACT PERSON IN EMERGENCY SHALL BE PROVIDED IN SUBSTATIONS AND
NEAR ALL DISTRIBUTION BOARDS/LOCAL PANELS.
OPERATION OF EARTH LEAKAGE DEVICE SHALL BE CHECKED REGULARLY BY TEMPORARILY CONNECTING

SERIES TEST LAMP (2 BULBS OF EQUAL RATING CONNECTED IN SERIES) BETWEEN PHASE AND EARTH.
12. THE FOLLOWING DESIGN FEATURES SHALL BE ENSURED FOR ALL ELECTRICAL INSTALLATIONS DURING
CONSTRUCTION PHASE.
12.1 EACH INSTALLATION SHALL HAVE A MAIN SWITCH WITH A PROTECTIVE DEVICE, INSTALLED IN AN
ENCLOSURE ADJACENT TO THE METERING POINT. THE OPERATING HEIGHT OF THE MAIN SWITCH
SHALL NOT EXCEED 1.5 M. THE MAIN SWITCH SHALL BE CONNECTED TO THE POINT OF SUPPLY
BY MEANS OF ARMOURED CABLE.
12.2 THE OUTGOING FEEDERS SHALL BE DOUBLE OR TRIPLE POLE SWITCHES WITH FUSES/MCBs. LOADS
IN A THREE PHASE CIRCUIT SHALL BE BALANCED AS FAR AS POSSIBLE AND LOAD ON NEUTRAL
SHOULD NOT EXCEED 20% OF LOAD IN THE PHASE.
2 02.03.12 REAFFIRMED & ISSUED );t46#14C UAP/JMS DM

1 26.09.06 REVISED & ISSUED AS STANDARAD BP RKS/UAP JMS VC
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Page 196 of 564
Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved
SAFETY MEASURES FOR STANDARD No.
Of=a-ael ENGINEERS
INDIA LIMITED ELECTRICAL INSTALLATIONS 7-51-0332 Rev. 2
015leg, n di o Undertoking;
DURING CONSTRUCTION Page 2 of 2
12.3 THE INSTALLATION SHALL BE ADEQUATELY PROTECTED AGAINST OVERLOAD, SHORT CIRCUIT AND EARTH
LEAKAGE BY THE USE OF SUITABLE PROTECTIVE DEVICES. FUSES WHEREVER USED SHALL BE HRC TYPE.
USE OF REWIRABLE FUSES SHALL BE STRICTLY PROHIBITED. THE EARTH LEAKAGE DEVICE SHALL HAVE
AN OPERATING CURRENT NOT EXCEEDING 30 mA.
12.4 ALL CONNECTIONS TO THE HANDTOOLS/WELDING RECEPTACLES SHALL BE TAKEN THROUGH PROPER
SWITCHES, SOCKETS AND PLUGS.
12.5 ALL SINGLE PHASE SOCKETS SHALL BE MINIMUM 3 PIN TYPE ONLY. ALL UNUSED SOCKETS SHALL BE
PROVIDED WITH SOCKET CAPS.
12.6 ONLY 3 CORE (P+N+E) OVERALL SHEATHED FLEXIBLE CABLES WITH MINIMUM CONDUCTOR SIZE OF
2
1.5 MM COPPER SHALL BE USED FOR ALL HAND TOOLS.
12.7 ONLY METALLIC DISTRIBUTION BOXES WITH DOUBLE EARTHING SHALL BE USED AT SITE. NO WOODEN
BOXES SHALL BE USED.
12.8 ALL POWER CABLES SHALL BE TERMINATED WITH COMPRESSION TYPE CABLE GLANDS.
LUGS SHALL BE USED FOR MULTISTRAND WIRES/CABLES.
12.9 CABLES SHALL BE FREE FROM ANY INSULATION DAMAGE.
12.10 CABLES SHALL BE LAID IN UNDERGROUND AT A MINIMUM DEPTH OF 750 MM, FOR LV & CONTROLS
AND 900MM FOR HV CABLES COVERED WITH SAND, BRICK AND SOIL FOR ENSURING MECHANICAL
PROTECTION. CABLES SHALL NOT BE LAID IN WATER LOGGED AREA AS FAR AS PRACTICABLE
CABLE ROUTE MARKERS SHALL BE PROVIDED AT EVERY 25 M OF BURIED TRENCH ROUTE. WHEN
LAID ABOVE GROUND, CABLES SHALL BE PROPERLY CLEATED OR SUPPORTED ON RIGID POLES OF
ATLEAST 2.1 M HIGH. MINIMUM HEAD CLEARANCE OF 6 METERS SHALL BE PROVIDED AT ROAD CROSSING.
12.11 UNDER GROUND CABLES SHALL NOT BE ALLOWED TO CROSS THE ROADS WITHOUT PIPE SLEEVE
12.12 ALL CABLE JOINTS SHALL BE DONE WITH PROPER JOINTING KIT. NO TAPED/TEMPORARY JOINTS SHALL
BE USED.
12.13 AN INDEPENDENT EARTHING FACILITY SHOULD PREFERABLY BE ESTABLISHED WITHIN THE TEMPORARY
INSTALLATION PREMISES. ALL APPLIANCES AND EQUIPMENT SHALL BE ADEQUATELY EARTHED. IN CASE
ARMOURED CABLES ARE USED, THE ARMOUR SHALL BE BONDED TO THE EARTHING SYSTEM.
12.14 ALL CABLES AND WIRE ROPE USED FOR EARTH CONNECTIONS SHALL BE TERMINATED THROUGH TINNED
COPPER LUGS.
12.15 IN CASE OF LOCAL EARTHING, EARTH ELECTRODES SHALL BE BURIED NEAR THE SUPPLY POINT AND
EARTH CONTINUITY WIRE SHALL BE CONNECTED TO LOCAL EARTH PLATE FOR FURTHER DISTRIBUTION
TO VARIOUS APPLIANCES. ALL INSULATED WIRES FOR EARTH CONNECTION SHALL HAVE INSULATION OF
GREEN COLOUR.
12.16 SEPARATE CORE SHALL BE PROVIDED FOR NEUTRAL. EARTH/STRUCTURES SHALL NOT BE USED AS A
NEUTRAL IN ANY CASE.
12.17 ON/OFF POSITION OF ALL SWITCHES SHALL BE CLEARLY DESIGNATED/PAINTED FOR EASY ISOLATION
IN EMERGENCY.
13. ALL INSULATIONS SHALL BE INSPECTED BY ENGINEERINCHARGE ATLEAST ONCE IN A MONTH.
X--S('S/ 9Th .1
2 02.03.12 REAFFIRMED & ISSUED BP *- - C UAP/J MS DM
1 26.09.06 REVISED & ISSUED AS STANDARD BP RKS/UAP J MS VC
Rev. Prepared Checked Stds. Committee Stds. Bureau
No. by by
Page 197 of 564 Approved by
Format No. 8-00-0001-F4 Rev.0 Copyright EIL - All rights reserved
SPECIFIC PROJECT REQUIREMENTS Part A - Section: III
DISTRIBUTED CONTROL SYSTEM A133-000-16-51-SP-1503 Rev. B
SECTION-III
(SPECIFIC PROJECT REQUIREMENTS)
B 11-03-2014 REVISED & Issued with MR RK NZ AR

Date Purpose
No by by by

Page 198 of 564
1.0 FOREWORD
1.1 Bidder must note the following before filling up the forms enclosed in this section of the MR. Proposal
not accompanying information asked as per this section shall not be evaluated.
2.0 Bidder must ensure the following while quoting:
2.1 The system as offered must meet the proven-ness requirements in accordance with clause no: 4.2.1.2 of
PMC job specification for instrumentation ( 44NC-4600-0000/J.02//0101/A4) attached with MR
without exception and clause 6.0 of this section.
2.2 All activities as offered shall be carried out by agency and from the location which meets the proven-
ness requirements specified in clause 6.0 of this section.
2.3 In addition to clause no. 6.0 of this section, all bought-out items shall also meet the following:-
a) All bought-out items shall be designed, engineered, manufactured, fully assembled, wired and
tested by the manufacturer at their works only.
b) All bought out items/ sub systems shall be fully tested at a manufacturers shop prior to
shipment by manufacturer to vendor works for assembly. All such test reports shall be
submitted to Purchaser for review.
c) All such sub-systems shall also be made available during integrated factory acceptance test at
vendors works.
d) All bought out items (PLC, UPS, Giant Screen/CCTV system etc.) shall be supplied from the
approved vendors as per Approved Vendor List attached with the MR.
2.4 For the bought out items, in case Bidder proposes to carryout activities by any agency other than the
manufacturer then the following requirements shall be complied by the Bidder: -
a) The manufacturer of the item/ subsystem must furnish a certificate for owning full
responsibility of the overall system and its performance.
b) The agency and activity location must meet the requirements specified in pare 6.0 of this
section. The information must be filled up in the PTR format enclosed along with this
requisition.
c) The manufacturer must approve all documents including software documents generated by the
agency (if other than manufacturer).
d) The manufacturers qualified, competent and regular employee must be present during all
technical meetings, system integration, factory acceptance test, system start-up &
commissioning and site acceptance testing.
2.5 Separate PTR form shall be filled for each system being proposed.
3.0 CERTIFICATE FOR LOGISTIC SUPPORT & COMPLIANCE STATEMENT
3.1 Bidder shall furnish a certificate for providing necessary support services. The certificate shall be as
per the format enclosed (Annexure-I) in this section and shall be duly signed by them and their
principal(s).The formats enclosed along with Annexure-1 shall be completed as follows:-

Page 199 of 564
Sht 2 of 5:- To be completed and signed by Bidders principals corporate level signatory. For Bidders
who have their controlling business group corporate office overseas, it must be completed and signed
by their overseas corporate official only.
Sht 3 of 5:- To be completed and signed by Bidders corporate level signatory.
Sht 4 of 5:- To be completed and signed by the corporate level signatory of the bought out items like
PLC, UPS, IAMS, Giant screen, FieldBus components, etc. Bidders who have their controlling
business group corporate office overseas, it must be completed and signed by their overseas corporate
office only.
Sht 5 of 5:- (Performance Guarantee).To be completed and signed by Bidders corporate level
signatory.
3.2 Proposals received without the certificate, or with unsigned/ unstamped certificate, or matter with
revised text, or certificate not on companys letterhead shall not be considered for further evaluation.
3.3 Certificate from sub vendors for systems such as PLC, UPS, IAMS, Giant screen, Field Bus
components, etc. shall also be furnished. The certificates issued by the local agents shall not be
acceptable.
3.4 Bidder shall provide bidders principal recommended antivirus software, software patches to fix bugs
free of cost for the entire warranty period of project.
4.0 RESPONSIBILITY CHART
4.1 Bidder shall fill up the Responsibility Chart (Annexure-II) clearly and unambiguously. Prime
responsible agency shall meet the bidder qualification criteria and Proven Track Record (PTR) outlined
in Para 2 & 6 respectively.
4.2 No shift in the responsibilities shall be entertained at a later date, during the project execution for any
reason what so ever.
5.0 SYSTEM UTILITY DATA
5.1 Power Consumption and UPS Requirement
5.1.1 Bidder must fill complete information in the form enclosed (Annexure-III) including in-rush current,
and its duration for MCR.
5.1.2 Bidder shall also submit the sizing calculation for the UPS system (static type) for MCR necessary for
the offered Distributed Control System including PLC and other items indicated in this MR clearly
indicating its required rating, in-rush current, its duration and any sizing factor over and above the
actual consumption, as to be considered for the offered system. UPS sizing shall include the load
requirements given in this part-B of this MR with specified characteristics.
Additional UPS, if found necessary during detail engineering on account of the equipment in
their scope of supply, from the UPS size provided by the bidder along with their offer, shall be
supplied by bidder without any implication.
5.2 Ventilation and Air Conditioning Requirement

Page 200 of 564
5.2.1 The DCS along with other systems shall be installed in Main Control Room normally maintained at
231C. Bidder must furnish the total ventilation and air-conditioning requirement as per the enclosed
form (Annexure-IV) for MCR.
5.3 Air Quality Requirement
5.3.1 Bidder must fill complete information in the form enclosed (Annexure-V) to indicate the allowable air
quality requirements for the systems i.e. DCS, PLC or any other system as indicated for MCR. In
addition bidder to note that the control room may not have any air quality control. Limitations if any
must be indicated in the same form.
Bidder to note that Chemical filters will be provided in the HVAC system of purchaser to limit the
concentration of contaminants as below:
S02: Less than 0.05 ppm by Volume
NOX: Less than 0.05 NO2 by Volume
H2S: Less than 0.01 ppm
NH3: Less than 0.1 ppm
SPM: Less than 100 micro gram/NM3
CL2: Less than 0.001 ppm by volume
Bidder shall confirm suitability of offered system for the same.
6.0 PROVEN TRACK RECORD
6.1 Bidder shall fill the Proven Track Record (PTR) form enclosed (Annexure-VI) in this section with
information as asked for the system proposed and shall comply with the proven track record
requirement specified in clause no: 4.2.1.2 of PMC job specification for instrumentation ( 44NC-
4600-0000/J.02//0101/A4) attached with MR without exception
6.2 Bidder to note that proven record must be available for the offered console/ controller combination as a
minimum. Accordingly, information must be provided in the form.
6.3 Proposal received without properly filled PTR form not, or incomplete form, or the proposed system/
subsystem(s)/ agency responsible for any activity/ activity location not meeting basic qualification
specified in clause no. 6.4 shall not be evaluated. Activities shall be as defined in Para 8.5 of Proven
Track Record format.
6.4 The system should be supplied, engineered, integrated, tested, etc. from a factory from where the
system/ sub-systems as offered/ supplied have already been supplied, engineered, integrated tested, etc.
6.5 Over and above requirements specified in clause no. 2.3 and 2.4, for system confirming to Safety
Integrity level (SIL) certified by statutory authorities like TUV, etc., the basic engineering of the
system comprising of system configuration diagram, system loading calculation, system scan time
calculation, system network design shall be carried out by the agency on whose name TUV/ SIL
certificate has been issued. Application engineering should be carried out by the agency meeting the
proven-ness requirements as a minimum.
6.6 The system should be supplied by the manufacturer in the fully engineered condition or by the
manufacturers representative/ subsidiary who have proper infrastructural facilities.
Page 201 of 564
ANNEXURE-I
(SECTION-III)
TO DCS MR A133-000-YE-MR-1500
Page 202 of 564

Page 203 of 564
Page 204 of 564
Page 205 of 564
Part A - Section: III
DISTRIBUTED CONTROL SYSTEM
RESID UPGRADATION PROJECT Annexure II to
A133-000-16-51-SP-1503 Rev. A
CHENNAI PETROLEUM CORPORATION LTD
Page 1 of 7
SECTION-III
ANNEXURE II
(RESPONSIBILITY CHART)
B 11-03.2014 Revised & ISSUED with MR RK NZ AR
A 17-01.2014 ISSUED with MR RK NZ AR

Rev.
Date Purpose Prepared by Checked by Approved by
No

Page 206 of 564
A133-000-16-51-SP-1503 Rev. A
Page 2 of 7
NAME OF VENDOR:
NAME OF THE PRINCIPAL:
SL. DESCRIPTION RESPONSIBILITY ACTIVITY REMARKS
NO OWNED BY OWNED BY OWNED BY LOCATION
BIDDER PRINCIPAL SUB
(YES/NO) (YES/NO) VENDOR
(YES/NO)
A SOURCE OF SUPPLY
1 Controller And Data Acquisition Subsystem
i. Processor Modules
ii. I/O Modules
iii. Communication Modules
iv. Power Supply Modules
v. Any Other (Please specify)
2 Operator Console Subsystem And Engineering Console
i. CPU cabinet including Processor Modules,

Memory Modules, Power Supply Modules and
Communication Modules
ii. Keyboards
iii. Monitors
iv. Any Other (Please specify)
3 Hardwired Instruments
i. PB / SS / Lamps
ii. Interposing relays
iii. Signal Isolators

Page 207 of 564
A133-000-16-51-SP-1503 Rev. A
Page 3 of 7

NO iv. Safety Barriers LOCATION
v. Line fault detector
vi. FieldBus junction boxes
vii. FieldBus power supplies
viii. Fieldbus Surge Protector
ix. Any Other (please specify)
4 Programmable Logic Controller (PLC) -ESD
i. Processor Module
ii. I/O Modules
v. Remote I/O Modules
vi. PLC SOE Console
vii. PLC Programming Terminal
viii. Any Other (please specify)
5 Programmable Logic Controller (PLC) F&G
i. Processor Module
ii. I/O Modules
v. Remote I/O Modules
vi. PLC SOE Console
vii. PLC Programming Terminal
Any Other (please specify)

Page 208 of 564
A133-000-16-51-SP-1503 Rev. A
Page 4 of 7

NO LOCATION
6 Printers and Hard copier unit
7 Instrument Asset Management System (IAMS)
8 Hardwired Console, Racks and Other System Racks
9 Documentation Node (DON)
10 Unit History Node (UHN)
11 Giant Screen
12 Alarm Information and Management System (AIMS)
13 OPC Server with Firewall
B SYSTEM ENGINEERING
1 Distributed Control System (DCS)
i. Basic System Design

ii. Detailed System Engineering including finalizing
worksheets
iii. Standard Configuration and Generation
iv. Logging and Report Generation
v. Foreign/ Third Party Device Interface

Page 209 of 564
A133-000-16-51-SP-1503 Rev. A
Page 5 of 7

NO vi. System Software Loading and Debugging LOCATION
vii. Fieldbus engineering including segment design
viii. Any Other (Please specify)
2 Programmable Logic Controller (PLC) - ESD

ii. Detailed System Engineering including Finalizing
Worksheets
v. Foreign Device Interface
vi. Special Software
vii. System Software Loading and Debugging
viii. Any other (please specify)
3 Programmable Logic Controller (PLC) F&G

ii. Detailed System Engineering including Finalizing
Worksheets
v. Foreign Device Interface
vi. Special Software
vii. System Software Loading and Debugging
Any other (please specify)
4 OPC Server with Firewall

Page 210 of 564
A133-000-16-51-SP-1503 Rev. A
Page 6 of 7

NO LOCATION
5 Instrument Asset Management System (IAMS)
7 Unit History Node (UHN)
8 Giant Screen
9 Alarm Information and Management System (AIMS)
C System Integration And Factory Testing
i. Factory Testing of PLC.

ii. Integration of complete system including PLC,
IAMS, OPC server, DON, Giant Screen, AIMS
and DCS.
iii. Integrated Factory acceptance testing
iv. Interface of CCTV with Giant Screen
D Installation, Field Testing & Commissioning
E Training
i. DCS including IAMS, DON, AIMS etc

ii. PLC ESD
iii. PLC F&G

Page 211 of 564
A133-000-16-51-SP-1503 Rev. A
Page 7 of 7

NO LOCATION
F Post Warranty Maintenance Contract for 5 years
i. DCS
ii. PLC ESD
iii. PLC F&G
iv. Instrument Asset Management system (IAMS)
v. Foundation Field Bus interface Devices
vi. Alarm Information and Management System
(AIMS)
vii. Any Other bought out items supplied by bidder
(Please Specify)
G Any Other (Please Specify)
NOTES:
1. Bidder must fill the form completely.
2. Information filled in this form shall be unambiguous and without any qualification.
3. In case vendor does not have any proven record, it must be backed by the collaborator and accompanied by the letter from the collaborator for the back up
guarantee.
4. While filling this format Bidder must ensure that the prime responsibility shall be owned by the original equipment manufacturer of the equipment, while
overall responsibility shall be owned by the bidder.

Page 212 of 564
RESID UPGRADATION PROJECT Annexure III to
A133-000-16-51-SP-1503 Rev. A
Page 1 of 5
SECTION-III
ANNEXURE III
(POWER CONSUMPTION AND UPS REQUIREMENT)
B 11-03-2014 Revised & ISSUED with MR RK NZ AR

A 17-01-2014 ISSUED with MR RK NZ AR
Rev.
No

Page 213 of 564
A133-000-16-51-SP-1503 Rev. A
Page 2 of 5
Sl Item description Unit Total Power factor Inrush current Duration

No consumption Consumption (A) (ms)
(VA) (VA)
Location: MCR
1 DCS Controller/ Controller File
2 DCS Data acquisition I/O Modules

i. Fieldbus Interface Module
ii. 4-20mA
iii. Digital input
iv. Digital Output
v. Serial Interface
vi. Any other Module ( Please specify)
3 DCS Controller & Data Acquisition Cabinet

with maximum loading
4 DCS Marshalling Cabinets
5 DCS Operator console, with electronics &

monitor only
6 DCS Engineering station, with electronics

&monitor only
7a ESD PLC Processors
7b F&G PLC Processors

Page 214 of 564
A133-000-16-51-SP-1503 Rev. A
Page 3 of 5
8a ESD PLC I/O Modules

i. 4-20mA
ii. Digital input
iii. Digital Output
iv. Any other Module (Please specify)
8b F&G PLC I/O Modules

i. 4-20mA
ii. Digital input
iii. Digital Output
iv. Any other Module (Please specify)
9a ESD PLC processor and I/O cabinet with

maximum loading
9b F&G PLC processor and I/O cabinet with

maximum loading
10a ESD PLC Marshalling Cabinets
10b F&G PLC Marshalling Cabinets
11a ESD PLC Engineering Station, with

electronics & TFT only
11b F&G PLC Engineering Station cum Operator

Station, with electronics & TFT only
12a ESD PLC SOE station, with electronics & TFT

only

Page 215 of 564
A133-000-16-51-SP-1503 Rev. A
Page 4 of 5
12b F&G PLC SOE station, with electronics & TFT

only
13 Hardwired consoles, with instruments installed
14 Hard copier unit
15 Multi-purpose color printer
16 Instrument Asset Management System
17 Foreign device interface, if mounted separately

and as applicable
i. Machine Monitoring system
ii. Governor control system
iii. Anti surge control system
iv. Any other ( Please specify)
18 OPC Servers
19 Documentation Node
20 Alarm Information & Management System
21 Network Components
22 Giant Screen
23 CCTV System with detail break up
24 Unit History Node

Page 216 of 564
A133-000-16-51-SP-1503 Rev. A
Page 5 of 5
25 C & M Printer
26 Training Kit
27 Any other ( Please indicate)
TOTAL POWER CONSUMPTION IS _________ VA @ _______ LEAD/ LAG POWER FACTOR

TOTAL IN-RUSH CURRENT IS _____ A FOR A PERIOD OF ______ milliseconds
ACTUAL UPS REQUIREMENT ________ VA UPS SIZING FACTOR (IF APPLICABLE)
UPS SIZE IS _______ VA @ ______ LEAD/LAG POWER FACTOR WITH IN-RUSH CURRENT OF _____ A FOR ____ milliseconds

Page 217 of 564
RESID UPGRADATION PROJECT Annexure IV to
A133-000-YE-SP-1503 Rev. A
Page 1 of 7
SECTION-III
ANNEXURE IV
(VENTILATION & AIR CONDITIONING REQUIREMENTS)

Rev.
No

Page 218 of 564
A133-000-YE-SP-1503 Rev. A
Page 2 of 7
NAME OF VENDOR:
Temp. Limits Humidity Temp. Humidity Operating time

Sl. Unit load Total load limits for Limits for limits for without air-
Item description for operation
No. (kcal/hr) (kcal/hr) operation storage storage conditioning
(oc) (%) (oc) (%) (s)
Location: Main Control Room
Console Area
A DCS Operator console, with electronics & monitor

only
1
Hardwired consoles, with instruments installed
2 Giant Screen
4 CCTV Monitor
5 Printer
TOTAL HEAT LOAD _______________ kCAL/h

(oc) (%) (oc) (%) (s)
B Engineering Room Area
1 DCS Engineering station, with electronics &

monitor only
2 PLC Engineering station, with electronics &
monitor only

Page 219 of 564
A133-000-YE-SP-1503 Rev. A
Page 3 of 7

(oc) (%) (oc) (%) (s)
3 PLC SOE Station
4 Hard Copier Unit
5 Multipurpose printer
6 C&M printer
7 Instrument Asset Management System
8 OPC Servers
10 Alarm Information & Management System
12 CCTV Programming Unit & Printer

Page 220 of 564
A133-000-YE-SP-1503 Rev. A
Page 4 of 7

(oc) (%) (oc) (%) (s)
C Rack Room
1 DCS Controller/ Controller File
2 DCS Data acquisition I/O Modules

i. Fieldbus Interface Module
ii. 4-20mA
iii. Digital input
iv. Digital Output
v. Serial Interface
vi. Any other Module ( Please specify)
3 DCS Controller & Data Acquisition Cabinet

with maximum loading
4 DCS Marshalling Cabinets
5 PLC Processors (ESD)
6 PLC I/O Modules (ESD)

i. 4-20mA
ii. Digital input
iii. Digital Output
iv. Any other Module ( Please specify)
7 PLC processor (ESD) and I/O cabinet with

maximum loading
8 PLC (ESD) Marshalling Cabinets
9 Foreign device interface, if mounted

Page 221 of 564
A133-000-YE-SP-1503 Rev. A
Page 5 of 7

(oc) (%) (oc) (%) (s)
separately and as applicable
i. Machine Monitoring system
ii. Governor control system
iii. Anti surge control system
iv. Wireless Gateway
v. Any other ( Please specify)
10 PLC Processors (F&G)
11 PLC I/O Modules (F&G)

i. 4-20mA
ii. Digital input
iii. Digital Output
iv. Any other Module ( Please specify)
12 PLC processor (F&G) and I/O cabinet with

maximum loading
13 PLC (F&G) Marshalling Cabinets
15 CCTV System
16 DCS Engineering work stations with monitor
17 PLC engineering work stations with monitor
18 SOE PLC PC
19 SOE PLC PRINTER

Page 222 of 564
A133-000-YE-SP-1503 Rev. A
Page 6 of 7

(oc) (%) (oc) (%) (s)
OPC SERVER
20

Total
Sl. Unit load limits for Limits for limits for without air-
Item description load for operation
No. (kcal/hr) operation storage storage conditioning
(kcal/hr) (oc) (%) (oc) (%) (s)
D OPC Server Room
1 OPC server
2 Client PC
3 OPC server Printer
E TRAINING ROOM
1 Training System with break up
2 Operator Work Station

Page 223 of 564
A133-000-YE-SP-1503 Rev. A
Page 7 of 7

Total
Sl. Unit load limits for Limits for limits for without air-
Item description load for operation
No. (kcal/hr) operation storage storage conditioning
(kcal/hr) (oc) (%) (oc) (%) (s)

Page 224 of 564
RESID UPGRADATION PROJECT Annexure V to
A133-000-YE-SP-1503 Rev. A
Page 1 of 2
SECTION-III
ANNEXURE V
(AIR QUALITY REQUIREMENTS)

Rev.
No

Page 225 of 564
RESID UPGRADATION PROJECT Annexure V to
A133-000-YE-SP-1503 Rev. A
Page 2 of 2
NAME OF VENDOR:
SYSTEM: DCS Vendor / Sub Vendor: ..
All consoles including All Disks & Disk
Sl. No Maximum Allowable Concentration of All cabinets All Printers
Keyboards Drives
1 CORROSIVE GASES (in ppm)

i. Hydrogen Sulphide
ii. Sulphur Dioxide
iii. Chlorine
iv. NO/ NO2/ NOx
v. Any Other (Please Specify)
2 i. Maximum Dust concentration (in g/m3)

ii. Dust Particle Size
SYSTEM: PLC Vendor / Sub Vendor: ..

All consoles including All Disks & Disk
Sl. No Maximum Allowable Concentration of All cabinets All Printers
Keyboards Drives
1 CORROSIVE GASES (in ppm)

i. Hydrogen Sulphide
ii. Sulphur Dioxide
iii. Chlorine
iv. NO/ NO2/ NOx
v. Any Other (Please Specify)
2 i. Maximum Dust concentration (in g/m3)

ii. Dust Particle Size

Page 226 of 564
RESID UPGRADATION PROJECT Annexure VI to
A133-000-YE-SP-1503 Rev. A
CPCL LTD
Page 1 of 5
SECTION-III
ANNEXURE VI
(PROVEN TRACK RECORD)

Rev.
No

Page 227 of 564
A133-000-YE-SP-1503 Rev. A
CPCL LTD
Page 2 of 5
Sl. Description As offered for System as installed System as installed System as installed System as installed
No this project @ site 1 @ site 2 @ site 3 @ site 4
1 Name of the Plant
2 Name, Address, Telephone No./ Fax No.

& E-mail of the contact person in the
Plant
3 Name, Address, Telephone No./ Fax No.

& E-mail of the contact person of the
Consultant
4 Month & Year of System Supply
5 Month & Year of System commissioning
6 Any major breakdowns till date
7 If Yes, Cause of Breakdown
8.1 System details & Model No. for

i. DCS system with all operational
and engineering data base
8.2 System Used for:

i. Overall Regulatory Control &
Data Acquisition
ii. Data Acquisition only
iii. Package Units Only
iv. R&D/ Pilot Plant Only

Page 228 of 564
A133-000-YE-SP-1503 Rev. A
CPCL LTD
Page 3 of 5
8.3 Major Subsystems

i. Number of Controller & Data
Acquisition Subsystem offered
ii. Model Number of Controller
modules
iii. Model number of I/O Modules
- Analog
- Digital
iv. Model number of FieldBus
interface cards offered
v. Number of operator Consoles
Model No
vi. Number of Engineering station
Model No.
vii. Independent PLC for ESD along
with Process Interlocks
Make & Model No. of
Processor
Model number of I/O Modules
- Analog
- Digital
Number of PLCs
Remote I/O capability
viii. Independent PLC for Fire Gas
Detection
Make & Model No. of
Processor
Model number of I/O Modules
- Analog
- Digital
Remote I/O capability

Page 229 of 564
A133-000-YE-SP-1503 Rev. A
CPCL LTD
Page 4 of 5
ix. PLC interface with the DCS:

Directly on DCS network as
part of same family
Serial Interface
Hardwired
x. Any other Foreign Device
Interface
PLC
Anti-Surge Controller
Machine monitoring System
Speed Governor System
Wireless Gateway
xi. OPC interface and server model
no. with
a. Offered Architecture
b. Unified Architecture, if
available and offered
xii. Instrument Asset management
System
xiii. Alarm Information &
Management system
xiv. Documentation Node
xv. Giant Screen
8.4 System Details

i. Number of Open Loops for DCS
ii. Number of Closed Loops for DCS
iii. Number of Foundation FieldBus
Segments (Open & Close Loops)
iv. Number of Graphic Pages
v. Number of Historic trends Points

Page 230 of 564
A133-000-YE-SP-1503 Rev. A
CPCL LTD
Page 5 of 5
vi. MIS Reports

vii. Advance Control
viii. Number of Analog inputs for PLC
ix. Number of Digital I/Os for PLC
8.5 Scope of Vendor Responsibility

i. Design & Supply
ii. System Engineering
iii. Installation
iv. Testing
v. Commissioning
vi. Training
8.6 Salient Features of the offered System over

the earlier installed

Page 231 of 564
PROJECT SPECIFICATION Part A - Section: IV
CPCL , CHENNAI Page 1 of 2
SECTION-IV
(PROJECT SPECIFICATION)
B 11-03-2014 Revised & Issued with MR RK NZ AR

Rev. Prepared Approved
Date Purpose Checked by
No by by

Page 232 of 564
PROJECT SPECIFICATION Part A - Section: IV
TABLE OF CONTENTS
S. DESCRIPTION DOCUMENT No. No of Sheets

No.
1 PROJECT INFORMATION A133-000-16-51-SP-1507 4
2 SPECIAL INSTRUCTIONS TO VENDOR A133-000-16-51-SIV-1500 25
3 ADDITIONAL REQUIREMENTS OF DCS / ANNEXURE-A 22

PLC SYSTEM
4 SPECIFICATIONS FOR F&G SYSTEM ANNEXURE-B 12
5 TAGGING PHILOSOPHY FOR JUNCTION ANNEXURE-C 7

BOXES, PANELS AND CABLES
6 CABLES AND JUNCTION BOX ANNEXURE-D 3

REQUIREMENTS
7 PMC JOB SPECIFICATIONS 44NC-4600- 32

(INSTRUMENTATION) 0000/J.02/0101/A4
8 INSTRUMENT CABLE DUCT 20

44NC-4600-0000/JSD/0004
FABRICATION DRAWING

Page 233 of 564
PROJECT INFORMATION Part A - Section: IV
RESID UPGRATION PROJECT A133-000-16-51-SP-1507 Rev. A
SECTION-IV
(PROJECT INFORMATION)

No by by
1.0 INTRODUCTION

Page 234 of 564
1.1 The offer shall be compiled in line with Section VI Vendors Proposal Outline.
1.2 Definitions
The following definitions shall apply for this document:
OWNER : Chennai Petroleum Corporation Limited (CPCL)
PMC : Jacobs Engineering India Limited
SITE : CPCL Refinery, Manali
Manali, Tamil Nadu, India
2.0 Plant Description:

2.1 Chennai Petroleum Corporation Limited (CPCL), formerly known as Madras Refineries Limited
(MRL), was formed as a joint venture in 1965 between Government of India (GOI), AMOCO and
National Iranian Oil Company (NIOC). In 1985, AMOCO disinvested in favour of GOI. As a part of
restructuring steps taken by Government of India, Indian Oil Corporation Limited acquired equity
from GOI in 2000-2001. In view, CPCL becomes subsidiary of IOCL IN 2001. The Coker Block
consisting of Delayed Coker and LPG-CFC treating unit is being executed by Engineers India Limited
on Lump sum Turnkey (LSTK) basis.
2.2 This Material Requisition (MR) consists of three parts as below:
Part-A: Distributed Control System and Emergency Shutdown Systems, Fire and Gas Systems Safety
Instrumented System
Part-B: UPS system
Part-C: CCTV system
The system described in the requisition shall be latest state-of art microprocessor based technology for
control and data- acquisition system. The System shall permit control and data acquisition functions
with interface for various packages defined below in this section.
2.3 The various Unit covered under this MR are as defined below:
2.3.1 Process Units consisting of :
a) Delayed Coker Unit - Unit no: 086
b) LPG-CFC Unit - Unit no: 087
c) Instrument Air Compressor Package Unit Unir no: During detail engg.
d) Cooling Water System Package Unit Unit no: During Detail engg
2.4 Dedicated monitoring/ control systems which are provided for some units, packages by respective
contractor / package vendor are as follows. Interface with those shall be provided with DCU Main
Control Room as defined in the MR.
Sr. Unit/ Package Type of Type of Connection TO DCS

No. Monitoring/ Interface with FROM
Control System DCS
1. Coke Decoking Package PLC based Serial Serial

Page 235 of 564
System
2. Coke Un-heading Package PLC based Serial Serial
System
2.5 The plant area is generally electrically hazardous and following philosophy has been followed for
instrumentation system design. Generally intrinsic Safety type of protection is adopted for all analog
inputs (4-20 mA DC) from field, analog outputs (4-20 mA DC) to field, limit switches and solenoid
valves. Flameproof or other protection for hazardous area has been selected for MCC interface and
where intrinsically safe instruments are not available. For fieldbus devices, refer special instruction to
vendor.
The filed hazardous areas is instruments are suitable for the Zone-1 , Gas Group IIA/IIB and
Temperature : T3 and in special cases few instruments in IIC ( The list of instruments in IIC areas)
will be furnished during detail engineering.
All field equipments have the approval of local statutory authority i.e. Petroleum Explosives Safety
Organisation (PESO) / Chief Controller of Explosives (CCE), Nagpur. Accordingly all associated
equipment requiring certification e.g. barriers etc. supplied by Bidder shall also have the valid
approval from local statutory authority i.e. PESO/ CCE.
2.6 Control Room Concept
2.6.1 All the process units and package units specified shall be controlled and/ or monitored from the MCR.
This shall provide total plant information to the plant operators and Plant managers simultaneously at
one locationy
Sr. No Control Room Process/ Utility Unit
1. Main Control Room (MCR) Delayed Coke Unit and Heater Packages
LPG-CFC Unit
Instrument Air Compressor Package Unit
Cooling Water System Package Unit
2.6.2 Then approximate cable distance between process units and Main Control Room are as given below.
Approx.
distance from
Unit/ Area TRAINS/UNITS/SYSTEM respective
units to MCR
(Meters)
Delayed Coker Unit Unit No: 086 550
Composition analyzer in DC Unit No: 086 500
Heater Package Unit No: 086 700
Analyser Shelter in Heater Pkg. Unit No: 086 800
LPG-CFC Unit Unit No: 087 350
Instrument Air Compressor 1250

Page 236 of 564
Package
Cooling Water System Package 1250
2.7 Site location

Plant location : Manali, Chennai.
State : Tamil Nadu.
Nearest Railway Station : Chennai.
Nearest Airport : Chennai.
Nearest State Highway : NH- 214
2.8 Site conditions
Ambient Conditions: The site environmental conditions are as follows:
Maximum ambient temperature : 47 C
Minimum ambient temperature : 12 C
Relative humidity : 89% (max)
Maximum recoded rainfall : 220.9 mm in 24 hour.
3.0 Other Operation requirements
3.1 The DCS shall be primary platform for gathering operational data for Plant Information System
Computers.
3.2 The plant operators shall run the plant through operator consoles consisting of Mouse, Touch screen
& Trackball, high resolution TFTs and keyboards. All screens and keyboards shall be of the same
design and shall enable operator to view the process, controller outputs, shutdown status, and to
manipulate parameters to control the plant.
3.3 The overall control system shall be structured to function in an integrated fashion, comprising of
regulatory control and advanced control. The regulatory control level shall form the foundation for the
overall system with the advanced control level added above the regulatory control. The regulatory
level shall be capable of functioning without the advanced control.
3.4 The specifications / requirements shall be met for DCS / PLC / SOE / IAMS / AIMS / Giant Screen /
CCTV and associated hardware / software unless specifically stated otherwise. Any specific licensor
requirements shall be met as stated elsewhere.

Page 237 of 564
SPECIAL INSTRUCTIONS TO Part A - Section: IV
VENDOR A133-000-16-51-SIV-1500 Rev. B
SECTION-IV
(SPECIAL INSTRUCTIONS TO VENDOR)
B 11-03-2014 REVISED & ISSUED with MR RK NZ AR

No by by

Page 238 of 564
VENDOR A133-000-16-51-SIV-1500 Rev. B
1.0 General
1.1 Bidder shall read this Special Instruction to Vendor (SIV) in conjunction with PMC job
specifications(44NC-4600-0000/J.02/0101/A4), Annexure-A (Additional requirements for DCS/PLC) ,
Annexure-B(Specification for fire and gas system), Standard Specification for DCS 44NC-4600-
0000/J.SS/0102/A4),Standard Specification for Programmable Logic Controllers( 44NC-4600-
0000/J.SS/0103/A4) other specifications attached with MR.
1.2 Bidder shall note that in the PMC/Owner specification attached with MR, wherever, it is mentioned as
Contractor, the same shall be replaced and considered as Bidder ( DCS Vendor) for complying to the
requirements specified in the documents.
1.3 All the instruments/equipments/items shall be procured from the approved vendor list attached with
MR without exception. For any specific item/instrument , not in approved vendor list in the MR, bidder
shall obtain prior approval from Purchaser before ordering.
1.4 Bidder shall note that pre-bid meeting clarifications necessitate the revision of MR( wherever required)
had been considered in the revised MR. Bidder shall refer the revised MR for the scope and detail
specifications and pre-bid clarifications resolution and shall comply in accordance with revised MR
specifications.
1.5 Bidder shall be responsible for the submission of all the applicable statutory certification for all the
instrumentations items including the certification from PESO/CCOE as applicable.
1.6 Bidder shall be fully responsible to comply with the total scope of work indicated in this MR on turnkey
basis and meeting all functional requirements specified in this requisition through hardware and
software during detail engineering. Bidder shall be fully responsible for the Bill of Material submitted
by them.
Bidder shall note that evaluation shall be carried out on the bottom line (lump sum) basis of complete
DCS system including UPS and CCTV system.
Bidder shall be fully responsible for proper engineering, integration, installation, performance and
operation of all equipments including I/O and marshalling racks and bought out items supplied by
them as per the requirement.
Further the following are bidders scope/ responsibility:
a) All Serial interface cables/ connectors from purchasers supplied system located within MCR shall
be in DCS vendor scope.
b) All fibre optic cables , convertors and connectors with HDPE conduits for Serial communication
between analyzer shelter to MCR shall be in DCS vendors scope
c) Spares as specified in this MR
d) Bidder shall be responsible to involve sub-vendors of major items like Giant Screen, AIMS, DON,
UPS, CCTV for all engineering, engineering reviews, system definitions and software definition
meeting, drawing/ document review meetings without any exception as per responsibility chart..
1.7 In case of conflict, SIV and its attachments shall override in general, however it shall be obligatory on
the bidder part to bring to the notice of the Purchaser all such conflicts, wherein the purchases
decision shall be final. However, in case of conflict with respect to specifications and any other
engineering requirement or legal regulation, bidder shall consider the most stringent requirement by
default while selecting the DCS and PLC.
1.8 System Modification/ Change Management :
Page 239 of 564
VENDOR A133-000-16-51-SIV-1500 Rev. B
Refer to Annexure-A - Additional requirements for DCS/PLC system attached with MR. The
changes/modification specified in the above referred document in clause no: 1.3 shall be carried out
by vendor without any time and cost implications as long as the I/O quantities specified in the I/O
summary table including installed spares does not increase.
1.9 Bidder to note that purchaser reserve the right to associate their personnel at any or all stages of
project execution. Further, Bidder shall not proceed without getting prior approval from
purchaser/Owner/PMC for the documents required to be approved under Vendor Data Requirement.
1.10 Bidder is required to get prior approval from Purchaser, in case he plans to sub-contract a part of
their site activities job to any other Vendor.
1.11 The handling and storage of the equipment at site shall be Bidders responsibility for all equipments
supplied by them. No ware house shall be provided for storage of system at site and only open
space shall be provided. Bidder shall be responsible for the storage of bidder supplied
equipments/items including bought-out items at their risk and cost. The open storage space
requirement shall be intimated by vendor during detail engineering. The delivery schedule of
complete system shall be in accordance with time schedule and requirements specified in
commercial section.
1.12 Loop checking : Shall be carried out by DCS vendor in accordance with requirement specified in
Annexure-A( Additional requirements for DCS/PLC system), PMC job specifications(44NC-4600-
0000/J.02/0101/A4) and standard specifications.
1.13 Bidder shall note that exceptions to PMC job specifications(44NC-4600-0000/J.02/0101/A4),
Annexure-A (Additional requirements for DCS/PLC system) , Annexure-B (specification for fire and
gas system) which are not applicable for the MR are deleted in the respective specifications. Other
requirements specified and considered in above referred documents and attached with MR shall be
mandatorily complied by bidder.
1.14 P&IDs and other licensor documents will be given to the successful bidder after order, which will be
used for preparing functional schematics, network/ segment diagrams, graphic diagrams etc. Vendor
shall be required to sign confidentiality and secrecy agreements for non disclosure and limited use of
licensor documents/information.
1.15 Power Supply
1.15.1 110V AC UPS power supply voltage shall be used for DCS/PLC and F&GS system.
The UPS for F&GS system shall be dedicated and separate from UPS of DCS/PLC system. For
specification, quantities load, rating and other details refer to Part-B UPS system.
The duration after main power supply failure shall be 60 mins for DCS/ESD UPS system and 48
Hours for F&GS UPS system.
In addition to Part-B( UPS specifications), bidder shall also refer to refer to PMC job
specifications(44NC-4600-0000/J.02/0101/A4), Annexure-A ( Additional requirements for DCS/PLC
system)
1.15.2 All types of power supply distribution ( UPS and Non-UPS) to DCS and Non-DCS equipments and
purchasers free issued items within control room shall be in DCS vendors scope . The supply of all
Power supply cables, cables glands, cable lugs including installation , glanding and termination and
testing at both ends for distribution of power supply from UPS ACDB to bidder supplied PDB to all

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bidder supplied equipments and to purchasers free issued equipments within DCU Main Control
Room shall be in scope of bidder only.
1.15.3 All power distribution from UPS ACDB to field instruments shall be through isolation transformer.
1.15.4 110 V AC UPS
a) The feeders from UPS ACDB including the spare feeders shall be provided as per
requirements specified in Part-B
b) The Non-DCS feeders/load shall be provided as per list in (Annexure VIII Section V)
attached with MR. 20% or minimum one no. spare feeder shall be provided by the bidder for
each feeder rating over and above specified in Annexure VIII. The actual number of feeders
and feeder rating shall be finalized during detail engineering and bidder shall supply the same
without any time and cost implications.
c) The UPS for DCS/PLC and F&GS system shall be sized and provided by DCS vendor. The
power supply feeders from UPS ACDB ( DCS PLC and F&GS) to power supply distribution
cabinets shall be provided as per DCS vendor requirements.
1.15.5 230V AC
a) The 230 V AC power supply shall be used for cabinet lighting and for utility socket. The
distribution shall be as per drawing no A133-000-16-51-3102 attached with MR. Bidder shall
furnish the 230VAC consumption requirements with break up along with offer.
b) Owner shall provide incoming power supply cable for 230VAC at a single point in the DCS
Power Distribution cabinet, which will be glanded and terminated by DCS vendor. The exact
size of the cable shall be provided during detailed engineering. Further distribution from PDB
including supply and installation of feeders, cables, glands, cable lugs, glanding and
termination at both ends shall be in the scope of DCS vendor.
1.15.6 Bulk Power Supply (BPS)
a) Power supply distribution other than 110V AC shall be provided using dual redundant Bulk
Power supply (BPS) by bidder. Such redundant BPS shall be fed from two separate AC
feeders. For other details, refer to Annexure-A, ( Additional requirements for DCS/PLC
system) and other specification attached.
b) The power supply 24VDC with feeders list for purchasers use shall be provided as per
Annexure-IX attached with MR
c) Separate sets of BPS shall be used for each application i.e DCS controller and data
acquisition sub-system, PLC sub system, field bus instrumentation and HART
instrumentation/input interrogation as minimum and shall be housed in respective controller
system marshalling cabinets.
2.0 SPECIFIC REQUIREMENTS FOR DCS/PLC:
2.1 Foundation Fieldbus system is considered for monitoring open loops in non-critical applications. For,
the transmitters in critical open loops, closed loops and inputs for PLC shall be based on SMART type
with HART protocol . The PLC system shall be SIL 3 , TUV certified with Triple Modular Redundant
(TMR) with hot stand-by without I/O or QMR (Quad Modular Redundant) with hot stand-by with I/O
configuration for ESD system & F&GS system. The DCS/PLC for each unit shall be sized
considering I/Os and other sizing requirements like scan time, CPU loading etc as per MR. The sizing

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calculations shall be reviewed during detail engineering. Bidder shall be fully responsible to supply
additional number of DCS/PLCs controllers as required meeting above requirements and approved
sizing calculations without any implications. The PLC scan time shall be 250 msec. The resolution
time for SOE shall be same as PLC scan time ( i.e 250 msec)
2.2 The following redundancy philosophy shall be considered as minimum for the DCS / PLC and F&GS
system.
Controller sub-system : 1:1 redundant
Data Acquisition sub-system : 1:1 redundant
Communication sub-system : 1:1 redundant
Power Supply : 1 : 1 redundant
Closed Loops : 1 : 1 redundant
FF loops : 1 : 1 redundant
Critical Open loops : 1 : 1 redundant
The processor loading shall be 60% ( with 20% installed spares, future space, Advanced Process
Control, spare tags, foreign devices). The communication bus loading shall not exceed 60%. All sub-
system components of DCS and PLC including processors, communication, I/O and power supply
modules and all hardware modules shall be of latest proven version only. DCS and PLC shall have
software wizards to effectively manage the process of decommissioning the failed devices,
commission the replacement device and reconcile the configuration.
2.3 Programmable Logic Controller (PLC)
2.3.1 The PLC controller subsystem and engineering work station , Sequence Of Events ( SOE) PC,
Printers and other accessories for PLC system shall comply with the requirements specified in PMC
job specifications(44NC-4600-0000/J.02/0101/A4), additional requirements for DCS/PLC system
attached as Annexure-A to this document, specification for fire and gas system attached as Annexure-
B to this document , Standard Specification for DCS 44NC-4600-0000/J.SS/0102/A4),Standard
Specification for Programmable Logic Controllers( 44NC-4600-0000/J.SS/0103/A4) without
exception.
2.3.2 The PLC system shall be of Triple Modular Redundant ( TMR) or Qudruplicated Modular Redundant (
QMR) configuration , SIL-3 TUV certified as minimum. Wiring inputs and outputs to the PLC system
shall be as per the OEM recommended philosophy. The PLC FTA shall be from the OEM and shall be
as per the TUV certificate. Any I/O multiplication hardware required for wiring of the field inputs to PLC
I/O module as per standard architecture of the PLC shall be TUV certified meeting the requirements of
SIL-3 as specified. The resolution time for SOE shall be same as PLC scan time ( i.e 250 msec) ( i.e
maximum resolution between two events shall not exceed the PLC scan time).
2.3.3 Vendor shall clearly list out the type of online changes/modifications which are possible in their PLC
system with complete details and examples. The vendor shall clearly specify if there are cases where
replacement of a component can lead to a complete PLC stop, de-energising of out puts or any loss
of functionality etc.
2.3.4 The system shall have an automatic and on demand data protection scheme for the preservation of all
data during planned or unplanned outage. The entire control software shall be backed up including
vendor software, control data base , user built programs, source code and data files. Logic diagram
shall only be used for PLC programming and ladder diagrams are not acceptable.
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2.3.5 The PLC system shall be designed/selected such that it should be possible to make online changes
to the trip settings for analogue inputs, setting of timers and selection of normally open or normally
closed configuration for digital I/O etc. in the ESD PLC. The relays shall be low power continuously
rated type and shall have LED for status.
2.4 Fire& Gas Detection System (F&G)
2.4.1 One common fully integrated PLC based Fire& Gas Detection system is envisaged for the project
facilities for the monitoring, interlock/ shutdown of F&G related field inputs/outputs namely Gas
Detectors, Fire Detectors, Manual Call Points, Linear Detector, Fusible loops, transmitters, switches,
deluge system in accordance with system configuration document ( Doc. No: A133-086-16-51-MD08
sheet 3 of 4) and Annexure-B (Specification for fire and gas system ) other specifications attached
with MR.
2.4.2 Redundant Ethernet communication interface shall be provided for interface with DCS and
redundant MODBUS serial interface shall be provided for interface with Data Gathering Fire alarm
Panel (DGFAP) ( soft addressable type) . Remote monitoring facility at fire station ( with HMI) shall
be provided with all required software and hardware. The remote monitoring station at fire station
shall be interface through OPC server located at Main Control Room. The supply of OPC server with
firewall at DCU main control room, network switches, fiber optic converter/ LIU at DCU main control
room and at fire station shall be in the scope of bidder. The fiber optic cables for remote monitoring at
fire station shall be supplied and installed by others. Bidder shall be responsible for the seamless
interface of data/communication between OPC server and remote monitoring station at fire station.
2.4.3 The DGFAP system consisting of smoke and fire detectors( building areas) , manual call points(
building),shall be connected to a dedicated fire alarm panel DGFAP (located at Control Rooms). The
Data Gathering Fire Alarm Panel (DGFAP), smoke and fire detectors, manual call points and its
interconnecting cables shall be supplied and installed by purchaser. However, the DGFAP shall have
hardwired and serial communication with DCS.
2.4.4 The supply and installation of field devices for fire and gas system (gas detectors, fire detectors,
manual call points, siren, hooters etc)are not in the scope of bidder.
2.5 Touch Screen:
a) The Touch screen facility provided for the work station as specified in PMC job specification
44NC-4600-0000/J.02/0101/A4 shall operate only when finger (or any other device) touching
the screen target is withdrawn. It should not operate on mere touching. Touch screen shall be
provided with Disabling & Enabling function.
b) No special or specific configuration should be necessary for displays while using touch
screen.
2.6 Fieldbus Requirements
2.6.1 Fieldbus system ,segment design, barrier assemblies . junction boxes, power supply shall be
designed and implemented in accordance with Foundation Field Bus Design Criteria ( Doc no: A133-
086-16-51-FFS01) attached as Annexure-X with this MR. Bidder scope includes supply of field bus
junction boxes and its accessories like barrier assemblies, terminators, short circuit protectors,
terminals, surge protectors etc and supervision of installation of field bus junction boxes during
installation activities. In addition to above, the following requirements shall be complied by vendor.:

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The FF junction boxes shall have dual compartment. One separate compartment for isolating
power supply and other for field barriers, surge protectors and terminals etc. FBJB shall be
provided with DIN rails for mounting of field barrier assemblies. Adequate space shall be
provided in the FBJB for termination of all cables and mounting of field barrier assemblies,
short circuit protectors, terminators etc, FBJB shall be mounted vertically. Each FBJB shall
have a data pocket & ground stud. For more than one field barrier assembly in a FBJB, built in
terminator of any field barrier assembly shall not be used to allow isolation of faulty field
barrier assembly without affecting other field barrier assembly in the segment. Bidder shall
provide Fieldbus terminator for each segment inside junction box.
Field barriers assemblies shall have integral short circuit protectors. Adequate space shall be
provided in the FBJB for termination of all cables and mounting of field barrier assemblies,
short circuit protectors, terminators etc. The type of protection of FBJB shall be as per
foundation field bus design criteria ( Doc. No: A133-086-16-51-FF-S01) and material shall be
LM-6 alloy material as minimum.
10% spare field bus junction boxes with field barriers , power supply including all its
accessories over and above the quantities required as per I/O summary table shall be
supplied as loose items.
Integral short circuit protection for each spur (short circuit current <= 45 mA).
Each segment shall be provided with dedicated redundant field bus power supply with over
current protection. FFPS shall be powered from the primary and secondary ( redundant) bulk
power supply. Minimum 28VDC, 500mA shall be available at output of FFPS. Foundation field
bus power supply used in trunks shall be hot swappable. Over current protection shall be
provided for feed to FFPS.
Foundation Field bus Power Supply ( FFPS) with diagnostic module shall be provided by
vendor meeting the specification requirements .Failure or faults in diagnostic module shall be
annunciated in DCS. Vendor shall supply Advanced Diagnostic Module in FFPS motherboard.
The quantities of advanced diagnostic module in FFPS shall be minimum 5 Nos. All FFPS
mother board shall have provision for connecting the advanced diagnostic module which will
be used during commissioning.
The advanced diagnostic module shall have functionalities like comprehensive diagnostics for
the field bus physical layers and power supplies, provide details of exact segment and field
device data, each diagnostic module shall be suitable for providing the diagnostics data for at-
least four numbers of segments concurrently.
Bidder shall supply standard engineering special tools kit from reputed make consisting of 1
number of field bus monitor, 2 nos field bus tester, LAN tester as loose supply items.
Serial number, tag name and process use description shall be configured for each device. All
field devices shall be checked with EDDL compliance or FDT/DTM compliance. Accordingly,
suitable software shall be loaded at device level and HOST field bus maintenance system.
Bidder scope includes the supply of trunk junction box (L2) for 12 spur connections ( 9
installed + 3 spares) as per Foundation Field Bus Design Criteria ( Doc. No: A133-086-16-51-
FF-S01 page no: 15/15) attached as Annexure-X attached with MR. The material specification

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and type of protection of trunk junction boxes shall be same as FBJB. The number of junction
boxes shall be finalized based on field bus segments indicated in I/O summary.
2.6.2 Fieldbus Networking
a) Bidders scope includes supply and installation of H1 cards, Foundation Fieldbus Power
supplies (FFPS) with standard diagnostic module and surge protector in marshalling rack in
the control room. Field bus segment , network , macro cycle and other technical /functional
requirements shall be designed in accordance with requirements specified in Foundation
Field Bus Design Criteria ( Doc no: A133-086-16-51-FFS01) attached as Annexure-X .
b) Circuit analysis shall be done by bidder using validation tools for each segment to determine
operating voltage at each field barrier.
c) Redundant H1 interface card shall be provided for segments in the DCS system. Each
segment shall be independently connected to H1 card.
d) Bidders segment design will be reviewed by Purchaser/Owner/PMC and changes, if required,
shall be incorporated by bidder without any implications
e) During the pre-commissioning checks, if any segment has to be modified, this shall be done
without any cost and time implication. Accordingly the field bus segments and FFJB drawings
shall be revised.
2.7 Integrated Asset Management System (IAMS)
2.7.1 IAMS System shall be provided by bidder in accordance with PMC job specifications(44NC-4600-
0000/J.02/0101/A4), Annexure-A ( Additional requirements for DCS/PLC system), Standard
Specification for DCS 44NC-4600-0000/J.SS/0102/A4) and system configuration attached with MR.
2.7.2 IAMS system shall be provided for all ( SMART and Field bus) for all analog input signals to DCS and
PLC. IAMS shall also applicable for F&G system PLC inputs. In case bidder can supply IAMS and
HART configuration system as an integrated system in single PC/work station complying to all the
specification requirements, the other PC/ workstation shall be supplied as loose supplied spares and
installed in the control room as per system configuration diagram.
2.7.3 For PLC analog inputs , HART pass through card shall be provided if available as a standard form
from the PLC manufacturer. Only, if HART pass through card is not available as standard form from
the PLC manufacturer, then vendor shall provide necessary HART multiplexer, as required, for
commissioning to IAMS. The barriers to be provided by DCS vendor shall be suitable for both analog
as well as HART output. The barriers to be provided for PLCs with non-HART pass through analog
input cards shall be single input dual output barriers with one of the outputs suitable for HART.
2.7.4 The IAMS shall be tested and commissioned during pre-commissioning of DCS so that the same shall
be made available during loop checking and pre-commissioning. Vendor shall assist purchaser to
obtain the initial valve signature, diagnostics of all field devices( FF and HART) etc. during loop
checking/pre-commissioning stage itself. Vendor shall co-ordinate with purchasers instrument field
contractor for smooth pre-commissioning and commissioning activities.
2.8 Unit History Node (UHN)
2.8.1 UHN shall be a RTIMS (also called as Real Time Information Management system) shall be
considered and provided in accordance with PMC job specifications(44NC-4600-0000/J.02/0101/A4),
additional requirements for DCS/PLC system, Annexure-A ( Additional requirements for DCS/PLC

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system) and Standard Specification for DCS 44NC-4600-0000/J.SS/0102/A4) and system

configuration attached with MR.
2.8.2 UHN shall be web-based and shall be provided with min. 5 nos. client software license.
2.9 Giant Screen and its interface with DCS
2.9.1 The giant screen shall be provided in the control room wall. The size of the giant screen cube shall be
70( inch) as minimum. These large screens shall be interface with DCS system and CCTV system.
The giant screen shall be based on single chip DLP technology and the configuration of the giant
screen shall be two numbers each with 2x2 cubes configuration. The minimum operational time of
lamp shall be 8000 hours. Supply of giant screen with controller , server grade PC and all types of
interconnecting cables and its interface with DCS and CCTV system and integration/interface testing
during FAT shall be in the scope of DCS vendor. The giant screen shall be supplied from the following
approved vendors
(i) M/s Barco
(ii M/s Delta
(ii) M/s Planner
For details and other specifications, refer to PMC job specifications(44NC-4600-0000/J.02/0101/A4),
Annexure-A (Additional requirements for DCS/PLC system ), Standard Specification for DCS 44NC-
4600-0000/J.SS/0102/A4) and system configuration attached with MR
2.10 Documentation Node (DON)
2.10.1 Bidder shall be responsible to provide completely engineered documentation nodes including
necessary hardware and software to meet the requirements in accordance with PMC job
system) Standard Specification for DCS 44NC-4600-0000/J.SS/0102/A4) and system configuration
attached with MR.
2.10.2 Purchasers documents shall be provided in INTOOLS (SPI) soft file for the instrument index,
instruments data sheets and other documents like drawings, cable schedule , bill of materials etc in
the formats like autocad, excel, pdf, which shall be informed during detail engineering. The DON node
shall be suitable for uploading/downloading the purchasers data in these formats and meeting the
DON functionalities specified in the MR.
2.10.3 Vendor shall be responsible for the complete application engineering of documentation node including
for packages items. Any modifications or revision necessary because of as-built documentation shall
be carried out by vendor without any implications.
2.11 Open System Connectivity (OPC interface)
2.11.1 OPC server shall be server grade with full OPC functionality in accordance with PMC job
system) Standard Specification for DCS 44NC-4600-0000/J.SS/0102/A4) and system configuration
attached with MR
2.12 Alarm Information Management System( AIMS)
2.12.1 Apart from alarm handling requirements specified for DCS as per standard specification for
DCS44NC-4600-0000/J.SS/0102/A4)), bidder shall provide Alarm Information and Management
System in accordance with clause no: 8.0 additional requirements for DCS/PLC system attached as
Annexure-A attached with MR. AIMS software shall be loaded in Unit History Node ( UHN). In case
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supplier has proven software available as part of DCS, they must have proven reference of running
satisfactorily for a period of 4000 hours along with user certificate of satisfactory performance. In
case bidder is offering exclusive servers for AIMS (server grade) meeting the functional specifications
requirements the same shall be supplied and installed as a separate server along with printers.
2.13 Communication Sub-system
2.13.1 The communication subsystem shall be designed and supplied and installed in accordance with PMC
job specifications(44NC-4600-0000/J.02/0101/A4), Annexure-A ( Additional requirements for
DCS/PLC system), Annexure-B (Specification for fire and gas system attached), Standard
Specification for DCS 44NC-4600-0000/J.SS/0102/A4) and system configuration attached with MR.
2.14 Foreign Device Interface Sub-system
a) For ESD- PLC interface with DCS shall be through separate gateway(redundant) controller.
The DCS and PLC shall preferably be of the same make and family enabling bi-
directional communication through the common communication bus. In case, the PLC system
is not of the same make/ family as that of the DCS, then vendor shall provide dedicated and
redundant bi-directional serial interface gateways for each PLC processor for interfacing
the same with the DCS communication bus. The serial interface gateways shown in the
System configuration diagrams for free issued PLC system (Package PLC) interface shall
however be provided. Also, wherever serial interfaces are through gateways other than
controller & data acquisition subsystem / processor subsystem, the no. of serial links per
gateway shall be restricted to 4 subject to meeting loading criteria.
b) Separate controller sub-system shall be provided for redundant serial interface requirements
between DCS and foreign devices. These serial interfaces shall not be combined with any
process unit controller sub-system. Wherever serial interface shall be through controller &
data acquisition subsystem / processor subsystem, the no. of serial links per serial
interface module shall be restricted to 4 subject to meeting loading criteria. Also, wherever
serial interfaces are through gateways other than controller & data acquisition
subsystem / processor subsystem, the no. of serial links per gateway shall be restricted to
4 subject to meeting the loading criteria. Wherever redundant serial link is specified, each
link shall be connected to separate serial interface cards. Spare port of a serial interface
card shall not be used to connect the redundant link from the same foreign device. Total no.
of redundant gateways / serial interface modules shall be calculated and provided
accordingly by vendor for each network meeting the other requirements. All serial interface
points coming from each foreign device shall be interfaced and annunciated in DCS.
c) For Governor speed control system, anti surge controllers, machine monitoring system, UPS,
Data concentrator system in sub-station, DGFAP fire alarm panel redundant Modbus serial
communication shall be provided.
d) It is Bidder's responsibility to co-ordinate with the supplier of foreign devices and establish
communication for transfer of data with them. Unless the above communication is established
and seamless transfer of data/communication is ensured , the Control System shall not be
considered commissioned. It is the responsibility of the Bidder to make final documentation for
all the interfaces with DCS.

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e) Bidder scope shall includes supply and installation of all serial communication cables within
control room for all the bidder supplied equipments/items and purchasers free issued items
and fiber optic communication cables with HDPE conduits between analyzer shelter and
control room including supply of terminators, converters ,glanding and termination at both
ends etc. Trenching, digging, road cutting required for laying of fiber optic cables outside the
control room shall not be in the scope of bidder.
f) Bidder shall be responsible for providing serial link for all the foreign devices indicated in the
configuration diagram and list of serial interfaces in the I/O summary. The details of some of
these are provided below. Bidder to ensure that there should not be any operational
disturbance in case of failure of serial link communication. For estimation purpose, the length
of each serial link cables inside the control room shall be considered as approx. 125M
i) Analyser system
The analyser shelter of heater package shall be interfaced with DCS using redundant
RS-485 MODBUS protocol .
ii) Machine Monitoring System :
Redundant Serial link with RS485 MODBUS protocol shall be considered for
connectivity with DCS for MMS system
All Alarm & shutdown contacts related to machines shall be hardwired to PLC from
MMS system and analog signals as per requirements shall be connected to DCS.
iii) Speed Controller (Governor) System
connectivity with DCS for Speed Controller ( Governor) system
iv) Anti surge Controller/ Performance Controller
Serial link with RS485 MODBUS protocol shall be considered for connectivity with
DCS for Anti-surge Controller System.
v) UPS/Data Concentrator system in sub-station
connectivity with DCS for UPS /Data concentrator system in sub-station. The serial
link interconnection cable shall be supplied and installed by others.
g) Refer I/O summary and corresponding configuration diagram for detailed connectivity. The
type of serial communication protocol ( Modbus protocol) specified is as per design
specifications. In case, any of the vendor serial link communication protocol in control room
is different from the specified modbus protocol, the required convertor and connectors for
establishing its interface with DCS shall be provided by DCS vendor..
2.15 Hardwired Console Requirements/Specifications:
a) The detailed layout for Hardwired console shall be worked out during detailed engineering by
Bidder in accordance with PMC job specifications(44NC-4600-0000/J.02/0101/A4), Annexure-
A ( Additional requirements for DCS/PLC system), Annexure-B (Specification for fire and gas
system attached), Standard Specification for DCS 44NC-4600-0000/J.SS/0102/A4) and
system configuration attached with MR. The layout for all hardwired consoles shall be
reviewed by the Purchaser/Owner/PMC.
b) HWC lamp test push shall be implemented win HWC itself with diode circuit boards.
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c) The numbers of Hardwired console and its dimensions shall be decided by Bidder based on
I/O summary for hardwired console instruments/components and other functional
requirements including the spares as specified in MR.
d) The ESD pushbutton shall be provided with protective guard and same shall be located in top
rows of HWC to the maximum extent possible.
e) The annunciator shall be microprocessor based and shall be hanging type installed from the
ceiling of roof.
2.16 Panels/ Cabinet wiring/ termination
a) All cabinets shall be Rittal approved Make only
b) Separate cabinet shall be provided for analog , FF signals, Digital separately for DCS and
PLC as applicable . Also, cabinet with interposing relays for MCC inputs and outputs,
power supply distribution ( 110VAC UPS (separate for primary and redundant power supply
feeders) and 230VAC) cabinets shall be provided.
c) Screw-less terminals shall be provided by bidder for all terminations. All terminals shall be
sourced from reputed make like WEGO.
d) All system cabinets ( DCS/PLC) shall be provided with toughened glass door at front side.
e) The ferruling philosophy shall be finalized during detail engineering. Unless other specified,
cross-direct ferruling (printed type) shall be considered by bidder.
f) All field cables shall be first terminated in the separate TB( marshalling terminals) and further
the same shall be connected to barriers/relays. .
g) All the cable gland plates in cabinets/ panels/ consoles shall be minimum 3 mm thick.
h) Cabinet lighting shall be with 240VAC Non-UPS . Use of LED lights can be considered by
vendor and shall be finalised during detail engineering. Bidder shall ensure suitable lighting
arrangement so that cabinet illuminations does not cause interference in the performance of
these controllers/processors.
i) Provision shall be available for mounting Hand Held Configurator/field bus tester in all the
analog marshalling cabinets and telephone sockets in marshalling cabinets and Hardwired
console.
2.17 Multi Cable Transit (MCT)
a) Field Instrument cables and electrical interface cables entry into the Main Control Room
shall be through Multi Cable Transit The MCT frame and blocks specifications and make
including the spares blocks, space, packing plates, etc. requirements shall be in accordance
with PMC job specification (44NC-4600-0000/J.02/0101/A4 attached with MR. The MCT
blocks shall be peel off type. The MCT frames shall be of standard RGB type of M/s Brattberg
or G-type of Roxtec or equivalent. The material of MCT frame shall be of Galvanized Iron( GI)
steel construction.
b) MCT frames shall be suitable for the cutout opening sizes as specified below. MCT cut-out
drawings will be handed over to successful bidder after order.
For Instrumentation Field cables : 5 nos. of RGB 6+6 x 8 (or equivalent)
For Electrical Interface Cables : 1 No. of RGB 8+8 x 3 (or equivalent)

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Bidder shall develop detailed MCT layout drawings for each frame based on finalized cable
schedule including indicating the spare blocks and submit to Purchaser/Owner/PMC review.
2.18 Other requirements
2.18.1
Operator chairs for all DCS and PLC operator/ engineering consoles, OPC/PIN consoles and free
issued work station in console room, engineering room OPC room, training room, and rack room shall
be provided . Also, cup-boards, document racks and spares shall be provided and the make shall be
M/s Godrej. Bidder shall consider supply of 10 nos documentation racks and 10 numbers racks for
housing spares for the supply of the same and the size and dimension shall be finalized during detail
engineering.
Bidder shall comply with console type mounting arrangement for in accordance with clause 4.2.1.14
specified in 'Job Specification - Instrumentation' (Doc. No. 44NC-4600-0000/J.02/0101/A4) attached
with the MR for mounting of work stations/printers etc. in the console area, rack room, engineering
room , OPC server room and training room .
Bidder shall supply and install console for purchasers free issued work stations and printers etc
including operator chairs in the control room. Further, bidder shall provide and install HWC console for
ASC, WWG , PA system and CCTV joy stick . The free issued works stations( PC) and printers shall
be as per system configuration diagram ( A133-086-16-51-MD08) and additional requirements for
DCS/PLC system attached with MR. Further, bidder shall consider 20 numbers of free issued
cabinets for installation in the rack room for estimation purpose.
Four number of LED/LCD clock with GPS connectivity shall be provided
Six number panel mounted phones for operator consoles and four number cordless phones for rack
room shall be provided.
Two numbers Cu(Copper) and Ag(Silver) corrosion transmitter ( 4-20 mA DC and RS-485 interface to
DCS) .Make shall be Purafil or Circulaire or equivalent.
2.18.2 Bidders scope of work also includes but not limited to the following
a) Installation of UPS with battery and other associated hardware including Structural frame in
UPS room for mounting of UPS cabinets.
b) Installation of all DCS/ PLC cabinets/items and free issued package system PLC system
(system cabinets, marshalling cabinets, relay cabinets, hardwired consoles, operator
consoles, PDBs, printers etc.), in Main Control Room and Fire Station . The structural
frame required for mounting of consoles/printers/cabinets etc. Areas where false flooring is
applicable shall be provided by bidder.
c) Any civil work necessary with respect to fixing and finishing for new cable entry, any fixing &
finishing required for structural fixing, floor finishing, etc shall be taken care of by the bidder.
d) Removal, modification and re-fixing of false floor tiles & chequered plates as applicable. Any
addition structural support, if required, for false flooring shall also be provided.
e) Installation of all purchasers free issued equipments/items including cabinets, racks,
consoles, panels etc
f) Bidder shall provide necessary cable duct inside the cellar room and cable trays in
engineering room/UPS room/OPC server room etc. for laying of cables.

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g) FAT/ SAT procedures shall be such that all functionalities specified in MR are included.
However the same shall be approved during detail engineering.
2.18.3 The following shall be considered for all bought-out items:
a) UPS shall be designed, engineered, manufactured and tested by manufacturer at their works
in line with MR requirements.
b) All DCS/PLC sub-systems shall be made available during integrated factory acceptance test
at vendor works.
c) All bought-out items/sub-systems shall be fully tested at manufacturers shop prior to
shipment by manufacturer to vendor works for integration as per MR requirements. All such
test reports shall be submitted to Purchaser/Owner/PMC for review.
d) Supervision of installation of FBJB.
e) All the bought out items shall be commissioned and site accepted in the presence of
manufacturer representative.
f) All bought out items shall be supplied from approved vendor list attached with MR.. For any
specific item, not in approved vendor list in the MR, bidder shall obtain prior approval from
Purchaser before ordering.
g) P&IDs will be given to the successful bidder after order, which will be used for preparing
functional schematics, network/ segment diagrams, graphic diagrams, Logic diagram, etc.
Wherever Licensor logic or cause & effect chart/ diagram are available, the same shall be
furnished to the successful bidder for implementing logic diagram. Dynamic interlocks
graphics indicating the current status of all interlocks shall be provided in DCS operator
station. The details shall be made popped up when the cursor is placed on the equipment
graphics and clicked.
h) The system and documentation and instruction manual CD/DVD shall be submitted with
proper labelling with CD storage/carry case and not loosely.
i) Bidder shall carry out tuning of controller, complex control scheme simulation, and interlock
simulation at site during field testing.
j) Procurement and Engineering done by bidder on third party procurement if any shall be
certified by original equipment manufacturer.
k) Bidder to provide/ select the best possible accessories/ peripherals of PC during detail
engineering for PLC and DCS system in accordance with minimum configuration specified in
MR.
l) Graphic, control Groups, Trends, logs and reports shall be approved by purchaser prior to
start of engineering/ implementation.
m) Zooming facility of all history trends with respect to time scale and parameter value shall be
provided. History of all tags required for 30 days historic trending on each console for all
points (PV,SV,MV). Real time trends of all AI and AO shall be provided.
n) Rodent control after start of cabling to Site acceptance test shall be done by DCS vendor.
General cleaning of system and daily housekeeping in the control room operating and
marshalling area will be done by DCS vendor till the mechanical completion of the respective
process units.

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2.18.4 Bidder shall provide necessary cable duct inside the cellar room and cable trays in engineering
room/UPS room/OPC server room below the false flooring etc. for laying of cables .All cable duct
and cable trays used in control room shall be Pre-fabricated galvanised Iron . Perforated cable trays
shall be used for cable trays. The cable duct shall cover entire section of each rows ( Total 5 rows
each rows of approx. 40M distance) of cabinets below the rack room in cellar area and its
interconnection. For the length of each row for cable duct and its interconnection, refer to control room
layout drawings attached with MR. The indicative size of cable duct shall be 1200 mm (W) x 400 mm
(H). However, actual size shall be finalized by bidder during detail engineering. The typical instrument
cable duct fabrication drawing attached for the fabrication and installation of cable duct. The
instrument cable duct shall be supported with ISMC 125 channel section at continuous/regular interval
inside the cellar areas. The cable trays shall be installed with proper supports using angles of proper
size. All the structural supports shall be properly painted with primer and finished painting. The cable
trays shall be made out of Mild Steel sheets of 2.0 mm thickness in standard lengths (section) . The
size/width of the trays shall be finalised by vendor during detail engineering based on number of
cables and routing etc. Hot dip galvanising for the cable trays shall be carried out as per IS-4759 after
fabrication of trays. The amount of galvanizing shall be 66 m / 460 g/m2.. Each section of tray shall
be supplied with required accessories such as connector plates, nuts, bolts, washers etc. required for
connecting ends of each tray section. Fasteners / nuts, bolts, washers etc. shall be SS material. 40%
spare space shall be considered in cable duct/cable trays in the control room.
2.18.5 Cable glands for all types of cables inside control room for all cabinets including free issued
cabinets/console and for all field cables , power cables, serial communication cables, package
cables, MCC interconnection cables etc. shall be in bidder scope. The details of all types of incoming
field cable like overall diameter/ over armour/ under armour diameter etc shall be furnished during
detail engineering. However bidder shall collect actual cable samples from site for same during detail
engineering. All cable glands shall be SS-304 and double compression type.
2.18.6 Cabling Philosophy inside Control room:
All cables inside the control rooms/Rack Room/UPS Rooms shall be properly dressed and routed in
GI perforated trays under false flooring and in GI cable duct in the cable cellar areas which will be
supplied & installed by the bidder. Separate partition/trays shall be used for signal and power cables.
Bidder shall develop and furnish detailed cable duct and cable tray route drawing in cellar and other
areas of control room and submit to purchasers for review.
System cables shall be routed on conduits/closed cable perforated trays.
Separation with electrical cables shall be maintained as per API guidelines.
2.18.7 Smart Positioners are provided with On/Off valves/shutdown valves by purchaser for performing
Partial Stroke Testing ( PST) from DCS. The DCS analog output for the positioners are included
the I/O summary for PST . Bidder shall demonstrate the partial stroke testing during DCS/ PLC
system FAT.
PST shall be performed to ensure satisfactory operation of on-off valve including all accessories on
demand. The test shall be performed automatically by partially ( around 10%) stroking of the valves
from control room through positioners.
The PST design shall ensure:
a)The testing shall be carried out automatically at pre-defined intervals which shall be adjustable
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b)The shutdown demand shall always over-ride if PST is in operation at that time
c)The analog output for the positioners shall be limited in such a way that valve shall not operate
beyond a predefined maximum allowable stroke valve under any condition or failure. \
d) Information shall be made available to indicate time and date of PST, test results(OK/Fail), reason
for failure, changes made etc. as a minimum.
e) PST data / information shall be made available to UHN system.
FF macro cycle time shall be demonstrated at DCS vendors works during FAT on a typical segment
using field components like FF Barrier & FF field instruments for each unit. DCS vendor shall be
responsible for collecting these FF devices (1no. of Pressure Transmitter, 1no of Diff. Pressure
Transmitter, 1 no. of temperature Transmitter and 1no of positioners) from site if required ,
transporting the same to their factory for testing and sending them back to site. All necessary
arrangement for the same shall be in DCS vendors scope.
2.18.8 Free Issue Instrument/ Equipment Details
a) Some of the other package vendor supplied cabinets, PLC system, operator , engineering
work stations, printers etc. items shall be free issued by purchaser to the Bidder. Installation
of these items /equipments including its testing and commissioning with
supervision/assistance from respective supplier in control room shall be in Bidders scope
Bidders scope shall also include;
i. Supply, installation, laying, glanding, ferruling and termination at both ends of all
interconnecting cables between free issue items/cabinets including power supply
cables, serial communication cables.
ii. Supply and installation of structural base frame( wherever required) for free issued
items.
iii. Supply of consoles ( Same design as operators console of DCS) for HMI located in
console area, furniture for PC, Printers etc.
iv. Transfer/shifting of free issue items including its accessories from Owners
store/warehouse to MCR.
v. Completion of earthing for the free issued items (cabinets/equipments) including
supply of cables, installation and termination of earthing cables at both ends.
vi. Powering up of free issued items.
vii. Establishing and Proving the seamless serial communication for the free issued items
as defined in I/O summary. All the required co-ordination with the Package
System/free issue items vendors for establishing and proving the communication links
shall be the responsibility of Bidder. Any converters if necessary because of any
limitation shall be supplied by Bidders at both ends. The serial communication links,
in general shall are MODBUS RTU protocol.
viii. The details of free issued package vendor cabinets, HMI/PC and other accessories
for installation in Main Control Room shall be furnished during detail engineering.
Number of free issued cabinets for installation to be considered is specified in 2.18.1 (
i.e excluding HMI/PC/Printer, ASC, WWG, which shall be as per system configuration
diagram)
Anti-Surge Controller (ASC), Load Sharing/Performance Controller:
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Bidder shall install free issued redundant Anti-surge controllers, load sharing
/performance controller for the compressor package in bidders supplied Hardwired
console located in console area. The serial link communication as defined in I/O
summary shall be considered for each anti-surge controllers, load sharing
/performance controller with DCS. DCS shall have facility to work as back up to anti-
surge controller when selected by operator. DCS shall have graphical display for the
compressor controls including system design screen, online operation and control,
alarm and event management and event archiving for the compressor instruments.
Bidder scope also includes installation of free issued signal multiplier for the anti-
surge controller in the HWC. All the terminals, rails mounting required for mounting
signal multiplier and termination of cables and further interconnection between
terminals in HWC to ASC shall be in the scope of bidder.
Machine Monitoring System (MMS):
The MMS system consisting of Vibration and Temperature monitoring rack/cabinets
for various package equipments shall be located in Rack room. The serial link
communication as defined in I/O summary shall be considered for each unit of
vibration/temperature monitoring systems with DCS. The signals exchange between
vibration and temperature monitoring system and DCS/PLC for alarm and interlock
application shall be through hardwired.
The number of items shall be considered as defined in I/O summary.
Package PLC:
Some of the sub-packages like coke un-heading system and coke decoking system,
which has dedicated PLC based control system ( By others) with marshalling
cabinets , system cabinets, HMI, printers and other accessories shall be installed in
MCR and interfaced with DCS system.
Bidder shall consider serial communication for each PLC based control system as
defined in I/O summary/configuration diagram.
The number of items shall be as define din I/O summary.
b) Public Addressing (PA) system
The PA system shall be free issued to the bidder for installation on bidder supplied installed
hardwired consoles.
2.18.9 Interface with other Vendors/Bought-out items at Main Control Room:
The following systems supplied and installed by others are required to be housed in the control room
a)Data Gathering Fire Alarm Panel( DGFAP)
b)PA/Communication System
Bidder shall be responsible for indicating the cabinets/equipments in the overall control room layouts
including in the as-built documents. The cable trays requirements for installation of cables for the
above system shall be provided by bidder. Bidder shall also provide earthing for the above cabinets
along with DCS earthing.
For the bought-out items through DCS vendor like CCTV system, Giant screen, bidder shall be overall
responsible for co-ordination , installation, testing and commissioning and interface and integration
with DCS system. Bidder shall ensure the following for bidders bought-out items in general.
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Indicating all the cabinets/equipments supplied/installed in the Main Control Room

layout developed by bidder.
Supply and installation of consoles (Similar design of operator console) for housing
the HMI/ operator console in the console area of MCR.
Furniture for the PC, Printers for the other vendor supplied items. ( Design similar to
Bidder supplied DCS items)
Power supply (110VAC UPS and 230VAC Non-UPS) for all bought-out items
including supply, laying and glanding and termination of cables.
Supply, installation of cable trays/conduits in rack room area, console area and
engineering room of MCR.
Glanding, ferruling and termination of all the interface cables ( serial
communication/special cables/hardwired cables) in the bidder supplied cabinets.
Earthing of cabinets/equipments including supply of cables, installation and
termination of earthing cables at both ends.
2.18.10 Network Switches or Media Converters and its power supply units shall be of Industrial Grade and
shall be as per approved vendor list attached with MR. The Network Cabinet shall be free standing
type and shall be located in the Rack Room.
2.18.11 For bypassing the field inputs for operational and maintenance requirements, Key-operated hardwired
enable switch located on hardwired console shall be provided.. Bypassing shall be event recorded
and logged with date and time stamping.
2.18.12 Bidder shall provide bidders principle recommended antivirus software, software patches to fix bugs
free of cost for the period till the logistics support period. All the software packages supplied shall be
original license. The DCS/PLC and any other system software supplied by vendor shall not have any
recurring license fee.
2.18.13 Firewall protection shall be provided as per requirements specified in system configuration diagram
and in accordance with PMC job specifications(44NC-4600-0000/J.02/0101/A4), Annexure-A (
Additional requirements for DCS/PLC system) Annexure-B ( Specification for fire and gas system),
Standard Specification for DCS 44NC-4600-0000/J.SS/0102/A4) and system configuration attached
with MR.
2.18.14 Type of report generation shall be finalised during detail engineering by operation/process department
of client.
2.18.15 In case of cascade control, minimum scan time of tags as applicable is to be considered for both the
controllers.
2.18.16 The Operator console, Hardwired console, engineering console and other work stations console
including for the free issued items , printer console located in control room shall have same colour to
meet the control room aesthetics. The dimensions of above shall also be the same to the extent
possible.
2.18.17 Bidder shall follow the tagging philosophy for instruments, junction boxes and cabinets in accordance
with Annexure-C( Tagging philosophy for junction boxes, panels and cables)

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2.18.18 The DCS and PLC shall be designed with capability to discriminate between transmitter failure and
zero signal failure. For DCS, in case of detection of transmitter failure, the controller output shall be
held at the prior valid signal output value until the operator take action by transferring the control to
manual. For PLC, the interlock action shall drive the outputs to fail safe position.
2.18.19 The procedure for communication between DCS vendor, Purchaser and Owner/PMC shall be as per
agreed procedure during KOM.
2.18.20 The isolating type intrinsic Barrier shall be with 3 Port isolation. For analogue output barrier, LINE
FAULT DETECTOR shall be provided. 4-wire instruments signals shall be connected to Control
System through Isolators.
2.18.21 Relays used for hardwired switches, push-buttons, lamps etc. in Aux. consoles connected with ESD
PLC system shall be SIL-3 certified. Relays used for hardwired switches, push-buttons, lamps etc. in
Aux. consoles connected with DCS system shall be non-SIL type. No. of contacts for SIL-3 relays
shall be min. 2 nos.
2.18.22 All cables including spare pair / core shall be terminated inside cabinets and no loose cables shall be
allowed. All cables shall be glanded in cabinets. In general, spare holes shall be avoided to prevent
any rodent entry into the cabinets. Vendor shall use suitable material for closing of all cutouts/
openings to make the cabinet totally sealed.
2.18.23 All the system provided by vendor shall be upward compatible i.e. new enhancements can be
incorporated in the system for future upgradation allowing the user to migrate to newer revision levels
of software and thereby to take advantage of continuing technical enhancement.
2.18.24 Application software shall be designed in a manner that requires no modification to the system
operating software. Software design shall be such that future revisions or updates of the system
operating software will not affect the successful operation of the system.
2.18.25 All software shall be the most recent proven revision that is applicable to the system
hardware at the time of the hardware freeze date. The system shall allow for upgrading of system
operating software on all redundant modules of the system without the necessity of shutting
down the process, without losing the operator interface and without the loss of access to any control
function.
2.18.26 Application software shall not require modifications in order to be able to run under new releases of
the system operating software. Any new release of system software shall be backward compatible
with files created using the previous software releases.
2.18.27 Vendor shall note that the offer will be evaluated on the basis of the following documents only. Vendor
shall submit the same along with the offer:
a) Compliance Statement
b) Deviation List (if any)
Offers will be evaluated as received on the basis of acceptance criteria set forth above. Vendor shall
note that there may / may not be any subsequent technical correspondence.
2.18.28 Time Synchronization: The time synchronization with external clock i.e GPS shall be provided by DCS
vendor for entire DCS, ESD PLC, F&GS PLC, IAMS, OPC and third party devices like Machine
Monitoring System. The frequency of time synchronization shall be configurable. DCS vendor scope
shall include the following as minimum
a) Development of time synchronization documents part of functional design specifications (FDS)
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b) Identification of the specific material required for time synchronizing between all the control
system and its sub-systems
c) Design, supply and installation of GPS antenna, receiver units, splitters, special cables for
interconnection time synchronization equipments with DCS, GPS antenna etc. including
glanding and termination at both ends
d) The GPS system as show in system configuration diagram shall be provided with minimum 2
nos of additional NTP ports and 2 Nos of IRIG-B ports for connection to external third party
devices. The supply, laying, and termination of cables for interface with third party devices
within control room shall be in the scope of DCS vendor.
2.19 Earthing Requirement

Bidder shall provide the instrumentation system earthing in accordance with clause no: 4.12 of PMC
job specifications(44NC-4600-0000/J.02/0101/A4) attached with MR. The earthing shall cover
earthing for all bidder supplied equipments/items and free issued items in the control room. In case
free- issued systems (supplied by others) requires separate system earthing with earthing value
different from DCS vendor, one set of dedicated earthing system with earth pit for package vendor
shall be provided by DCS vendor.
The requirement of earth pits for control systems shall be as follows:
Earth Pit-E1:For rack room mounted system cabinets/ marshalling rack body earths( includes panel
mounted bulk power supply)
Earth Pit-E2: For Instrumentation earth ( For circuit ground, shield, drain wires etc.)
Earth Pit- E3 : For Machine Monitoring System
The earth pits shall be constructed with dual ground electrodes. The earthing system shall have resi
stance to earth of 5.0 ohms or less.
Bidder scope shall includes supply and installation of earth electrodes, insulation bar, all
interconnected grounding cables (separate for signal grounding and instrument grounding) and other
related accessories required for barrier earth, system earth and installation shall also be in the scope
of work of DCS vendor. For details of earthing interconnection cables and other requirements, refer to
above referred specification. Bidder shall consider the distance between earth bus bar in control room
to earth pit outside the control room as minimum 150 meters.
2.20 Spares Philosophy
2.20.1 Expandability Philosophy
All the spares shall be calculated based on various requirements specified in the MR, including I/O
summary, power supply etc. for each of the unit separately.
2.20.2 Spare adjustment:
The system design shall be carried out based on the I/O summary given elsewhere in general. At any
stage of the projects, if one or more groups I/O counts are found to have actual requirement less than
the provision, the same shall be considered for adjustment with other unit(s)/groups for which the
actual requirements exceeds the provision given, with the approval of purchaser. The above
adjustment is for I/O, Fieldbus segments and auxiliary items only. Any changes with respect to wiring,
cabinets, system sizing etc. shall be considered by Bidder without any implication. No change order is

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permissible as long as the overall I/O, Fieldbus segment quantity including installed spares does not
increase.
2.20.3 Mandatory Spares:
Mandatory spares for DCS/PLC and bought out systems as applicable shall be supplied by bidder as
per Annexure XII ( Mandatory Spares List ) attached with MR.
The mandatory spares list is not verified at the offer stage. Bidder shall furnish complete list of
mandatory spares in the purchasers format( format will be furnished during detail engineering) and
submit to Purchaser/Owner/PMC for review/approval.
The quote for mandatory spares shall be as per pricing schedule attached with MR.
2.20.4 Commissioning and consumables spares
Bidder shall be fully responsible to provide any and all commissioning spares. These shall be over
and above the Mandatory spares required as per MR.
The price for the same shall be included in the base lump sum price of the MR.
2.20.5 Operation and Maintenance Spares:
Bidder shall separately quote for the recommended 2-years of operation and maintenance spare for
the total system which shall includes all types of I/O modules, processor modules, communication
modules, communication modules, auxiliary items like barriers, annunciator modules, switches,
lamps, video display units, Optical fibre switches, network switches, media converters, special
system cable connectors, Batteries, special system cables like RS485/ 232/ 422 etc, end connectors
etc. The prices shall valid for 2 years from the date of placement of DCS order.
2.21 System Delivery
The system shall be delivered with time schedule and conditions in accordance with commercial
section of this MR.
2.22 FACTORY ACCEPTANCE TEST AND SITE ACCEPTANCE TEST:
2.22.1 Factory acceptance test shall be carried out as per the Standard Specification for DCS, this special
instructions to bidder . Bidder shall develop detailed FAT procedure in accordance with above
specifications and submitted to purchaser/Owner/PMC for approval. The FAT shall includes specific
testing requirements for field bus system in accordance with applicable field bus system guidelines. .
2.22.2 Bidder shall set up a test facility consisting of various Fieldbus devices (FF transmitters, FF positioner,
Mega block, FF power conditioner etc) used in the project.
2.22.3 Bidder and shall have simulation capability for fieldbus devices and function blocks, making it possible
to mimic process conditions and alarms to verify system behaviour during factory acceptance Test.
Bidder shall follow the following testing guidelines/requirements for the field bus devices during FAT
a) A complete functional test shall be conducted for each type of FF device used in the project
(i.e. third party and DCS vendor products). This test will include, but not limited to, plug-and-
play interconnectivity to DCS, verify access to all device function blocks, and actual device
operation, (e.g. simulate process inputs for transmitters, etc.)
b) All calibration and setup procedures, for each FF device type, shall be documented in detail
by the DCS Vendor and approved by Purchaser/Owner/PMC.
c) DCS Vendor shall develop a redundancy fall-over test procedure for the FF interface cards
and FF Power Supplies. The test shall verify that automatic fall over shall not cause an upset
(i.e. I/O signal bumps, loss of operation view, mode changes etc.). All FF interface cards and
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FFPS conditioner cards shall be tested. Purchaser/Owner/PMC shall approve the test
procedure.
d) Each segment, including spares, shall be operationally tested by live connection of at least
one FF device and one coupler device. The Test Segment shall be connected to the terminal
block designated for the field wiring.
e) A full loaded segment shall have one spur short circuited, while confirmation is made that all
connected devices continue operation.
f) Each FF segment wiring configuration shall be required to be tested with typical FF device on
the link.
2.22.4 Following minimum test shall be performed for the field bus system.
a) I/O and Linking Device Redundancy
b) Application Software Test for Controller
c) I/O and Linking Device Test
d) Set up for Fieldbus Tests
e) Field Devices with the Host system
f) Remote Calibration (Field Device Adjustment) Test
g) Field Devices Function Blocks
h) No. of Devices in a Segment
i) Asset Management System
2.23 INSTALLATION, TESTING AND PRE-COMMISSIONING
2.23.1 The installation , testing and commissioning of DCS system and bought items shall be considered in
accordance with standard specification for DCS system, PLC system and other specification attached
with MR.
2.23.2 Commissioning of the FF device shall be based on downloading of the configuration parameters from
the host to the FF device once connected to the segment. As downloading takes considerable time,
the commissioning procedure shall take into account batch downloading, in this case it is advised to
perform the commissioning of the field devices in several step as applicable.
a) Cables, Junction Box, Coupler Device continuity test
b) Earthing (grounding) test
c) Insulation test
d) Connect device and link to system this will be done for a batch of devices in
Sequence.
e) Batch downloading to connected devices and software checks
f) Bus monitor capture, scope waveforms capture
g) Process connection pressure testing and inspection
h) Loop checking performed but not limited to the following:
Ensure that an applications engineer is available to work closely with field technicians as they
connect each device to the FF network. This availability is important due to the rapidity with
which FF loops can be commissioned. Disconnect the point from the segment at the device
end. This action ensures that the correct tag number is installed in the correct location.
Reconnect type device upon confirmation of loss off signal.
2.24 Site Acceptance Test
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2.24.1 Bidder shall carryout the Site acceptance test as per standard specification for DCS and PLC system
and other specifications attached with MR including specifically as per clause no: 9.0 of PMC job
specification (44NC-4600-0000/J.02/0101/A4) attached with MR.
2.25 Control System Security
2.25.1 Vendor shall ensure that security of the system is addressed from both IT and control System
perspective. Vendor shall design multiple layers of network, system and application security. Vendor
shall ensure that industry, regulatory and international standards are taken into account while
designing the security system.
2.25.2 USB mass storage media drive monitoring software shall be provided on all computers/servers
(wherever USB port is given). This shall alert administrator by playing selected sound or by CPU
warning beep sound when any USB stick is being connected or removed. Surveillance utility
shall explain entire details of connected USB storage device including manufactures company name,
hardware ID, storage capacity with client machine name, IP address and save information in txt or
html file. USB data protection software enables or disables access permission (read / write) of
any storage media in domain. Data theft protection application shall be applicable for all USB
storage media devices.
3.0 Training requirement

Bidder shall provide different type of training for Owners personnel at manufactures works and at
site. The courses shall be offered for in hardware and software aspects of various system in the field
of engineering, operation and maintenance for operation/ process engineers and operators,
instrument maintenance engineers and technician. For details of training days and its requirement,
refer to clause no: 15.0 PMC job specifications(44NC-4600-0000/J.02/0101/A4) attached with MR .
Training for following system are applicable and shall be considered by bidder.
Distributed Control System
Programmable Logic Controllers
IAMS system
AMS system
CCTV system
UPS system.
For Site Training for all above systems, following shall be considered
2 days for 10 persons : 20 Man days
For details of training for UPS system ( number of days, personnel and its courses its location) refer
to Part-B of this MR.
4.0 POST WARRANTY MAINTENANCE AND SPARES MANAGEMENT CONTRACT

4.1 The bidder shall provide quote for providing Post Warranty Maintenance for 5( Five) years ( Year
wise quote is required) for the following systems ( with spares) along with offer in the format attached
with commercial section. The offer for PWMC contract shall be valid for five years from the date of
expiry of defect liability (i.e warranty) period. The defect liability ( warranty) period shall be 12 Months

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from the date of Site Acceptance Test or 36 Months from the date of supply whichever is earlier. For
scope, technical details refer to clause no: 15.0 PMC job specifications(44NC-4600-
0000/J.02/0101/A4) attached with MR.
4.2 The system requires PWMC contract are:
Distributed Control System
Programmable Logic Controllers for ESD system
Programmable Logic Controllers for F&GS system
Foundation Field bus Interface Devices
Asset Management System
CCTV system
5.0 UNIT RATE:
Bidder shall also furnish unit rates of each DCS / PLC / Sub-systems items with its necessary
hardware and software required as per MR for addition / deletion purpose which shall include the
following minimum items. Unit rates furnished by bidder shall be comprehensive i.e. shall include cost
of supply( inclusive of all associated cables, connectors and termination assemblies), engineering,
documentation, transportation, unloading, installation, termination & testing etc.
a) Unit rate for DCS controller ( Redundant set) complete with power supply module,
communication module, connectors, etc
b) Unit rate for PLC controller ( Redundant set) complete with power supply module,
communication module, connectors, etc
c) Unit rate for serial communication gateway.
d) DCS close loops ( Redundant cards) :
i. AI
ii. AO
e) DCS open loops ( Redundant cards) :
i. AI
ii. AO
iii. DI
iv. DO
f) PLC (I/Os only) :
i. AI
ii. DI
iii. DO
g) DCS serial interface card.
h) Foundation Fieldbus H1 interface card ( Redundant)
i) FF power supplies/ conditioner including surge arrestor ( Redundant)
j) MCT frame of size specified with insert blocks.
k) Each type of Fieldbus Junction Box (1/2/3 barries) with all duly wired & installed hardware.
l) Advanced Diagnostics Module
m) Surge protector for field devices
n) Optical Fibre converter along with LIU

Page 261 of 564
VENDOR A133-000-16-51-SIV-1500 Rev. B
o) Network Switches.
p) Fibre optic cable.
q) Special cables ( System cables) of each type
r) Termination assemblies
s) Operator Work Station( single)
t) Engineering work station
u) Analog Barriers
v) Digital Barriers
w) Non-IS isolators
x) Interposing relays SIL-3
y) Interposing relays Non-SIL certified
z) Each type of push buttons, selector switches, lamps in Aux. console
aa) Annuniciator ( each type with number of rows/column offered)
bb) Blank cabinet with power socket, receptacle and lighting
cc) Blank Hardwired console with power socket and receptacle
dd) Blank Operator console with power socket and receptacle
ee) OPC server
ff) CCTV-DVR
gg) CCTV-32 LED monitor
hh) Giant Screen of cube size 70 minimum in 2x2 configuration
6.0 TEST EQUIPMENTS
Bidder shall supply the test equipments consists of multimeter, calibrators, pneumatic test
bench, dead weight tester, temperature bath etc. in accordance with clause no: 16 of job
specification ( 44NC-4600-0000/J.02/0101/A4) attached with MR. The make and quantities
shall be as per above referred clause in the specification. These items shall be supplied as
loose supplied items with valid test certificates.
7.0 TAKE-OFF PRICE
Bidder shall furnish take-off price for dedicated SIL-3 PLC controller subsystem indicated in
the System Configuration Diagram (Doc. No. A133-086-16-51-MD08) for interlock operation
of overhead pressure monitoring for equipment 086-C-07 & 086-C-10 respectively.

Page 262 of 564
CPCL Chennai Additional Requirement for PART III Section B 8.2
44NC-4600 DCS & PLC PAGE 1 OF 22
LSTK-1 Coker Block Annex. IV to 44NC-4600-0000-/J.02/0101/A4 Rev. 0
ANNEXURE-A
ANNEXURE-IV
ADDITIONAL REQUIREMENT FOR DCS & PLC
Page 263 of 564 1 of 22

1.0 SPECIAL INSTRUCTIONS 0
1.1 The additional requirements for DCS &PLC shall read in conjunction with Job Specification,
standard specification for DCS, PLC & any other specifications and other requirement as
specified in feed documents
1.2 Contractor to note that they shall be fully responsible for the Bill of Material submitted by
them to meet all hardware and functional requirements as indicated in tender document. In
addition, contractor shall be fully responsible for the total scope of work indicated in the
document on turnkey basis and meeting all functional requirements through hardware and
software during detail engineering
1.3 In case of conflicts with respect to specifications, and any other engineering requirement or
legal regulations, the contractor shall consider the most stringent requirement by default while
selecting the DCS and PLC system, however it shall be obligatory on the contractor's part to
bring to the notice of the owner/PLC all such conflicts, wherein the PMC/ OWNERS decision
shall be final.
1.3 System Modification / Change Management.
a) Contractor shall carry out all the modifications/changes/revisions necessary to be

incorporated and pointed out at the time of FAT including graphic changes, wiring
changes, I/O assignments, logic changes etc.
b) Contractor shall carry out all changes/modifications/revisions which are to be carried out
during installation including additional inputs for sub-package items, configuration of new
tags, termination changes, incorporation of cable schedule connections, modification and
addition of new graphics, modification of group trend history etc.
c) Contractor shall carry out any changes required during loop checking and
precommissioning activities such as range change, graphic display changes,
reassignment of I/O, termination changes etc. shall be performed by contractor.
d) Contractor shall carry out changes/modifications required in the system during

commissioning and start up due to operational requirements like graphic changes, tag
reassignment, tags new assignment, history trend and grouping, format changes, set point
range changes, logic modifications etc. Contractor scope shall include incorporation of all
such software/hardware configuration, engineering changes that may occur for normal
engineering project execution.
1.4 Contractor to note that Owner/PLC reserve the right to associate their personnel at any or
all stages of project execution. Further, contractor shall not proceed without getting prior
approval from Owner/PLC for the documents required to be approved under Contractor
Data Requirement.
1.5 The storage of items / equipment at site shall be contractors responsibility for all the
items / equipments supplied by them. Handling of material at site is contractors
responsibility.
1.6 The loop checking shall be carried out in co-ordination with other package contractors,
owner/PMC in accordance with Job specification & standard specification and the
requirements given in this document. It is essential that dedicated team of skilled
personnel from contractors side shall be provided at site for each package item so that
the execution activities such as installation, loop checking, commissioning, SAT are
independently and conveniently done as required.
Page 264 of 564 2 of 22

1.7 POWER SUPPLY

0
1.7.1 110 VAC UPS
1.7.1.1 110 VAC UPS systems shall be provided for New DCU units by contractor as per
specification the Electrical part of this document. In general Min two Nos of UPS one for
Coker Unit along with sub packages ,utility packages, like IA compressor Package,
cooling water Package & another UPS dedicated for F & G system which shall have 48
Hrs Back Up.
1.7.1.2 UPS system shall be Part of DCS/PLC system & supplied by DCS vendor.
1.7.1.3 For Utility and other package contractor supply items, separate Power supply distribution
cabinet (by LSTK-1) shall be provided in Rack room.
1.7.1.4 For Non-DCS loads, major loads above 1.0 KVA, the feeder shall be provided from UPS
AC Distribution Board (UPS ACDB) located at UPS room and for smaller loads, the
distribution shall be provided from power supply distribution cabinet (by contractor) in
Rack Rooms.
1.7.1.5 UPS feeders except for field Instruments & Analyser shelter shall be redundant.
1.7.1.6 20% or minimum one no. Spare feeder shall be provided by the contractor for each feeder
rating.
1.7.2 The Size of UPS shall be arrived at after considering system and user loads. The system
load shall be calculated considering:
a) Expandability of I/Os including installed spares and installed future spare space.
b) In rush current and PF for system/user load shall be considered.
1.7.3 The UPS sizing shall be arrived at after considering additional 10% capacity over and
above the total of both system and user load.
1.7.4 230V AC
The contractor shall provide 230V AC feeders with power distribution cabinet at Rack
Room for the 230V AC power supply for cabinet / Panel lighting, utility sockets and fans
other load requirement. Similar arrangement shall be provided for field local panel
requirements with necessary isolation transformers.
1.7.5 24 VDC
1.7.5.1 24 VDC power supply required for interrogation voltage, solenoid valve supply, lamp,
pushbutton, etc and for other packages shall be supplied by contractor using dual
redundant Bulk Power Supply (BPS). Such redundant BPS shall be fed from two separate
AC feeders. Power looping In & looping Out shall be avoided.
1.7.5.2 Each redundant bulk power supply shall be sized for 35% loading of its capacity in normal
time; the maximum loading is to be 70% of its capacity of BPS.
1.7.5.3 All bulk power supply (BPS) shall be provided with surge protection capability. BPS shall
also provide with cooling fans and with fan failure alarm indications in DCS. In the event of
one BPS failure the second BPS shall take the complete load.
1.7.5.4 BPS Failure alarm shall be provided on Hardwired console & in DCS with highest
priority.
Page 265 of 564 3 of 22

1.7.6 The system Power cables from PDB at rack room to DCS contractor supply items
including cabinets etc. within control room shall be of copper only and shall be supplied by
Contractor. The supply and laying of all incoming and pout going cables is in contractor
scope.
1.7.7 110 VAC UPS Power supply feeder failure alarm before PDB shall be provided in DCS by
using double pole MCB in PDB. One contact of these MCBs shall be wired to DCS for 0
alarm purpose.
1.7.8 Fan failure alarm shall be provided in DCS for each cabinet. RTD for cabinet temperature
monitoring from DCS
1.7.9 Separate PDB cabinet shall be provided for primary & redundant feeders in Rack Room.
1.7.10 The power distribution schemes shall be submitted for review and approval bt PMC /
Owner.
2.0 SPECIFIC REQUIREMENTS FOR DCS/PLC 0

2.1 The PLC system shall be Triple Modular redundant (TMR) or Quadruplicated Modular
redundant (QMR) SIL-3, TUV certified PLC as a minimum.
2.2 The DCS / PLC for each unit shall be sized considering I/Os and other sizing requirements
like scan time, CPU loading etc as per PR. The sizing calculations shall be reviewed during
detail engineering. Contractor shall be fully responsible to supply number of DCS/ PLC as
required meeting above requirements and approved sizing calculations.
2.3 The main PLC processor and I/O cards replacement should be possible on line without
compromising the plant safety and TUV guidelines. The PLC system shall have high
availability.
2.4 In case of two out of three voting inputs in PLC, the inputs shall be wired in three different
cards. Also the I/O shall be segregated equipment wise and redundant equipment shall be
configured in different rack.
2.5 All PLC I/O signals shall be two wired, with no looping or common sharing of power supply or
negative points.
2.6 Maintenance over ride switches (software switches) shall be implemented from PLC console.
2.7 Interposing relays, Power Supply unit for TUV, SIL-3 Certified PLC shall be TUV, SIl-3
certified. However For IS barriers for PLC, both SIL-3 and SIL-2 certified barriers are
acceptable.
2.8 Instrumentation shutdown and interlock shall be de-energizing to trip.
2.9 All Intrinsically safe DI / DO shall be provided with barrier. All MCC Digital inputs / output,
Field input / output (Non IS, if any) shall be connected through external interposing relay.
2.10 Hardwired switches, pushbuttons, lamps in Aux. Consoles shall be powered in 24 VDC circuit
through external relays.
2.11 Contractor shall provide touch screen facility for the bottom tier TFT monitor of the dual tier
operator console. Touch screen facility shall also be provided for Engineering station as well
as Operator cum engineering station.
Page 266 of 564 4 of 22

2.12 IAMS System shall be considered and provided by contractor for all (SMART and Field Bus)
for all analog signals to DCS and PLC. All Non-Field Bus signals to DCS and PLC shall be
SMART type with HART protocol. The I/O cards for DCS (for Non field Bus section) shall be
HART protocol compatible.
2.13 For PLC analog inputs only, if HART pass through card is not available as standard from the
PLC manufacturer, bidder shall provide necessary HART multiplexer, as required, for
communicating to IAMS.
2.14 The offered IAMS system shall be suitable for running / loading advance diagnostic software
of following makes of SMART Positioner: Metso, Fisher, and Dresser.
2.15 The plugin advance diagnostic / valve signatures software of Smart positioner, shall loaded
on the IAMS station. However proper loading, integration and compatibility checking with the
DCS vendors IAMS system shall be the complete responsibility of Contractor. Any other
specific software other than plug-in software, if required by for implementing advanced
diagnostics features in IAMS shall be supplied by Contractor / DCS vendor.
2.16 The time synchronization with external clock i.e. GPS shall be provided by DCS vendor for
DCS, PLC, IAMS, OPC, PSA PLC and other third party devices like VMS etc.
2.17 For Analog output of DCS, the barriers shall be provided with line fault detector.
2.18 All proximity probe input to PLC / DCS shall be provided with IS barrier cum pre-amplifier.
2.19 Fan failure alarm shall be provided in DCS individually for all cabinets.
2.20 For all split range applications the controller shall provide two independent output signals one
for each control valve.
2.21 For fieldbus loop repeat indication shall be a part of fieldbus segment and not through the
DCS.
2.22 Separate cabinet shall be provided for analog, Digital, FF signals separately for DCS and
PLC as applicable. Similarly separate cabinet with interposing relays shall be provided for
MCC inputs and output.
2.23 Type of report generation shall be finalized during detail engineering by operation/process
department of client.
2.24 Screw less terminals shall be considered by contractor for all terminations. All terminals shall
be sourced from reputed make like WAGO.
2.25 Repeat indication in field shall be separate DCS non-redundant AO with IS output barrier for
signal transmission to IS local indicator.
2.26 For control systems where the architecture necessitates that the transmitter power supply be
segregated from controller power supply and the input/output power supply, the system shall
be designed with capability to discriminate between transmitter failure and zero signal value.
The detection of the transmitter failure shall be alarmed and shall cause the controller output
to be held at the prior valid signal output value until the operator takes action by transferring
the control to manual.
Page 267 of 564 5 of 22

2.27 Expandability Philosophy

All the spares shall be calculated based on various requirements specified in the tender
document, including I/O summary, power supply etc.
2.28 Communication Sub-system
2.28.1 The communication subsystem cable shall be secured in G.I. / HPDE conduit. The
communication subsystem, in each case must perform to the offered specifications for error
rate, signal attenuation, noise immunity, etc. No other cable (signal, alarm, power) should
be kept in conduit.
2.28.2 All communication cables, data highway cable routed outside (i.e. between Control Room
and Rack Room / Field) shall be via dual redundant optical fibre type. The optical fibre
cables shall be with two layers of steel tape armouring. Contractor shall provide specific
converters wherever necessary for the same. All fibre optical cables shall be routed through
hard HDPE conduits and shall be totally enclosed within using HDPE matching fittings. The
HDPE conduits shall be as per IS-4984 or equivalent IEC standard. The outer colour of the
conduit shall be orange with black fittings throughout the run. Use separate conduits for
laying redundant fibre optical cables.
2.28.3 Wherever fibre optical cable is to be routed underground, this shall only run in duct provided
in concrete trenches with HDPE conduits provided as above. For redundant system / fibre
optic / serial link, the two cables shall be laid apart as far as possible in same cable duct.
2.28.4 Contractor may use common fibre optical cables to carry more than one data signals. In
such cases, separate fibres shall be used for each of the signals. For all such multi fibre
cables, provide minimum four fibres for future use. Individual fibre optical cable if used shall
have minimum one pair of spare fibre. All fibre optical cables shall be rodent resistant and
armoured type only. 0
2.28.5 In case of non-availability of any control room equipment, the Operator station at Rack room
would be able to continue the operations/ monitoring, and all the other sub systems within
the Rack room would continue normal operations without any degradation.
2.29 Contractor shall provide the web based server with firewall for remote log in and these
servers shall be located, one in connected to the main network as indicated in system
configuration drawing. Web Based server shall be a UHN also and shall meet the
specifications for UHN.
2.30 All items shall be supplied from PMC/ Owner approved contractor list. For any items not
listed in approved contractor list, contractor shall obtain prior approval from PMC /Owner
before ordering.
2.31 The system and documentation and instruction manual CD/DVD shall be submitted with
proper labeling and CD/DVD storage / carry case and not loosely.
2.32 System installation audit shall be carried out by system expert technical audit team of the
vendor for the entire DCS / PLC system including all subsystem to ensure compliance to
the vendors quality installation procedure. Such audit shall be carried out during system
internal loop checking & field loop checking for all I/Os, interlock simulation, taking all the
controls including complex controls in auto mode, tuning of controllers, proving of all
subsystems. Vendors technical audit team shall carry out following minimum checks at site
before power on and detailed report shall be furnished.
1) Earthing checks.
2) PDB checks.
3) System bus cable laying as per recommendation.
4) Individual cabinets wiring checks.
Page 268 of 564 6 of 22

5) Hardwired console checks.

6) Third party system checks, etc.
Site acceptance test for all the subsystem /packages to be considered i.e AIMS, IAMS etc.
2.33 Contractor shall carry out tuning of controller, complex control scheme simulation, and
interlock simulation at site during field testing. Contractor shall be responsible for taking all
the interlocks in line without any bypass & all the controls shall be in auto / cascade mode &
shall be tuned for both max capacity & turndown condition of the unit.
2.34 Procurement and Engineering done by contractor on third party procurement if any shall be
certified by original equipment manufacturer.
2.35 Contractor to provide / select the best possible accessories / peripherals of PC during detail
engineering for PLC and DCS system.
2.36 Graphic, control Groups, Trends, logs and reports shall be approved by Owner/PLC prior to
start of engineering/ implementation, however plant graphics colour shall be as per existing
plant operating philosophy.
2.37 Wiring for Inputs and outputs to the PLC system shall be as per the OEM recommended
philosophy that is with use of recommended FTA boards (with fuse blown indication), TBs,
barriers etc. Recommended philosophy must have requisite PTR.
2.38 For anti-surge controllers, field cables to/ from transmitters/ anti-surge control valve to be 0
directly wired to anti-surge controllers console and outputs also to field directly, not via
marshalling panel.
2.39 Static transfer time will be verified during SAT or before SAT by online changing over the
UPS, by pass UPS, UPS on battery bank etc. The functionality of DCS, PLC should not be
affected. Contractor to demonstrate at site after the Power on of the system.
2.40 Emergency shutdown switches (push buttons) shall be red in colour and Push type with lamp
and cover protection.
2.41 For Operator console & SOE PC, engineering console, and IAMS PC shall be minium sever
grade with dual hot swappable power supply and
2.42 Site Acceptance shall be carried out as per clause 9.0 of of Job specification (44NC-4600-
0000-J-02-0101).
2.43 The Owner / PMC / Licensor shall participate in the following areas of system engineering:
Kick off Meeting, System definition Meeting, Software Definition Meeting
& other Engineering review meeting.
Review of system sub contractor drawings / documents.
Factory acceptance test at sub contractor works for bought out items & FAT
for DCS/PLC.
Loop Checking / testing & commissioning.
2.44 The Project schedule shall be made during KOM for achieving the various milestones.
2.45 Any meetings considered necessary by PMC / Owner in order to achieve the Project
schedule with DCS contractor, the contractor & DCS contractor shall consider the same at
discretion of Owner / PMC.
2.46 DCS I/Os for all closed loops shall be redundant. No Remote I/O shall be used for this
project.
Page 269 of 564 7 of 22

2.47 Process Licensor / Package Contractor shall witness the FAT at DCS system contractors
works.
2.48 All the serial interface points coming from each foreign device shall be interfaced and
annunciated in DCS.
2.49 Smart Positioners are considered for Partial Stroke Testing on ON-OFF Valves and these
positioners shall be connected to AO cards of DCS (open loops). Contractor shall
demonstrate the partial stroke testing during DCS system FAT.
2.50 FF cycle time shall be demonstrated at DCS contractors works during FAT on a typical
segment using field components like FF Barrier & FF field instruments. DCS contractor shall
be responsible for collecting these FF transmitters from site and transporting the same to
their factory for testing. All necessary arrangement for the same shall be in DCS contractors
scope.
2.51 Fault Tolerant Ethernet Switch; the make shall be preferably from CISCO. Separate Ethernet
switch shall be considered for each bus cable. No. of ports (IN & OUT) shall be indicated for
switch. Ethernet switch shall be mounted in a separate cabinet at both locations.
3.0 OPERATOR INTERFACE STATION 0
OIS (Operator console) consisting of operator stations with keyboard and printers shall be
provided considering the operability.
An operator station shall be a console based color TFT with touch screen facility, membrane
type keyboard, track ball & mouse, floppy, hard disk driver units and DCS data bus interfaces.
The operator station collects process information from data acquisition system and allows
operator to monitor and control the plants.
No. of Operator stations per process Units:
- 4 Nos (8 Nos TFT monitors) in console room
- 1 No (1 No. TFT monitor ) in Rack room
- 3 Nos. printers alarm, log and color laser printer common for all Operating stations shall
be provided in Console Room.
Each OIS shall have separate electronics. The electronics of OIS shall be server grade PC.
Min. configuration : Dual-Core CPU; Dual Monitor capable: Ext. speaker; 73GB (min) SAS
rd
Driver; 2G RAM; 48/32 (min) DVD-CDRW; Red control network Ports: 3 E-net Port, cooling
fans with dust filters & 20.1" color TFT with touch screen facility, membrane type keyboard,
Track ball / mouse.
The operator keyboard shall be membrane type. Each keyboards either integral or as a
separate attachment shall have a set of dual function user configurable keys. 64 nos. of such
functional keys are required and the same shall be provided in either of the following ways:
64 Hard keys.
Minimum 32 hard keys with balance functions provided as soft keys.
Page 270 of 564 8 of 22

However when soft keys are provided as per above, for the balance 32 nos., the following
condition shall be met:
For soft keys, key graphic display to be available to operator all the time without occupying
the operator area of display.
These 64 nos. functional keys shall be configured to access important pages in single
keystroke. These keys shall have LEDs which flash on preconfigured alarm conditions.
However LEDs on hard keys which flash on Pre-configured alarm conditions can be realized
in DCS monitor as a soft display. These requirements supersede the requirement specified in
elsewhere in the tender document.
4.0 ENGINEERING WORK STATION FOR DCS

Engineer work station shall be primarily an engineers interface, which shall normally be
used for configuring, tuning and maintenance of the Distributed Control System. This shall
consist of a station provided with operator keyboard and engineering keyboard. This as a
minimum shall also have one configuration and maintenance printer (C & M).
The hardware shall support and supplied with server grade PC Dual Xeon 3.2GHz (min)
CPUs; Five 73GB (min) SAS drives; RAID 5: 2GB RAM; 24X DVD-CDRW Drive; Redundant 0
Control Network Ports ; 3rd Ethernet Port with cooling fans with dust filters, 20.1" colour TFT
(table top), keyboard, mouse.
Two nos. Engineering work station (EWS), one along with common configuration and
maintenance A3 colour laser printer located in Engineering Room & other in the Rack Room
shall be provided. EWS shall have engineering software also to perform all engineering
functions like change in software program, booting, maintenance & diagnostic of system
hardware etc.
EWS shall be used as an Operator station
5.0 ENGINEERING WORK STATION FOR PLC

Engineer work station shall be primarily an engineers interface, which shall normally be
used for configuring, Programming and maintenance of the Programmable logic system. This
shall consist of a station provided with one operator keyboard and one engineering keyboard.
This as a minimum shall also have one configuration and maintenance printer (C & M).
CPUs; Five 73GB (min) SAS drives; RAID 5: 2GB RAM; 24X DVD-CDRW Drive; Redundant 0
rd
Control Network Ports ; 3 Ethernet Port with cooling fans with dust filters, 20.1" colour TFT
(table top), keyboard, mouse .
Six nos. Engineering work station (EWS) with common configuration and maintenance printer
(C & M) printer located in the rack Room shall be provided. EWS shall have engineering
software also to perform all engineering functions like change in software program, booting,
maintenance & diagnostic of system hardware etc.
EWS shall be used as an Operator station
Page 271 of 564 9 of 22

6.0 DOCUMENTATION NODE (DON)

6.1 Contractor shall be responsible to supply completely engineered documentation node
including necessary hardware of proper size and the software necessary to meet the
requirements of the node. The relational database shall be Oracle based. The relational data
base (Oracle Based) shall be generated by the supplier to display and print out all unit
documentation on the documentation node. Menu driven option to be provided for
accessing/searching/filtering all related data of a particular tag from relational database.
The node shall comprise of a workstation or a 20.1" color TFT (table top), Keyboard and
Mouse, PC latest configuration (Pentium - V @ 1.2 GHz or better), 512 MB memory (RAM)
minimum, 1 MB (Min) Cache, HDD capacity min .160 GB having Redundant hard disk (SCSI)
RAID 1 controller, Dual Channel 10/100 Ethernet card, CDRW drive, Floppy Drive 3.5,
1.44MB with, cooling fans with dust filters.
The node shall meet the following requirements as a minimum:

- Store complete unit wise documentation (As Built) & retrival on CPCL intranet with Login
ID. Necessary firewall for the same shall be Provided
- Unit wise store all instrument specification sheets including all field devices and P&IDs for
all the units. The specifications will essentially consist of tag number, location, service
and all major attributes to uniquely identify the instruments in the refinery.
- Provision for Editing Documents.
- Link DCS documentation with unit documentation and instrumentation specification.
- Unit wise updation and maintenance of documentation file.
- Generation of new drawings and document and load these in the system if required.
- Provision of transferring / accessing information to / from MS access/ Excel formats
from/to other PCs on network.
- Print out various documents as required.
6.2 The documentation node shall be dedicated one. The sizing of the node shall be carried out
based on the above facts. Any information should be accessible from the system in a menu
driven program only. Contractor shall be responsible for the complete application engineering
of documentation node including those of packages. Documentation data as available from
sub packagers will be made available to the contractor.
6.3 Following documents should be possible to be printed from the documentation node as a
minimum. Contractor shall indicate the capability of their offered system and shall engineer
the same as per CPCL requirements:
- Loop wiring diagram for every input and output including field interconnection up to
instrument inclusive of junction box.
- Loop schematic and instrument hook-up drawing showing sample tubing, fittings, joints,
etc.
Page 272 of 564 10 of 22

- Alarm and trip settings (software and hardware along with field settings) for DCS and PLC
tag numbers in tabular form in total or in part as per requirements based on type of
instruments / parameters.
- Transmitter calibration ranges, span, elevation / suppression provided.
- Safety valve set points.
- DCS PLC input / output tag list with location.
- The document containing all information attributed to the particular tag number like its
loop wiring diagram, cable schedule number, tubing hook up number, installation
standard number etc.
- Provision of viewing / printing logic diagrams, PLC configuration (if possible).
- Generate any report in the user definable format.
- DCS point database.
6.4 It shall be possible to add delete modify any attribute, data, specification, parameter etc. from
the system with proper protection, password protection may be provided.
All documentation can be achieved on CD /DVD and also can be printed in the printer
attached. Provision for printout shall be possible in a suitable segregated manner for :
i) DCS /PLC input/output tags.
ii) Tuning parameter tag wise.
iii) Loop wiring diagram.
iv) Cable Schedule
v) Any table containing any set of parameters/ specification for any number of DCS/ field
tags based on database.
vi) Any other documentation
6.5 Any information should be accessible for the system in a menu driven program only.
6.6 Contractor shall be responsible for the complete application engineering of documentation
node including those of other units; Contractor shall obtain and load all documentation data
as available from sub packagers/ vendors.
7.0 UNIT HISTORY MODULE NODE (UHN)

7.1 Contractor shall be responsible to supply unit history node, which shall be utilised primarily
for:
- Collection of historical data and its storage and archiving.
- Provide display services to other users.
- Provide interface to higher-level plant-wide network.
Page 273 of 564 11 of 22

7.2 The UHN shall be a High capacity data storage device where data from various process units
shall be stored in a fast access database .The node shall support Standard open system
interfaces like OPC, SOL, OLE, DDE and shall provide active X facility.
7.3 The UHN shall collect data from the distributed control system as of various data types like
process variable, set point, computed variable, and outputs for trend of last one year and log
reports as required and also from various other UHN in the system.
7.4 It shall also be possible to calculate maximum, minimum and average values of the data
gathered. Data collection rate, high/low alarm limits and damping etc. should be definable
Tag number wise.
7.5 The UHN shall act as network server and shall perform administrative activities like back up,
Archiving Restoring, disc storage monitoring activities. It shall also support two way
communications.
7.6 Contractor shall supply a suitable hardware platform meeting system throughput and capacity
requirements. All supporting softwares necessary for the operation and meeting all functional
requirements shall be supplied. The system shall support RDBMS as server software as a
minimum with TCP /IP network protocol.
7.7 The hardware shall support and supplied with PC latest configuration (Pentium - V @ 1.2
GHz or better), 512 MB memory (RAM) minimum, 1 MB (Min) Cache, HDD capacity >40 GB
having Redundant hard disk (SCSI) RAID 5 controller, Dual Channel 10/100 Ethernet card,
CD / DVD RW drive, Dual Redundant Power Supply, Floppy Drive 3.5, 1.44MB with
cooling fans with dust filters, 20.1" colour TFT (table top), Keyboard and Mouse.
7.8 The system shall be sized as follows:

- The system shall be able to interact concurrently with minimum 10 nos of users apart
from CPCL main computer. It shall be possible to access data from remote location
through dialing or client network with proper ID and password protection. Firewall
protection shall be provided to protect the system from any external virus sources.
- For the purpose of sizing the UHN, contractor may follow the following:
Storage time : 1 Year (365 days)
Scan rate : 30 seconds for all data
Storage interval on RAM : 20 min
No. of tags : All
7.9 It is envisaged to connect the UHN to CPCL refinery plant LAN. Contractor shall be
responsible to provide suitable hardware and driver software based on the operating system
and RDBMS.
10,000 tags from/to users for plant wide network shall be considered for sizing purpose.
However details shall be discussed during detailed engineering.
Page 274 of 564 12 of 22

The complete details related to connectivity specifications and data definition will be provided
to contractor during detail engineering.
7.10 Contractor to provide firewall in UHN. The same shall be CISCO (system appliance firewall
(PIX) and software (IOS) firewall) or equivalent.
7.11 Two-way communication shall be possible through UHN from /to the plant wide LAN.
7.12 UHN shall have dual disk with both discs working in parallel.
7.13 UHN sizing shall be approved by Owner/PMC.
8.0 ALARM INFORMATION MANAGEMENT SYSTEM (AIMS)

8.1 Apart from alarm handling requirements specified for DCS, Contractor shall meet the
requirements of AIMS defined herein.
The alarm Management system shall offer a variety of alarm handling feature for processing
and presenting alarms in most efficient way. The system shall be a comprehensive tool with
capabilities to:
- Unit wise separate file for alarms to achieve even with segregation of Alarms related to
DCS, PLC & Third party Items.
- Unit wise report building /Configurable & Printing.
- Present only logical alarm information to the plant operator in case of unit start up and
upset condition.
- Logical processing of events to aid operator to quickly access the normal or emergency
situation and take corrective action.
- Alert all concerned plant personnels and officials in case of any problem as per plant
operating philosophy.
8.2 AIMS software shall be loaded in Unit History Node. Incase supplier has a proven Software
available as a part of DCS ,they must have proven references of running satisfactorily for a 0
period of 4000 hours along with user certificate of satisfactory performance.
8.3 AIMS shall meet the following requirement also as a minimum:
8.4 Computed Alarms

- The system shall have capability to generate/compute alarms based on a logical
combination of states, conditions and events
8.5 Information Analysis

- The system shall have capability to analyze and present only the meaningful information
to the operator like frequency analysis.
Page 275 of 564 13 of 22

- The system shall be designed to analyse the frequency of occurrence of an alarm during
a pre-defined period. The data shall be presented in a Bar graph and its form with most
frequent occurred alarm at the top of the list.
8.6 Expert Alarming

a) The system shall be able to carry out statistical analysis as the alarms data gathered and
perform.
- Real-time frequency analysis
- Alarm frequency break-up
- Alarm frequency monitoring
- Standing alarms
- Time elapsed between two alarms/events
b) The system shall also have capability to analyse various alarms/data and inform plant
operator the probable reason, make recommendations as the action to be taken and
provide operational alterative.
c) System shall be capable of analyzing and recommend maintenance requirements based
on preset rules.
d) The system shall have advanced search feature to present to operator the alarm data
based on the search 'Note'.
8.7 Alarm Notification and Audio Messaging

The system shall be capable of performing following functions also:
a) E-mail
When a predefined tag alarm occurs, the system shall be able to send message through
an e-mail to the predefined user.
This facility shall also be utilized to send e-mails to the manufacturers of various oriented
items like DCS, PLC etc. in case of occurrence of a system alarm.
For e-mail, UHN shall be connected to the Plant-wide LAN. Cabling between the PC to
the LAN socket in control room shall be done by contractor.
b) Emergency Hooters.
The system shall be capable of generating input such that in case of an emergency
condition emergency hooters can be initiated along with Audio messages on the hard
wired console.
8.8 Report Printing

The system shall have capability to:
a) Store alarm messages for a period of minimum one year and shall have facility for data
archival on disc.
b) The alarm shall be possible to be printed as and when required, as a user defined
formats. These formats shall be defined during engineering.
Page 276 of 564 14 of 22

8.9 OEM enabled port shall be provided for enabling connectivity of logging printer also.
8.10 Hardware requirement of Alarm Information Management:

Contractor to ensure that all the requirements as specified above are fully complied by the
offered alarm system. In addition, following hardware requirements and connectivity
requirements shall also be complied:
a) The AIMS shall run on a UHN server with monitor. An additional server if required shall
also be offered which shall support same keyboard type for operational ease. Although no
server redundancy has been envisaged, the bulk data storage disc must be redundant.
b) The AIMS shall handle all process & system alarms irrespective of their origin. That
means the system shall handle all alarms as configured in DCS and PLC.
c) For the purpose of connectivity, not more than four (4) devices shall be multi-dropped on
one serial link to server. Moreover, these links should also of the same unit and shall not
be mixed with others.
d) Following peripherals or outputs shall be provided from the AIMS:
- A laser printer to be provided attached to the server or client for printing reports and
alarm
- A speaker / Horn to be provided in the control room & Check & Change Room for
suitable audio message broadcast in control room.
- The connectivity of the systems important telephone numbers.
8.11 The system shall be able to display and printout the alarm history of minimum of '10000
alarms.
8.12 The system must have facility of keeping at least 96 hours of record at the time with last in
and first out facility.
8.13 AIMS shall have a provision to segregate DCS/PLC and diagnostic data. The alarms shall be
segregated based on tag nos. and in case a unique tag nos. are used for DCS/PLC, the same
can be provided.
8.14 AIMS Sizing shall be done based on one-month data availability.

Automatic log printing should be possible from the port. The log reports should be web
enabled. Logging shall be provided at AIMS for all units all tags.
9.0 PLC CONSOLE
9.1 One No. PLC Console with printer shall be provided which shall be capable of monitoring
logics, displaying, storing & printing SOE alarm. The PLC console shall be located along with
operator console and shall be used by the operator for monitoring, issuing commands, 0
maintenance override etc. The PLC console shall have full graphic capability and shall display
shutdown and interlock graphic of the unit.
Page 277 of 564 15 of 22

The hardware shall support and supplied with PC latest configuration (Pentium - V @ 1.2 GHz
or better), 512 MB memory (RAM) minimum, 1 MB (Min) Cache, HDD capacity >40 GB
having Redundant hard disk (SCSI) RAID 5 controller, Dual Redundant Power Supply, Dual
Channel 10/100 Ethernet card, CD / DVD RW drive, Floppy Drive 3.5, 1.44MB with cooling
fans with dust filters, 20.1" colour TFT (table top), Keyboard, Mouse & Printer
9.2 Manual forcing of any input or output connected to PLC shall be possible by keyboard.
It shall be possible to print out the ladder / logic diagram on the dedicated PLC printer. In
addition to it the printer shall also print the followings.
(a) The diagnostic messages as and when generated and diagnostic reports, when called
for.
(b) Process alarms connected to the programmable logic controller as and when they appear
or alarms will be stored in history.
(c) The I/O maps showing status of all inputs and corresponding output in a user defined
format.
10.0 SEQUENCE OF EVENTS (SOE) PC
One number of SOE PC per PLC subsystem i.e. min. 6 nos as indicated in system
configuration Diagram shall be provided. SOE PC is required for recording sequence of
alarms / events for shutdown inputs, all 2oo3 logic inputs and shutdown outputs
Vendor to note that the alarm shall be printed on the SOE A&E printer common for all SOE 0
PC with the same resolution or better.
At least 96 hours history for sequence of events should be available in PLC PC/ loader hard
disk with LIFO facility.
The SOE A&E printer shall automatically be updated on SOE PC as and when they occur and
shall have automatic periodic archive and retrieval facility to prevent database overflow errors.
On query of accessing A & E from CPU to SOE Work station is not acceptable. Updation of A
& E to SOE shall be done automatically without loss of data.
The printing shall be automatic and shall need no human intervention such as selecting and
dumping to print. The printout shall have time stamping with the resolution same as PLC
scan time.
Each SOE PC shall have separate electronics. The hardware shall support and supplied with
PC latest configuration (Pentium - V @ 1.2 GHz or better), 512 MB memory (RAM) minimum,
1 MB (Min) Cache, HDD capacity >40 GB having Redundant hard disk (SCSI) RAID 1
controller, Dual Channel 10/100 Ethernet card, CDRW drive, Dual Redundant Power Supply,
Floppy Drive 3.5, 1.44MB with, cooling fans with dust filters & 20.1" colour TFT (table top),
keyboard and Mouse.
Page 278 of 564 16 of 22

11.0 TRAINING KIT FOR DCS & PLC:

The training kit shall essentially be used for refresher and training courses for process
engineers, operating and instrument maintenance staff. The training Kit shall be hardwired
with each type of I/O card, hardwares, controller, etc; (similar to main plant DCS/PLC system) 0
with process simulator for a group of loops and shall include:
- An operator console with an operator key board and engineering keyboard.
- Processor with auto backup facility
- One each of the varieties of modules used in data acquisition.
- Signal simulator
- All necessary software & hardware to interface with plant DCS
Min. configuration shall be (Pentium - V @ 1.2 GHz or better), 512 MB memory (RAM)
minimum, 1 MB (Min) Cache, HDD capacity >40 GB ,Dual Channel 10/100 Ethernet card,
CD/DVDRW drive, Floppy Drive 3.5, 1.44MB with, cooling fans with dust filters & 20.1"
colour TFT (table top), keyboard and Mouse.
Contractor to provide the details of the kit offered along with the proposal.
Training kit system shall be stand alone with respect to hardware and software and in no way
be lined with the main system.
12.0 GIANT SCREEN AND ITS INTERFACE WITH DCS

Contractor shall provide a21 Nos of Giant Screen in the control room, which primarily shall be
used for:
a) Display important operational data of the plant/unit for ready reference like daily
production, shutdown required/requested etc.
b) Display operational situations like start up or shutdown to enable

mangers/operators to discuss without disturbing the unit operator.
c) Display any operator screen on the large screen & also have interface with CCTV
system for Coker Block
d) To provide real time clear luminous view of the unit to share informations between
operators, Unit managers and refinery manager.
e) To hold demonstrations to visitors for ready impressive and effective plant overview
and plant highlights.
f) The giant screen shall be installed in the control room wall. The size of the screen
shall be 70 as a minimum. The long screen shall be based on single chip DLP
technology & provided with 2 X 2 cubes configuration.
g) The giant screen system shall have the following specifications :
i) The screen design shall be based as Polysilicon LCD Rear Projection

technology. 0
Page 279 of 564 17 of 22

ii) Optical system shall have a resolution of 1024 pixels X 768 pixels Colour
pixels per cubic. Each cube shall have a screen diagonal of 70 inches with
16.7 million colours.
iii) The lamp shall be preadjusted in lamp module, which shall not require any
readjustment after replacement. The minimum operational time of lamp shall
be 8000Hrs.
iv) They shall be able to provide uniform brightness of 95% with a contrast
250:1, which shall be able to provide high contrast even in bright ambient
light.
v) The display screen shall be seamless and flicker less. It shall be black or
grey in colour. The brightness and contrast shall remain uniform irrespective
of the no. of cubes used.
vi) The control of screen displays shall be carried out either from the operator
console. The signal transfer shall provide guaranteed disturbance free
operation, which shall not effect sharpness and colour quality.
vii) The giant screen shall be light weight and low thickness type, which can be
supported from the control room wall. Only the front access shall be
provided for any maintenance.
viii) The system shall perform satisfactorily in ambient conditions with maximum
temperature of +40 degree Celsius and 80% non condensing humidity.
h) The Giant screen system shall be interfaced with the system such that any operator
display of any screen could be displayed on the Giant screen suitably. It shall meet
the following requirements:
- Any operator console display or all operator console displays shall be able to be
displayed or switched as desired.
- Screen areas should be protected for each console group.
- Priority of displays should be assignable.
i) The system shall be supplied complete with all hardware and software as necessary for
the specified application including interface software for DCS. Contractors offer shall
detail out complete requirement including methodology of interface.
j) Manufacturers representative must be present during Factory Acceptance Test,

Site installation and acceptance.
k) The Giant screen shall be supplied from following approved suppliers only
a) M/s Barco
b) M/s Delta
c) M/s Planer
Page 280 of 564 18 of 22

13.0 Hardwired Console Layout 0

i. The detailed layout for Hardwired console shall be worked out during detailed engineering
by contractor. The layout for all hardwired consoles shall be reviewed by the owner/PMC.
The No. of Hardwired console shall be decided based on functional requirement.
ii. Hardwired console shall match with the operator consoles including the dimensions and
shall be installed along with operator interface subsystem as man-machine interface,
which shall be equipped with indicating lamps, pushbuttons, Selector switches etc.
iii. Hardwired console shall be of mosaic finish design for ease of adding/ deleting any
hardware on the console. It shall be possible to add or remove any item from console
front by removing or adding mosaic tiles. Mosaic tiles shall be of Mauel or Symo make.
iv. When selector switches are specified and current signals must be used, dummy load
resistors shall be provided to maintain circuit continuity in all switch positions.
v. The HWC shall be sized to accommodate all HW items like lamps, pushbuttons,
Antisurge controllers, Steam turbine control system HMI as required.
vi. For preparing HWC drawing contractor shall note that all push buttons /selector switches
as indicated / required (manual reset of trip, manual activation of trip, control room reset
for solenoid valves etc.), auto start / stop logic for pumps, compressors and other
packages shall be indicated on HWC layout drawing with appropriate tag no. and
legends.
vii. All HW items like PBS, lamps etc, shall be of miniature type IDEC IZUMI, EAO or
equivalent. Back-lighted push-buttons / switches for status indication on HWC shall be
considered for all counts provided in the I/O summary.
viii. Contractor shall supply consoles for installing CCTV keyboard & DVR controls. Provision
shall also be kept for keeping Plant communication console /Handsets also on hardwired
console (Plant communication console shall also be flush mounted-details).
ix. Alarm annunciator shall be split type, with legend facia hung from the ceiling in control
room and electronics unit installed in Rack room. All necessary mounting accessories,
mounting rod, cables, support, etc. shall be supplied by vendor.
14.0 FUNCTIONAL SPECIFICATION OF OPC SERVER/CLIENT & PIN PC
14.1 CPCL has well established Web based Process Information Network (PIN)
with centralized real-time database server, which is interfaced with all DCS
through OPC connectivity. Real-time database Historian, InfoPlus21, from M/s
AspenTech is being used for centralized database in the Refinery. It is
intended to have field proven redundant OPC servers to interface with our PIN
and Advanced Process control system (DMC Plus).
a) Bidder should supply proven and latest version of two independent OPC
servers with two OPC server software licenses for redundancy.
b) OPC servers & software should run on windows 2003/2008 platform
c) Bidder should provide OPC Servers with necessary hardware and
software in order to meet the following requirement.
d) Each OPC server should read 10,000 real time data points from DCS and
write 1000 data points to DCS within 10 seconds. So minimum throughput
rate should be 1000 data points per second (read and write)
Page 281 of 564 19 of 22

e) Each OPC server should connect to minimum four OPC clients and
transfer real time data bi-directionally.
f) Bidder should provide necessary server side software to connect to
different OPC compliant clients.
g) Bidder should provide server tables, chairs and necessary accessories to
locate and connect OPC server in Optimization room.
h) Bidder should install OPC server, prove the read, and write throughput.
i) Bidder should provide two Cisco ASA 5500 series hardware based firewall
to prevent intrusion of Virus into DCS Network.
j) Bidder should configure the hardware firewalls and prove data transfer as
per client requirement. Configuration documentation must be provided to
client.
k) Bidder should provide licensed anti-virus software on the OPC servers to
protect the system.
l) Bidder should provide necessary documentary proof and test certificates
to support OPC server capabilities.
m) Bidder should provide three PCs and fix one in Operator console along
with DCS Operator consoles. This PC is used for PIN/SAP purpose. PC
cabinet should be same as DCS operator LCD monitor cabinet, to
accommodate 21 inch TFT Monitor and working space to keep PC
keyboard and mouse. Cabinet should also have the place to keep CPU
and locking facility for security. Power Supply to PC also should be
provided inside the cabinet. Other two PCs are used as OPC clients.
14.2 Minimum Configuration for OPC servers - 2 No
Processor Intel(R) Quad Core E5540 Xeon(R) CPU, 2.53GHz,

8M
Cache, 5.86 GT/s QPI, Turbo
Memory 4GB DDR3-RAM

RAID Controller C2: RAID 1 for PERC 6/i or SAS 6/iR Controllers
HDD Controller SAS6/iR, Integrated Controller Card
Hard Disk 2 * 146GB 10K RPM SAS 2.5 " Hot Plug Hard Drive
on RAID 1
Bus architecture PCI / PCie Architecture

Expansion Slots Minimum 3 nos. PCI Slots and 2 nos. PCIe x16 Slots
Power Supply Redundant Hot Swap Power Supply with ability to

replace without bringing down server
NIC 2 * Intel PRO 1000PT 1GbE Dual Port NIC, PCIe-4
Pre Failure Alerts Pre Failure Alerts and Pre failure warranty minimum
for
HDDs, Memory
Video Display With Min 1MB Video Memory
Monitor 20.1 Inch High Resolution LCD Monitor (OEM)
DVD 16x SATA DVD + / - RW Drive (with RAM)
Mouse Optical USB Mouse (2-Button with Scroll) (OEM)
Keyboard USB 104-key Standard Black Keyboard [English]
(OEM)
USB 6 Ports (2 on front and 4 in rear)
Power High output Power supply redundant 870 W
2 x Power Cord, G Type, 230V (5 amps Compatible
to India) for CPU.
Page 282 of 564 20 of 22

1 x Power Cord, G Type, 230V (5 amps Compatible

to India) for monitor
Warranty Three Year Comprehensive warranty for all the
hardware mentioned above
OS Microsoft Windows 2008 Enterprise Edition x32/x64
(5 user license) downgraded to Windows 2003
Enterprise Edition x3/x64 (Separate Installation Media
kit to be provided for each)
Management Server Management Software with ASR
Software
14.3 Minimum PIN PC / OPC Client PC Configuration (3 Nos)
Processor Intel Core2 Duo Processor E7500

Intel G965 Express Chipset Specifications - XPS 210
Memory 3GB (3x1GB) NECC DDR3 1066MHz SDRAM Memory
Hard Disk 500GB3 Serial ATA 3Gb/s Hard Drive (7200RPM)
w/Data Burst Cache
Video Card Integrated Intel Graphics Media Accelerator X4500
DVD 16X Max DVD + /- RW with Dual Layer Write Capabilities
Monitor 20.1 inch S199WFP Widescreen TFT
Adjustable Stand (OEM)
Sound card Integrated 7.1 Channel Audio
Keyboard USB 104 Key Standard Black Keyboard (OEM)
Mouse USB Optical Mouse (2-Button with scroll)
(OEM)

Network Broadcom Integrated Gigabit Networking (BRCM 57780)
Operating System Genuine Windows 7 Professional with Downgrade
Rights Service to Windows XP Professional 32-Bit
USB Eight: (2 front, 6 back) + 1 internal
Warranty Pre-Failure Warranty (Hard Disk and Memory)
3 Years Comprehensive warranty for all hardware
14.4 CISCO ASA 5500 series Adaptive Security Appliances (FIREWALL) 2 Nos
ASA 5500 Series Rack Mountable

Firewall Thruput Up to 300 Mbps
Integrated Network Ports - 5 Fast Ethernet ports (2 Gigabit Ethernet + 3 Fast Ethernet
ports)
User Accessible Flash Slot 1
USB 2.0 Ports 2
Serial Ports 2 RJ45 (Console and auxiliary)
Memory 256 MB
Minimum System Flash 64MB
Multi-bus Architecture
CAB-ACE-Power cord (India, Nepal, Srilanka)
Page 283 of 564 21 of 22

DCU
15.0 OTHER REQUIREMNTS:
15.1 Furnitures for all DCS and PLC operator / engineering consoles, PIN / OPC consoles in
control room, rack room, engineering and operator room shall be provided with operator
chairs. Also necessary furniture for housing documentation and spares shall also be
provided. . Quantity shall be estimated based during detailed engineering
15.2 The system and documentation and instruction manual CD/DVD shall be submitted
With proper labeling and CD storage / carry case and not loosely.
0
15.3 Four no. of LED / LCD clock with GPS connectivity
15.4 Six numbers of panel mounted phones for operator console and four numbers of
Cordless phones for Rack Room
15.5 Two number of Cu (Cooper) and Au (Silver) corrosion transmitter (4-20 mA and
RS485 interface to DCS) for Rack Room and control of following make Purafil or
Circulaire or equivalent
Page 284 of 564 22 of 22

ANNEXURE: B
SPECIFICATION FOR FIRE & GAS SYSTEM

(A133-000-16-51-OD-02 Rev. B)
ANNEXURE: B
Page 1 of 12
Page 285 of 564
ANNEXURE: B

(A133-000-16-51-OD-02 Rev. B)
1.0 SCOPE
This specification covers the design, manufacture, testing, packing and supply of Fire &
Gas System. The purpose of Fire & Gas System shall be to detect a fire or gas release &
automatically initiate audible and visual alarms in the respective designated emergency
response areas, central control room and in the vicinity of the hazard.
2.0 CODES & STANDARDS

The Fire & Gas System, the detectors and all ancillary equipment shall, as a minimum, be
designed, developed, installed & tested in compliance to the latest edition to all the
following applicable national & international codes & standards:
IEC 61508 Functional safety of electrical / electronics / programmable electronic safety
related system
IEC 60409 Guides for the Inclusion of Reliability Clauses into Specification of Components
(or Parts) for Electronic Equipment
IEC 60529 Degrees of Protection of Enclosures
IEC 60617 Graphic Symbols for Electronic Diagrams
IS 2189 Code of practice for installation of automatic fire alarm system using heat
sensitive type fire detectors (applicable clauses only).
IS 5780 Intrinsically safe electrical apparatus and circuits.
IS 5469 Code of practice for the use of semi-conductor junction devices.
BS 5839 Code of practice for installation of fire alarm system.
BS 3116 Part 4 - Automatic Fire Alarm Systems in Buildings: Control and Indicating
Equipment
BS EN Code of Practice for the selection, installation and maintenance of electrical

60079 apparatus for use in potentially explosive atmospheres
BS 5445 Components of Automatic Fire Detection Systems

Part 5 - Heat Sensitive Detectors-point detectors containing a static element
Part 7 - Smoke Detectors - detectors using scattered light, transmitted light or
ionisation
Part 8 - High Temperature Heat Detectors
BS 5446 Part 1 - Point type Smoke Detector
NFPA 72 Code of practice for automatic fire alarm system
Page 2 of 12
Page 286 of 564
ANNEXURE: B

(A133-000-16-51-OD-02 Rev. B)
3.0 FIRE DETECTORS & ACCESSORIES

3.1 GENERAL
The analogue reading sent by the detectors shall be sensed and if there is a rapid
increase an alarm shall be generated. However, if there is a gradual increase in the
analogue reading a maintenance alert shall be generated by the F & G System.
3.2 Barriers
Barriers, located necessarily in unclassified / non hazardous areas, in marshalling
cabinets shall be may be employed for wiring detectors / break glass boxes installed in
hazardous areas.
3.3 Line Isolator

3.3.1 Line Isolator shall be installed, as applicable.
Line Isolator shall be designed to provide short circuit protection to an analogue
addressable detector loop and isolate minimum possible part of the loop. It shall be
possible to wire the fault isolator at any point in the detector loop.
3.3.2 The Line Isolator shall have the capability to continuously check the faulted side of the loop to
determine if the fault still exists. On rectification of the fault, the isolator shall automatically reset
itself.
3.3.3 In case the Line Isolator nearest to the fault does not activate first, the isolator shall query other
isolators nearest to the short circuit and then de-activate/restore itself.
3.3.4 The panel shall be capable of accessing detectors / devices installed outside the zone covered
by the Line isolator modules.
3.3.5 Line isolator module shall be housed in a dust and vermin proof, weather proof enclosure, with IP-
55 degree of protection as a minimum.
4.0 GAS DETECTION SYSTEM

4.1 All detectors shall be suitable for operation from a nominal 24 volt DC
source supply derived from the F&G System.
4.2 Detectors alarms shall be self-latching with remote reset from the F & G system.
4.3 On-line calibration set up to be provided.
4.4 No separate alarm / monitoring panel shall be considered for gas detection system. All
alarms & graphics related to gas detection shall be configured in PLC based system on
separate graphic pages with facility for report generation.
5.0 FIRE & GAS PLC SYSTEM

System Description
5.1 The F&G system shall be a fail-safe with highest possible availability (99.99%), TUV
approved (SIL certified) Programmable Logic Controllers (PLCs) TMR / QMR architecture,
with no common point of the failure and suitable for carrying out all safety functions to
meet SIL3 / AK5 min. functionality. The hardware and firmware should be field proven in
Page 287 of 564 Page 3 of 12

ANNEXURE: B

(A133-000-16-51-OD-02 Rev. B)
the operating refineries. The system shall contain TUV approved main processors
operating in parallel. Memory shall be non-volatile. However in case of volatile memory is
provided, battery backup shall be provided for a minimum of 3 months to keep the stored
program intact.
5.2 The contractor shall submit along with the offer all documents related to certification like -
TUV certificate, its respective report and all such documents referred in TUV certificate
or report.
5.3 The F&G shall be connected directly to the DCS network via Fault Detecting Ethernet
based communication. High speed communication of 100Mbps is preferred. Redundancy
shall be maintained at all the levels including CPU, I/O module, power supply &
communication etc.
5.4 Diagnostics of F&G system shall be standard available feature in the main plant DCS +
PLC without any additional engineering requirement in F&G and DCS systems. F&G shall
support the extensive alarming features of DCS, as process alarms are detected; they are
brought to the operator attention at the operator console. Integrated sequence of event of
DCS & F&G shall be available in Operator Console.
5.5 There shall be a write protection or firewall between DCS & F&G. DCS is normally reading or
monitoring F&G system. To maintain the safe & reliable operation of the F&G system,
direct write access from DCS to all hardwired F&G points is not recommended. For write
request from DCS to F&G, if any, shall pass to the F&G control program via dedicated
boolean & numerical inputs. The inputs appear at the input side of the FLD, where the
conditions for write access are defined.
5.6 The scan time of programmable controller shall be of the order of 250 msec or less than
half the PST, whichever is less.
5.7 Serial interface between the F&G system (SIL-3 PLC) and addressable detectors via Fire
Alarm Panel shall be redundant without any engineered solution.
5.8 Online replacement of any module shall be possible in such a way that removal and
addition of a module shall be possible without de-energizing the system and there shall
not be any process upset while replacement. System software should also support
these online changes, replacements and modifications with out any compromise on safety.
PLC shall have the capability to allow hot swapping of I/O as well as processor modules
without causing any interruption to the process. Hot slot shall be provided for all TMR
cards & hot slot with I/O module shall be provided for QMR cards.
5.9 The system shall incorporate comprehensive self-diagnostics such that all permanent and
transient faults are identified, alarmed and reported on engineering and Operator station in
Control room. Diagnostics shall be capable of identifying, locating and reporting the
following faults as a minimum:
Scan failure of any processor

Memory faults, both PROM and RAM
Microprocessor faults
Communications faults
I/O interface or addressing faults
Software discrepancies
I/O modules faults
Voted signal discrepancy on inputs

ANNEXURE: B

(A133-000-16-51-OD-02 Rev. B)
Faults detected by output line monitoring / testing features

Fuse failure
Power supply faults including RAM battery backup monitoring and
output voltage verification
5.10 The main function of the FGS is to protect from hazards to human life. Furthermore it has
to provide the operator with proper status information of the process plant over any time
period via the SOE link to the DCS. In addition the FGS shall provide the SOE with
event information. The FGS shall be especially capable of automatic logic control in
accordance with the Logic diagrams provided by the Contractor. SOE shall have an
event resolution equal to or better than the scan time of the PLC. To enable this, the
following shall be provided:
Fail safe sequence and logic control

Binary logic (AND, OR, NOT).
Timers (on delay, off delay, single shot).
Latching.
Counting.
On/off switching
Alarm handling incl. date and time stamping
Sequence of event with date and time stamping.
High Speed Fault Avoiding Ethernet interface communication (100mbps) with
DCS.
Clock setting by means of external atomic clock communication link for critical or non
critical signal etc.
5.11 All field input/output modules shall be configured safety related SIL3 / AK5 and the same shall
be approved by TUV for application in SIL3 in the TUV report.
5.12 The maximum IO density shall not exceed 16 points for Input & Output modules.
5.13 Unless specified all analogue and digital inputs/outputs shall be 24 V DC powered by the
System.
5.14 Each plug-in module type shall have unique mechanical keying to prevent the physical insertion and
on-line activation of a module in the wrong location. No address links or switches shall be
mounted on the module themselves. The module address identifier shall be located on the main
chassis or in the firmware and automatically recognized by the operating systems.
5.15 Intrinsic Safety protection shall be via IS barriers.
5.16 Interfacing of each detector, to the data highway shall be via transmitters/communication modules
which convert the normal analogue signals to digital format. Transmitter communication module
should be capable of accepting Gas, Fire and MAC inputs.
5.17 All field mounted Gas, Fire detectors, MAC, beacons, sirens, deluge system etc; shall be directly
interfaced with F & G PLC system (Non addressable). All necessary hard ware & soft ware
required for interfacing shall be supplied by contractor. All MCP related to building are
addressable type & MCP related to plant area individually connected to PLC system.
5.18 The output shutdown component shall be automatically tested for "struck-on" or "struck-off"
condition at a regular interval. All Digital input cards and all output cards must have line monitoring
feature. This is to detect any short circuit or open loop between the system and the field devices.

ANNEXURE: B

(A133-000-16-51-OD-02 Rev. B)
Subsequent to this, there shall not be any relays between the Line monitored IO's and field
devices.
- Deluge output shall be normally energised.

- For HVAC tripping/fan stopping only one potential free contact shall be given to HVAC
system. Contact shall be multiplied as required in HVAC panel.
5.19 20% Installed spare I/O modules including all required hardware completely wired shall be
provided. In addition 30% spare space for future expansion at all levels shall be provided.
6.0 OPERATOR INTERFACE STATION (OIS)
6.1 One No. Operator Interface station (Dual Monitor) will be located Console room in Coker
Block Control room & other (Single Monitor) at fire station approximately 500 meter from main
control room for repeat alarms of F & G system from Coker Block . All signals shall be
transmitted through fibre optic cable (supplied & laid by others). All the necessary provision
for termination of Fibre Optic cable in Coker block control room shall be by contractor.
No. of Operator stations & Printers shall be as below:

- 1 No (2 No's TFT monitors) in Coker block console room ( Console Based)
- 3 Nos. colour laser printer( A3) ( printers alarm, log and Event) shall be provided in Coker
block console room
6.2 OIS consisting of operator stations with keyboard and printer.

An operator station shall be a desktop based color TFT with touch screen facility, membrane
type keyboard, track ball & mouse, floppy, hard disk driver units and DCS data bus
interfaces.
OIS shall have separate electronics. The electronics of OIS shall be server grade PC latest
configuration: Dual-Core CPU; Dual Monitor capable: Ext. speaker; 73GB (min) SAS Driver;
rd
2G RAM; 48/32 (min) DVD-CDRW; Red control network Ports: 3 E-net Port, cooling fans
with dust filters & 20.1" colour TFT with touch screen facility, membrane type keyboard,
Track ball / mouse.
7.0 SEQUENCE OF EVENTS (SOE) PC

One number of SOE PC shall be provided in the Rack Room of COKER Block Control room.
SOE PC is required for recording sequence of alarms / events for shutdown inputs, all 2oo3
logic inputs.
Separate printer (CLP A3 size) shall be provided for SOE PC. SOE printer shall be of 132-
column dot matrix heavy duty high speed line printer. Time stamping of the alarms shall be
displayed
The printing shall be automatic and shall need no human intervention such as selecting and
dumping to print. The printout shall have "time stamping" with the resolution same as PLC
scan time.
SOE PC shall have separate electronics. The hardware shall support and supplied with PC
latest configuration (Pentium - V @ 1.2 GHz or better), 512 MB memory (RAM) minimum,

ANNEXURE: B

(A133-000-16-51-OD-02 Rev. B)
1 MB (Min) Cache, HDD capacity >40 GB having Redundant hard disk (SCSI) RAID -1
controller, Dual Channel 10/100 Ethernet card, CDRW drive, Dual Power supply, Floppy
Drive - 3.5", 1.44MB with, cooling fans with dust filters & 20.1" colour TFT (table top),
keyboard and Mouse.
8.0 ENGINEERING WORK STATION FOR PLC

Engineer work station shall be primarily an engineer's interface, which shall normally be
used for configuring, Programming and maintenance of the Programmable logic system. This
shall consist of a station provided with one operator keyboard and one engineering keyboard.
This as a minimum shall also have one configuration and maintenance printer (C & M).
CPUs; Five 73GB (min) SAS drives; RAID 5: 2GB RAM; 24X DVD-CDRW Drive; Redundant
rd
Control Network Ports ; 3 Ethernet Port with cooling fans with dust filters, 20.1" colour TFT
(table top), keyboard, mouse .
One no. Engineering work station (EW S) with configuration and maintenance printer (C & M)
colour (A4) printer located in the rack Room shall be provided. EW S shall have engineering
software also to perform all engineering functions like change in software program, booting,
maintenance & diagnostic of system hardware etc.
EW S shall be used as an Operator station
9.0 FUNCTIONAL SPECIFICATION OF OPC SERVER
It is proposed to have OPC server interface between F & G PLC system & Operator station
located at Fire station to repeat all F & G system alarms. Connectivity between F & G PLC
system & Operator station located at Fire station shall be through fibre optic cable all
necessary hardware required for termination of FO cable shall be supplied by contractor.
a. Contractor should supply proven and latest version of OPC servers with OPC server
software licenses.
b. OPC servers & software should run on windows 2000/03 platform Contractor should
provide OPC Servers with necessary hardware and software in order to meet the
following requirement.
c. OPC server should read 5000 real time data points from F & G PLC system and write
500 data points within 10 seconds. So minimum throughput rate should be 1000 data
points per second (read and write).
d. server tables, chairs and necessary accessories to locate and connect OPC server in
Optimization room shall be provided
e. Contractor should provide Cisco ASA 5500 series hardware based firewall to prevent
intrusion of Virus into DCS Network.
f. Contractor should provide licensed anti-virus software on the OPC servers to protect
the system.

ANNEXURE: B

(A133-000-16-51-OD-02 Rev. B)
g. Contractor should provide necessary documentary proof and test

certificates to support OPC server capabilities.
Minimum Configuration for OPC servers - 1 No
Processor Intel Xeon with 3.2Ghz or above (Dual Processor

Capable) L2 Cache1 MB L2 Cache
Memory 2GB DDR-RAM
RAID Controller 2* 64 bit Dual Channel ULTRA 320 RAID
Controller with minimum 64 MB Cache with
support for Raid 0/1/5 min
HDD Controller Integrated Dual Channel Ultra2 SCSI Controllers
Hard Disk 2 * 72 GB hot swap Ultra320 SCSI HDDs (10k rpm) on

RAID 1 for OS in a separate Drive Cage.
3 * 72 GB hot swap Ultra320 SCSI HDDs (10k rpm) on
RAID 5 for Data in separate Drive Cage.
Bus architecture PCI Architecture

Expansion Slots Minimum 5 PCI Slots
Power Supply Redundant Hot Swap Power Supply with

ability to replace without bringing down
server
NIC 2 * 10/100/1000 Mbps Redundant LAN adapter
Pre Failure Alerts Pre Failure Alerts and Pre failure warranty minimum for
HDDs,
Memor
y
Video Display With Min 1MB Video Memory
Monitor 20.1Inch High Resolution LCD Monitor
DVD High Speed
DVD-RW Mouse
Yes (OEM make) Keyboard
Yes (OEM make)
USB 4 Ports (2 on front and rear each)
Warranty Three Year Comprehensive warranty for all the
hardware mentioned above
OS Microsoft Windows 2003 (2
user license) Management Software Server
Management Software
CISCO ASA 5500 series Adaptive Security Appliances (FIREW

ALL) - 1No
ASA 5500 Series - Rack Mountable
Page 8 of 12
Page 292 of 564

ANNEXURE: B

(A133-000-16-51-OD-02 Rev. B)
Firewall Thruput - Upto 300 Mbps

Integrated Network Ports - 5 Fast Ethernet ports (2 Gigabit Ethernet + 3 Fast
Ethernet ports)
User Accessible Flash Slot - 1
USB 2.0 Ports - 2
Serial Ports - 2 RJ45 (Console and auxiliary)
Memory 256 MB
Minimum System Flash 64MB
Multi-bus Architecture
10.0 OTHER REQUIREMENTS
10.1 Hardwired console & annunciation panel as required located in main control room the
specification & requirements shall be same as of Main Plant DCS/PLC system
10.2 All the cabinet construction & specification / requirements shall be same as main plant
DCS/ PLC cabinets.
10.3 Furniture's for all operator / engineering stations, OPC servers in control room, rack room,
engineering and operator room shall be provided with operator chairs. Also necessary
furniture for housing documentation and spares shall also be provided. . Quantity shall be
estimated based during detailed engineering
10.3 Training & Post warranty maintenance requirement shall be same as of main plant DCS /
PLC system.
10.4 The requirement of statutory approvals for usage of equipment / instruments / system in
electrically hazardous area shall be followed as defined elsewhere in MR.
10.5 All the co ordination required making data available at Fire Station to other OSBL contractor/
Owner/PMC shall be responsibility of contractor. And all the input required for the same
shall be provided by contractor.

Factory Acceptance Test shall be carried out by contractor for Fire & Gas System &
witnessed by OW NER / PMC. The testing shall be carried out by contractor as per testing
procedure approved by OWNER / PMC. In general all tests as defined for main plant PLC
system are applicable for Fire & Gas System.
12.0 SITE ACCEPTANCE TEST ( SAT)

Site Acceptance Test shall be carried out by contractor for Fire & Gas System & witnessed
by OWNER / PMC. The testing shall be carried out by contractor as per testing procedure
approved by OWNER / PMC. In general all tests as defined for main plant PLC system are
applicable for Fire & Gas System.
Page 9 of 12
Page 293 of 564

ANNEXURE: V
13.0 OPERATIONAL REQUIREMENTS
13.1 Whenever the glass of the break glass type manual call point is broken both audible and
visual (flashing) alarm shall be raised in the operator station indicating the
corresponding location of break glass type manual call point. On pressing "ACCEPT"
push button the audible alarm shall stop and lamp shall glow steadily. The action shall
be brought to normal condition by pressing "Reset" push button (only after the field
conditions are normalised)
13.2 The signal voltages for the system shall be so designed as to avoid spurious faulty
annunciation caused by any noise signal induced in the signal cable due to adjoining
power cables and to ensure a positive annunciation of faults.
13.3 The field contact wiring will be carried out by using multi-core, copper conductor, PVC,
insulated and armoured cable that may be running close to power cables. Hence the
logic circuitry shall be designed with sufficiently high signal-to noise ratio to avoid
spurious actuation due to noise induced in the field wiring because of switching etc.
Adequate noise filters and time delay shall be incorporated at the input stages to reduce
the effect of the noise.
13.4 The logic circuit shall be suitably designed to take care of capacitive currents, associated
with long run of cable required for field wiring.
14.0 POWER SUPPLY
14.1 The power supply for Safety PLC shall be TUV approved for SIL-3 application with
following features -
Dual built-in over voltage protection to comply with the strict functional safety
requirements of the IEC 61508/DIN V 19250 and VDE V 0801 standards,
undervoltage alarm,
redundant parallel operation, and
Optimum protection against continuous overload and short-circuiting.
14.2 The PDB cabinet in control room will be provided with dual 110 V AC 10%, 50 Hz 3%,
using live, neutral and ground from dedicated UPS system (48 Hrs Back up). Each
incoming cable shall be capable of taking the full load of the system. Sub-distribution to all
power users including 24 V DC users shall be by the CONTRACTOR including workstations,
and printers. All field devices including sirens and beacons shall be powered by the
Contractor's System.
14.3 CONTRACTOR shall provide a dual redundant 24 V DC battery systems rated for 48 hours
quiescent operation and 30 minutes in alarm.
14.4 The CONTRACTOR shall include miniature circuit breakers for AC supply to each power
supply unit and sub-distribution within the system. Sufficient isolation facilities on the DC
sub-system shall be provided to enable maintenance of components with minimum
disturbance to healthy devices. All power supplies shall be monitored for faults and failure
and have diode power loading. The CONTRACTOR shall increase the input count as
required to include these alarms.

ANNEXURE: V
14.5 Where individual loop protection is not a feature of the I/O cards, the CONTRACTOR shall
provide individual fusing in the termination cabinets.
14.6 All electrical terminals inside the cabinet shall be clearly numbered and permanently
identified on the terminals and the system wiring drawings
14.7 Electrical wiring shall be in accordance with applicable electrical standards. Wiring
diagrams shall be complete with grounds in recommended wire sizes, type, and shielding
required for the electrical circuits between components that are to be wired.
14.8 All the 24 V DC power suppliers for the system shall be supplied and mounted on cabinet
by the CONTRACTOR.
14.9 Internal power supply shall be fused for short circuit protection and shall have thermal
overload self-resetting protection unit. Every power failure shall generate a system alarm.
15.0 EARTHING
A common earth bus bar of minimum 25 x 3 mm copper or equivalent aluminium shall be
provided throughout the length of the panel. All non current carrying metallic parts of the
panel and mounted equipment shall be connected to the panel earth bus bar. All doors
and movable parts shall be connected to the earth bus by flexible cables. 2 Nos. earth
terminals shall be provided outside the panels. All panels are ring looped & connected to
earthing bus bar / pit. Separate earthing bus & pit for system & IS earth shall be provided.
16.0 NAME PLATES

All nameplates shall be engraved on anodized aluminum. Engraving shall be done with
square groove cutters. Hard paper or self adhesive plastic tape name plates will not be
acceptable. Name plates shall be fastened by screws and not by adhesive.
All panel mounted equipment (e.g. lamps, push buttons, switches, PCBs etc.) shall be
provided with suitable nameplates.
Labels shall be provided for every component on the cards, connecting wires as well as for
the terminals in the terminal strip inside the panel
Special warning plates shall be provided on all removable covers or doors giving access to
energised metallic parts above 24 volts.
17.0 DRAWINGS AND DOCUMENTS

17.1 Manufacturer shall provide a complete set of documents describing the system and its
design concepts, installation, final testing, commissioning and required operating and
maintenance procedure.
17.2 As a minimum following documents shall be provided for the system:
System description
Checklist of equipment & components
Installation instructions
Equipment connection diagrams showing wiring
Final testing instruction
Commissioning instructions

ANNEXURE: V
Certification documents
Log book
System operating instruction
Routine maintenance instruction & schedules.
17.3 As a minimum following drawings shall be provided:-

System schematic diagrams
Cabling & wiring diagram
Detailed equipment connection diagram
Further details regarding submittals shall be as per supplier's data requirement form.
Other documents / drawing not covered above but required for execution of system shall
be listed out by contractor & submitted to OW NER / PMC.
18.0 SPARE PHILOSOPHY

a) Mandatory Spares:
1) 10% or minimum 2 modules of each type (processor module, I/O module,
communication module, power supply module, FTA Cards, Switches, Operator
Keyboard, hard disk etc.) being used inclusive of those used in consoles. This
shall include spare modules for hardwired instruments also.
2) 10 % or minimum 2 nos. of Safety Barriers, Signal Converters, Trip Amplifiers,

PB, Selector switches, Lamps, Push Button, annunciator including all hardwired
Instruments, etc.
3) 20% or minimum one no. of each type of Fuses, MCB's, Auxiliary relays.
4) 10 % or minimum 2 Nos. of bulk power supply unit, diode O-ring Unit of each
rating
5) 10 % or minimum 2 nos. of communication system components such as hubs,

switches, routers, etc. whichever is higher
6) 10 % or minimum 1 nos. of Cables like FTA, communication bus, etc. of each

type and rating.
b) Two Years Operational Spares: Contractor to submit spares list for 2-year
Operation and maintenance. The prices shall be valid for at least 2 years from date
of order.
c) All spare items required for commissioning shall be supplied by contractor.
19.0 QUALITY ASSURANCE

19.1 Quality assurance shall follow the requirements of the Jacobs' Q.A documents applicable
to the fire alarm system.
19.2 QA involvement shall commence at the bid stage and follow through to completion and
acceptance, thus ensuring total conformity to the Purchaser's requirements.

CPCL Chennai Tagging Philosophy for PART III Section B 8.2
44NC-4600 Junction Boxes,Panels & Cables PAGE 1 OF 7
LSTK-1 Coker Block Annex.VI to 44NC-4600-0000-/J.02/0101/A4 Rev. 0
ANNEXURE-C
ANNEXURE: VI
TAGGING PHILOSOPHY FOR JUNCTION BOXES, PANELS & CABLES
Page 297 of 564 1 of 7

CONTENTS
1.0 Purpose
2.0 Instrument Junction Boxes
3.0 Instrument Panels (Control Room Mounted and Locally mounted)
4.0 Cables
4.1 Junction Box to Field Instrument
4.2 Instrument Multicore Cables (Multipairs & Multitriads)
4.2.1 Junction Box To Control room (Marshalling Cabinet)
4.2.2 Local panel To Control room
4.3 Inside Control room cables
4.3.1 Instrument Electrical Interface Cabinet (IEC) To MCC
5.0 Wire Number Ferrules
6.0 Foundation Fieldbus
6.1 Spur Junction Boxes (Multibarrier)
6.2 Fieldbus Junction Boxes (Multipairs)
6.3 Trunk Cables (Spur Junction Box To Fieldbus Junction Box)
6.4 Multipairs Trunk Cables (Fieldbus Junction Box To Marshalling cabinet)
Table 1 Group Codes
Table 2 Signal Type
Page 298 of 564 2 of 7

1.0 PURPOSE
The purpose of this document is to define tagging philosophy for Junction Boxes, Panels &
Cables, for Reside up gradation project for CPCL Manali,Chennai --Tamilnadu.
2.0 Instrument Junction Boxes
XXX - AA Y - 001
Unit Number
Group Code (Table 1)
For Serial No. 1
Signal Type (Table 2)
Sequence Number
3.0 Instrument Panels (Control Room Mounted and locally mounted)
XXX - AA - 001 - F or R
Unit Number
For Serial No. 6
Sequence Number
Suffix*
* - F = Front, R = Rear
Suffix* use only for control room mounted cabinet.
4.0 Cables
4.1 Junction Box to Field Instrument
Individual cables running between field junction boxes and field mounted instrumentation
shall be identified by the instrument tag number.
e.g. XXX-PT-0001
Unit No.
This is also applicable for Foundation Field bus Instruments. Hyphen and spaces do
not form part of the cable number and are shown for clarity only.
Page 299 of 564 3 of 7

4.2 Instrument Multicore Cables (Multipairs & Multitriads)
4.2.1 Junction Box to Control Room (Marshalling cabinet)
XXX - JB Y - 101
Unit Number
For Serial No. 3
Area wise
Cable Sequence Number
(Same as of JB X sequence Number)
4.2.2 Local panel To Control Room
XXX - LCP Y - 01 - 001
Unit Number
For Serial No. 3
Panel Sequence Number
Hyphens and spaces do not form part of the cable number and are shown for clarity only.
4.3 Inside Control room cables
4.3.1 Instrument Electrical Interface Cabinet (IEC) To MCC
XXX - AA Y - 900
Unit Number
For Serial No. 3
Hyphens and spaces do not form part of the cable number and are shown for clarity
only.
Page 300 of 564 4 of 7

Tagging for Cross wiring i.e. between Marshalling Cabinets to Marshalling Cabinets
or to relay cabinet or other cabinet etc. by DCS vendor.
5.0 Wire Number Ferrules
Wire Number Ferrules consist of Tag Number, Terminal Block Number and Terminal
Number.
E.g. XXXFT0001/1+ JB Side

XXXFT0001/2-
XXXJB X 001/1+ Instrument Side
XXXJB X 001/2-
6.1 Spur Junction Boxes (Multibarrier) (L1)
XXX SJB FF 001
Unit Number
For Serial No. 2
Sequence Number
6.2 Fieldbus Junction Boxes (Multipairs) (L2)
XXX - JB FF - 001
Unit Number
For Serial No. 1
Sequence Number
Hyphens and spaces do not form part of the junction box number and are shown for clarity
only.
Page 301 of 564 5 of 7

6.3 Trunk Cables (Spur Junction Box (L1) To Fieldbus Junction Box (L2))
XXX - TC FF - 001
Unit Number
For Serial No. 4
Sequence Number
(Same as of JB FF Sequence Number)
6.4 Multipairs Trunk Cables (Fieldbus Junction Box To Marshalling cabinet)

XXX - C FF - 001
Unit Number
For Serial No. 3
Sequence Number
(Same as of JB FF Sequence Number)
Page 302 of 564 6 of 7

Table 1 Group Code
Sr. No. Group Code Description

(AA)
1. JB Junction Box
2. SJB Spur Junction Box
3. C Cable
4. TC Trunk Cable
5. MR Marshalling Cabinet
6. PD Power Distribution Cabinet
7. DCS DCS System Cabinet
8. PLC PLC System Cabinet
9. IEC Instrument Electrical Interface Cabinet
10. LCP Local Control Panel
Table 2 Signal Type
Sr. Signal Type Description

No. (Y)
1. A Alarms,
2. C Control/Solenoid outputs, 24V DC
3. S Analogue, 4-20 mA
4. T Thermocouple
5. R RTD
6. V Vibration
7. FF Foundation Fieldbus
8. AZ Alarms (Shutdown Service)
9. CZ Control/Solenoid outputs, 24V DC (Shutdown Service)
10. SZ Analogue (Shutdown Service)
11. TZ Thermocouple (Shutdown Service)
12. RZ RTD (Shutdown Service)
13. VZ Vibration (Shutdown Service)
14. GZ Gas Detector (Shutdown Service)
Page 303 of 564 7 of 7

PROJECT NO.: 44 NC-4600 SPEC. NO. 44NC-4600-0000/J.02/0001/A4
TITLE: ENGINEERING DESIGN BASIS FOR REV. NO / ISSUE DATE - B / 25-May-10

INSTRUMENTATION
Page 30 of 34
ANNEXURE-D X
7.1.6 Valves Material SS 316 As per Piping
as minimum Material Spec
X
7.1.7 SignalCABLES
Tubing sizeAND BOX
JUNCTION OD REQUIREMENTS
X
7.1.8 Condensate Pot Required for steam & condensing vapour
Instruments
7.2 INSTRUMENT AIR SUPPLY PIPING
7.2.1 Air supply method for local instruments
X
Through Individual branch header and Individual air set.
X
Refer Drawing 4600-JSD-005
7.2.2 Material
X
- Piping material SS
X
- Valve material SS 316
X X
7.2.3 Air tubing size 6mm 12mm (based on requirement)
X
7.2.4 Air Tubing Material SS 304
7.3 INSTRUMENT CABLING
7.3.1 Cable Routing

X D
- Main cable way G.I. duct Ladder tray
X D
Built up trench Directly buried
X
- Branch cable way Branch Tray Perforated (60 mm, 100 mm,
150mm, 300mm size)
X
FRP cable trays For DM plant
X
- Fire Proofing of instrument
cable duct & Main Cable Tray
1
7.3.2 Cables
a)
7.3.2.1 Type
X
- For DC mA signals,SOV Single pair for individual run
X
Multipairs for main runs (Use 6 pair, 12 pair)
Page 304 of 564


INSTRUMENTATION
Page 31 of 34
X
- For RTD cables Single Triad for individual run
X
Multitriads for main runs (Use 6 Triad, 8 Triad)
X X
- For T/C (or compensating Single pair Multi pair
cables)
2 X
- For Power Supply (2.5 mm ) 2 or 3 core for individual run
(12, 24 core) For Multicore cables
X
- For FF Cables Single pair for individual run
X
Multipairs for main runs (2 pair, 12 pair)
b)
7.3.2.2 Cable specification
All cables shall be of FRLS type. For Fire safe application Fire Resistant
DC mA signal , mV signal ,alarms & Solenoid Valves
X
- Rated Voltage 1100 V
X
- Core size 1.5 mm for single pair
X
1.0 mm for multi pair (up to 300m length)
X
1.5 mm for multi pair (> 300m length)
X
- Core Material Copper
X
- Insulation Material Polyvinyl chloride (PVC),PE for H2 service
X
- Sheath Material Polyvinyl chloride (PVC)
X
- Individual screen required
for single pair
X
- Individual and overall Required
screen for multi pair
X
- Armouring Required
AC Power Supply and On-off Switch Signals

X
- Rated Voltage 1100V
X
- Core size 2.5 mm min. for Power supply
X
1.5 mm for Solenoid Valves.
X
- Core Material Copper
X
- Insulation Material PVC
X
XLPE (For Electrical Interface)
Page 305 of 564


INSTRUMENTATION
Page 32 of 34
X
- Sheath Material PVC
X
- Armoring Required
Compensating cable / Extension wire for Thermocouple

X
- Applicable code ANSI MC 96.1
X
- Core size 1.5mm or 16AWG for Single pair.
X
1.0 mm or 18 AWG for multi pair.
(For length up to 300m)
X
1.5 mm or 16 AWG for multi pair.
(For length > 300m)
X
- Insulation Material PVC (PE for H2 service)
X
- Sheath Material PVC
X
- Individual screen Required
for single pair
X
- Individual and over- Required
all screen for Multipairs
X
- Armoring Required Not Required
Foundation Fieldbus FF Cables

X
- Cable Type Type A
X
- Core size 1.13mm or 16AWG for Single pair & Multipairs
X
- Insulation Material XLPE or Polyolefin
X
- Individual screen Required for single pair
X
- Individual and over- Required
all screen for Multipairs
X
- Armoring Required Not Required
2
7.4 JUNCTION BOX
- Hazardous areas Weather proof type for intrinsically safe
X
& Non hazardous area Flame proof
X
FF junction Boxes Flame proof
X
For DM plant FRP
Page 306 of 564

CHENNAI PETROLEUM CORPORATION LIMITED
MANALI REFINERY, CHENNAI
LSTK-1: COKER BLOCK: DELAYED COKER UNIT & LPG CFC TREATING UNIT
PART : III
SECTION : B 8.2
JOB SPECIFICATION - INSTRUMENTATION
DOCUMENT NO : 44NC-4600-0000-/J.02/0101/A4
Rev No. Issue Date Pages Rev Description Prepared By Checked By Approved By
A 22 June, 2010 48 Issued for Comments VMK MSD BSP
0 19 July 2010 54 Issued For Feed VMK MSD BSP
Page 307 of 564

CPCL Chennai Job Specification- PART - III Section B 8.2
44NC-4600 Instrumentation Page 2 of 32
LSTK-1 Coker Block Spec.No: 44NC-4600-0000-/J.02/0101/A4 Rev. 0
1.0 GENERAL
1.1 This document describes the scope of work, supply & responsibilities of LSTK-1
contractor for carrying out Instrumentation activities of:-
- Delayed Coker Unit (DCU)
- LPG CFC Treating Unit (LPG unit)
These new Delayed Coker and LPG CFC Treating Unit will be located as one single unit
and will be called Coker Block, of CPCL Manali Refinery at Chennai & LSTK-1 contractor
hereafter referred as contractor
1.2 The description & requirements indicated in this specification are concise by necessity
and can not contain all details. However, it is the responsibility of the contractor to
execute the job on a turnkey basis in accordance with the guidelines of this specification,
its annexure, licensor's documents, engineering design basis, standard specifications and
engineering standards.
1.3 The basic engineering package for Delayed Coker Unit is provided by CB&I Lummus & for
LPG CFC Treating Unit is provided by Engineers India Ltd (EIL).
1.4 The Delayed Coker unit (Unit No. 86) is designed to process 2.2 million metric tonnes per
annum of mixed feeds consisting of Vaccum residue, PDA pitch and lube extracts. The
process scheme for the delayed coker unit consists of two coker heaters, two coke
drums, fractionator and vapour recovery system. The vapour recovery system consists of
wet gas compressors, absorber/stripper, sponge absorber, debutaniser, naphtha splitter,
LPG amine scrubber and fuel gas scrubber.
The feed to unit is received in feed surge drum and pumped to bottom of coker
fractionator. Before reaching fractionator bottoms it exchanges heat with heavy coker gas
oil and heavy coker gas oil pump around. The feed mixes with bottoms liquid of the
fractionator (recycle oil). The combination of the bottoms liquid and fresh feed is the coker
heater feed. The coker heater has four passes per heater. A controlled quantity of VHP
steam is injected into each pass to reduce coke formation. The coke drum inlet switch
valve diverts the hot feed to bottom of the coke drum. In the coke drum the hot feed
cracks and forms coke and cracked products. The hot vapour is quenched with HCGO to
stop further cracking and coke formation in vapour line to fractionator. The coker
fractionator separates the coke drum effluent into wet gas, naphtha, light coker gas oil,
heavy coker gas oil and a heavy recycle stream. The overhead vapours are routed to
vapour recovery section for separating fuel gas, LPG, light naphtha, and heavy naphtha.
Following are the major products from the unit and their destination / utilization:
1) Sweetened fuel gas (used within the unit or exported to header)
2) Sweetened LPG (sent to LPG CFC unit for removal of mercaptans)
3) Light coker naphtha (sent to NHT/ISOM unit or DHDT)
4) Heavy coker naphtha (treated in DHDT unit)
5) Light coker gas oil (treated in DHDT unit)
6) Heavy coker gas oil (processed in Hydrocracker)
7) Petroleum Coke (sent to off plot storage.
1.5 The CFC Coker LPG Treatment Unit (Unit No.87) has been designed for processing 8800
kg/hr of sweetened LPG from Amine Treatment Unit (as part of DCU) of Resid
Page 308 of 564
Upgradation Project. The feed stream shall contain mercaptans (0.28 wt %), H2S
(50 ppmw), H/C, CS2, COS, etc. The treated LPG, free from H2S and mercaptans (20
ppmw max.) will be routed to storage. The plant shall be designed for a stream factor of
8000 hours/annum. The overdesign and turn down for the plant is 110% and 50%.
The LPG treatment unit is designed to treat LPG from DCU ATU using CFC
(Continuous Film Contactor) technology. The unit is designed to remove H2S and
mercaptans from feed LPG. In caustic wash section, the H2S, COS & mercaptans in
the feed react with caustic to form sulphides. The caustic consumed in the reaction can
be regenerated by oxygen and the sulphides will be converted to thiosulphate &
mercaptide which in turn will be converted to disulphide oil (DSO) in the presence of
a catalyst. The DSO will be extracted from the caustic by use of a solvent.
The LPG is pre-washed in a packed column filled with caustic to remove

st nd
predominantly H2S. The LPG is sent to a filter & then to 1 and 2 stage caustic
wash column & separator where it flows co-currently with caustic thereby extracting
mercaptans & H2S
from LPG. The treated LPG is sent for
storage.
The rich caustic is sent to Regenerator column where it is contacted with air. Sodium
sulphide gets converted to sodium thiosulphate & mercaptides are converted to DSO
in presence of a catalyst. A slip stream of solvent, naphtha is added to enhance
DSO separation from caustic. The regenerated caustic along with some fresh 20 %wt
caustic (make-up) are sent back for LPG treatment. A slip stream of spent caustic is sent
to ETP for treatment. 12 %wt caustic is used for initial filling in the equipment. Facility
for 12 %,
20% & 45% caustic & spent caustic storage are
provided.
Chemicals & Catalyst: 45% caustic solution will be loaded & stored in fresh caustic
tank which will be used to prepare 12 wt% & 20 wt% caustic solution by dilution with DM
water. Liquid catalyst will be required for oxidation in the caustic regeneration section
2.0 SCOPE OF WORK AND RESPONSIBILITY
Contractor's scope of work and responsibility shall be as indicated in scope of work section
attached and as detailed in this specification.
2.1 Contractor shall be responsible for execution of complete work related to Instrumentation &
control systems of Coker Block on turnkey basis with scope of work which covers but
not limited to Design & detailed engineering, procurement, review of vendor documents,
supply, inspection, installation, site calibration, testing & commissioning of all the
instruments & control systems. Contractor shall also be responsible for his own inter-
departmental co- ordination as well as co-ordination with other contractors as necessary
through out the entire execution of the project.
2.2 Codes and standards

Contractor shall refer various codes and standards indicated in clause 2.1 of 'Engineering
Design Basis - Instrumentation' in addition to standards attached along with this package.
Page 309 of 564
In general, contractor shall carryout engineering as per IEC/BIS standards. Any other
standard, if necessary, can also be referred by contractor during the execution of the job,
without diluting the basic requirements, however with prior information to Owner/PMC. In
any case contractor must furnish a list of codes and standards other than those specified in
this document which shall be followed by them during engineering.
2.3 DELETED.
2.4 DELETED.
2.5 DELETED.
2.6 DELETED.
2.7 DELETED.
2.8 Contractor shall be responsible for satisfying the specific requests from the owner
without any time & cost implications.
2.9 Contractor shall be responsible for providing complete project documentation package
in requisite form and quantity which shall include all the engineering drawings &
documents generated by them as well as their sub contractors & vendors.
2.10 DELETED.
2.11 Contractor shall be responsible for obtaining all statutory approvals, as applicable for all
control systems.
2.12 DELETED.
3.0 DESIGN AND CONTROL PHILOSOPHY
3.1 GENERAL
3.1.1 DELETED.
3.1.2 DELETED.
3.1.3 Bidder to note that SIL-3 certified ESD PLC (TMR/QMR) is envisaged for all trips and
shutdown interlocks.
3.1.4 The control system( DCS/PLC) for Coker Block (DCU, LPG CFC) & IA Compressor
Package ,Cooling Water System & Tankages shall be single make & model & shall have
completely independent functionality & operability .
3.1.5 Control system shall have integrated PLC (with TMR/QMR architecture) system which
shall be used to carryout all interlocks & emergency shutdown functions.
Sequence of events functionality shall be incorporated in the PLC with time stamping at I/D
card level. Separate sequence of event retrieval PC shall be provided.
Page 310 of 564

3.1.6 It is proposed to use PLC system for all emergency shutdown interlocks related to a
Coker block inclusive of package units (heater package, Coke cutting /decoking package &
coke heading /unheading package) ,tankages & also for utility packages ( cooling water
system, IA Compressor package).
3.1.7 Dperating voltage for control system shall be 110 V AC, 50 Hz from UPS.
3.1.8 The philosophy for control of electrical equipment / drives shall be as follows
- No rotary equipment shall be started from control room
- Critical pumps & all compressors can be stopped from control room
- No utility pumps shall be stopped from control room
- Reset switch of a particular interlock shall be wired to 'Ready to start' lamp on
the local panel of the pump or compressor which has tripped as a result of that
shutdown interlock
Contractor shall take above into consideration while deriving I/D count for DCS / PLC.
3.2 DELAYED CDKER UNIT (DCU)

Control system for DCU shall be engineered to cover instrumentation and control
of following major units / packages -
- Fired heater
- Coker drum
- Coke unheading system
- Coke cutting system
- Wet gas compressors
- Fractionator
- Vapour recovery system
- Coke handling system ( Dnly serial Interface)
3.3 LPG CFC Treating unit (LPG unit)

Control system for LPG unit shall be engineered to cover instrumentation and control
of following major units/packages.
- Caustic pre-wash column
- Regeneration Column
- Separators
- Filters
- Caustic Heater
- Air compressor
- Jet Eductor
3.4 PACKAGE UNITS
3.4.1 DELETED.
3.4.2 DELETED.
3.4.3 Contractor shall ensure that the Instrumentation control & shutdown interlock
Philosophy of the main process plant shall be maintained throughout all the package
units.
3.4.4 Shutdown Interlocks of fired heater, coke cutting, coke unheading package units will be
executed in the Main plant PLC through dedicated controller for each package.
Page 311 of 564
4.0 INSTRUMENTATION & CONTROL SYSTEM REQUIREMENTS
4.1 FIELD INSTRUMENTATION
4.1.1 DELETED.
4.1.2 DELETED.
4.1.3 DELETED.
4.1.4 DELETED.
4.1.5 DELETED.
4.1.6 DELETED.
4.1.7 DELETED.
4.1.8 DELETED.
4.1.9 DELETED.
4.1.10 DELETED.
4.1.11 DELETED.
4.1.12 DELETED.
4.1.13 DELETED.
4.1.14 All non critical open loops connected to DCS shall be with FF, critical open loops & all
close loops are with 4- 20 mA DC SMART with HART protocol. All transmitters connected
to shutdown & interlock system are with 4- 20 mA DC SMART with HART protocol. Asset
Management System (AMS) for all SMART with HART instruments connected to
DCS/PLC & FF instruments is to be complete with hardware and software as indicated in
clause no. 4.5 below shall be provided.
4.1.15 DELETED.
4.1.16 DELETED.
4.1.17 DELETED.
4.1.18 DELETED.
4.1.19 DELETED.
4.1.20 DELETED.
4.1.21 DELETED.
4.1.22 DELETED.
4.1.23 DELETED.
4.1.24 DELETED.
4.1.25 DELETED.
4.1.26 DELETED.
4.1.27 DELETED.
Page 312 of 564
4.1.28 DELETED.
4.1.29 The square root extraction for the differential pressure based flow measurement shall be
carried out in DCS.
4.1.30 DELETED.
4.1.31 DELETED.
4.1.32 DELETED.
4.1.33 DELETED.
4.1.34 DELETED.
4.1.35 DELETED.
4.1.36 DELETED.
4.1.37 DELETED.
4.1.38 DELETED.
4.1.39 DELETED.
4.1.40 DELETED.
4.1.41 DELETED.
4.2 DISTRIBUTED CONTROL SYSTEM
4.2.1 General
4.2.1.1 The standard specification for DCS defines the minimum requirements for system
design, Configuration, inspection, testing, installation and commissioning.
4.2.1.2 Proven Track Record (PTR) requirements
The DCS vendor shall have presence in India for a period of minimum 5 years as DCS
supplier with expert manpower for support and shall have supplied minimum of two DCS
systems of similar size to refinery, petrochemical or fertiliser plants for a continuous
critical and hazardous application. The offered system shall have proven track record of
successful operation for minimum 1 year after completion of Site Acceptance Test and
vendor shall provide supporting documentation for the same. Also Note the following
i) The system should be supplied engineered & tested from a factory from where
the system/ sub-systems have already been supplied and meet the criteria
indicated above.
ii) All the activities including engineering should be carried out by the agencies
which have carried out the similar activity in the past and meets the criteria
indicated above.
iii) The system should be supplied by the manufacturer in the fully

engineered condition or should be supplied by the manufacturer's
representative/subsidiary that have proper infrastructural facilities and meets
the criteria indicated above.
iv) In any case, the manufacturer whose system is being offered / supplied should
Page 313 of 564 have a local representation/subsidiary which has the proper infrastructural
facilities like engineering, installation, maintenance, testing, spare

part support, system fault diagnosis and other related logistic support.
Systems which don't have the local base should be avoided.
4.2.1.3 As indicated in Control Philosophy (3.1.4), single DCS system with unit wise
segregation up to controller level shall be provided for Coker Block, tankages & utility
packages
4.2.1.4 The DCS system software shall operate on Windows XP platform
4.2.1.5 DELETED.
4.2.1.6 All analogue Input/output modules connected to DCS shall be HART type. Analogue
Inputs shall be interchangeable i.e.( 2 wire, 3 wire & 4 wire)
4.2.1.7 The system should be supplied by the manufacturer in the fully engineered condition or
should be supplied by the manufacturer's representative / subsidiary that have
proper infrastructure facilities. In such a case, vendor must submit a letter assuring
total involvement at all stages of work from their principal. Under any circumstances,
principal shall be responsible to resolve any problematic issues related to required /
specified performance of hardware and /or software.
4.2.1.8 Contractor / DCS supplier shall furnish data sheets / compliance sheets for DCS
indicating important parameters of each item to owner/PMC for approval before
finalisation of order.
4.2.1.9 DCS system shall be of latest evolutionary type with 'Open System Architecture'. For
open system connectivity the system shall adopt following standards as a minimum:
- The system shall support Ethernet communication conforming to IEEE 802.3.
- The method of data access by any user on the plant wide network shall be by I/O
tag name and not by any physical or logical address.
- Connection & transfer of data though TCP /IP for operating any window based
process package should be possible without any addition of hardware / software
4.2.1.10 The data base shall be global unit wise and shall be accessible by all TFT's of each
console or between consoles of same unit. However, a key lock/password protection shall
be provided to selectively inhibit console response to key action.
4.2.1.11 Any addition/deletion of tag number should be possible without booting of the system or
plant shutdown. Any changes in any portion of the database during running of the plant
should be possible. Downloading of the changed software to the respective sub system
should be possible in running condition of the plant. Saving, updation and taking back up
of the database with respect to the latest changes made should be automatic and without
affecting the plant running.
4.2.1.12 Controller shall have capability to hold output at its' last value during online downloading
operation and the output should not go to fail safe value.
4.2.1.13 It shall be possible to tune control loops on selective basis, automatically. Tuning
parameters computed by the system shall either be loaded automatically or manually by
the operator.
The software for the loop tuning may reside/ run on any system hardware including
controller subsystem, operator console subsystem etc. The tuning package shall ensure
that the system shall not be disturbed whenever a loop is being tuned.
4.2.1.14 All the TFT'S shall be console type only. This shall be extended to TFT'S of all systems
and package units also. All consoles shall be uniform in colour and size. Lower end of
the consoles (including operator, engineering, hardwired console, etc.) should not have
any opening from front side. There must be adequate space of at least 1500mm on the
rear side of these consoles for doing maintenance.
Page 314 of 564
4.2.1.15 Control systems shall be designed with availability requirements of 99.99% as minimum,
with a MTTR figure of 8 hours. The level of redundancy specified in the engineering
design basis, clause 5.12 is minimum. Additional redundancy if required must be provided
by contractor to meet these specified availability requirements.
The redundancy requirement for various system components shall be as follows:
- Controller system 1: 1 redundant
Input / output system
- For closed Loops 1 : 1 redundant
- FF loops 1 : 1 redundant
- Critical Open Loops 1 : 1 redundant
- Interlocks & shutdown system 1 : 1 redundant
- Communication system 1 : 1 redundant
- Power supply 1 : 1 redundant
4.2.1.16 CONTROLLER SIZING & LOADING CRITERIA
For DCS
Separate DCS controller subsystem shall be provided for DCU, LPG CFC
&Cooling water system Package. No's of controllers for these subsystem shall
be decided based on following criteria.
Separate controller sub-system shall be provided for redundant serial interface

requirements between DCS and foreign devices .not more than 4 serial interfaces
shall be connected to one controller. These serial interfaces shall not be combined
with any process unit controller sub-system
Separate gateway/Controller shall be provided for interfacing each PLC
system. For PLC
Separate PLC controller subsystem shall be provided for DCU, LPG CFC, Cooling
water system Package, IA compressor & Dryer package, Coke cutting (Decoking)
package & Coke Unheading Package.
No's of controllers for these subsystem shall be decided such that each Controller loading
shall not exceed 60% when configured for scan time as specified & also maximum control
loops in one controller shall not exceed 100 nos. including installed spares and future
space. Loading here is referred to the use of memory, CPU time and
communication
capacit
y
4.2.1.17 The system shall be sized to have real time trending for all tags with time base of
maximum 1sec. and historical trending for all the tags with time base of 30 sec. for analog
and 10 sec for digital tags for at least 40 days.
4.2.1.18 There must be a facility of zooming of all history trends with respect to time scale and
parameter value.
4.2.1.19 DCS alarms in critical category shall require unique colour, grouping, or graphical
display on the TFT and unique audible tone to clearly distinguish them from non critical
alarms. In addition, critical alarms to be provided on a separate alarm panel located
above or near the operator station.
4.2.1.20 Contractor must furnish bus loading calculations for each subsystem i.e. controller
subsystem, console subsystem and communication subsystem. These loading figures
shall be demonstrated by contractor at factory acceptance test and finally during site
Page 315 acceptance
of 564 test. Contractor shall quote for hardware and software to meet these loading
requirements. In case, actual loading is found to be higher than specified, contractor shall
supply additional controller and hardware/software to meet the requirements without
any cost and schedule implications.
4.2.1.21 W herever 3 transmitters are wired to PLC for 2oo3 logic, all 3 signals shall be repeated
to DCS using signal isolators/repeaters. In DCS Mid value shall be used for further
processing. DCS shall have capability to sense bad value due to transmitter fault,
open line or deviation in measured value more than specified limit and shall exclude such
signal for mid point calculation. Any transmitter fault shall be logged on event / message
logger.
PV value of all three signals shall be made available on a separate pop up window
accessible to operator by click of an icon on process graphic page.
4.2.1.22 Split range scheme to be incorporated in DCS by providing two separate 4-20mA outputs.
4.2.1.23 All controllers shall be configured so that 0% on the face plate indicates valve closed &
100 % indicates valve open. If the valve is fail open then the controller output signal shall
be reversed.
4.2.1.24 For Additional Requirements of DCS / PLC control system refer Annexure A.
4.2.2 DCS/PLC system for Coker Block control room shall include following as minimum :
- Four (4) numbers of operator consoles (8 Monitors each 20.1" TFT ) each with bottom
monitors with Touch Screen facility along with individual operator's keyboard, mouse &
track Ball .
- 3 Nos. printers alarm, log and event printer common for all Operating stations Shall
be provided
- Controller Subsystem, I /O subsystem, Communication Subsystem as per actual
Requirements.
- Auxiliary consoles for unit wise separate as required.
- Furniture as Required (Operator's Chairs, Printer Tables, cupboards, document rack
etc.) Godrej make only.
- Two (2) Engineering Station for DCS with operator key board, mouse & Colour laser A4
paper printers.
- Six (6) Engineering Station for PLC with engineering key board, mouse and common
one (1) colour laser A3 paper printer.
- Six (6) SOE PC with Keyboard Mouse & common one (1) colour laser A3 paper printer.
- Two (2) no's OPC server with Keyboard Mouse & colour laser A4 paper printer with 3
No's PIN /client PC.
- One (1) AMS PC with Keyboard Mouse & A4 paper printer & One (1) HART
Configuration PC with Keyboard Mouse & A4 paper printer
- One (1) ,PLC console with Keyboard Mouse one (1) colour laser A4 paper printer.
- One (1), Operator Interface Station with Keyboard Mouse with touch screen facility.
- One (1) ,Documentation Node with Keyboard Mouse & A4 paper printer
- One (1) ,Unit History Node with Keyboard Mouse & A4 paper printer
- All other hardware necessary for completion of system
Page 316 of 564

4.2.3 For interfacing third party equipment like anti surge controllers, Governor, analyser system,
machine monitoring system etc., contractor must use protocols which are industry de-facto
standards like MODBUS. Proprietary systems shall be avoided.
4.2.4 In addition to the system requirements as indicated above, following also

shall be considered while designing the DCS system :
For PLC / foreign device interface with the DCS, the communication interface
and interface software shall have speed and priority such that data transfer occurs
within one (1) second of an event at PLC input or on a foreign device event even
when both systems are operating under load. The data to be transferred to and
received from the DCS should be mapped into a separate section of memory.
4.2.5 It is contractor's responsibilities to co-ordinate with the supplier of foreign devices

identified and establish communication for transfer of data with them. Unless the
above communication is established, the control system shall not be considered
commissioned.
4.2.6 The serial interface shall be through controller & data acquisition subsystem/
processor subsystem and the no. of serial links per serial interface module shall
be restricted to 4
subject to meeting loading criteria. Further for Main PLC Systems and F&G System
0
separate dedicated redundant serial interface module shall be
provided.
4.2.7 Total no. of redundant gateways / serial interface modules shall be calculated
and Provided accordingly by vendor for each network meeting the other
requirements of specification.
4.2.8 Time synchronisation

All the real time clocks in the systems including DCS, PLC etc. supplied by
contractor shall be synchronized with each other. The accuracy of the resolution
of real time clock used as master clock for time synchronization of all the
systems shall be better than resolution of the SOE system.
The real time clock within various systems shall be crystal controlled which shall be
independent of line frequency. There must be a provision for manual
synchronization of time for various real time clocks in the systems. Such change shall
be possible through a menu driven facility.
4.3 PROGRAMMABLE LOGIC CONTROLLER
4.3.1 The standard specification for PLC defines the minimum requirements for PLC
system design, configuration, inspection, testing, installation and commissioning.
4.3.2 The PTR requirements for PLC shall be similar to that for DCS.
4.3.3 PLC system with unit wise segregation up to controller level shall be used
for all emergency shutdown interlocks related to a plant Including all package units
of that plant.
4.3.4 All interlocks & emergency shutdown shall be configured & executed in a fault
tolerant PLC based on Triple / Quadruple Modular Redundant architecture
certified by TUV for class V.
4.3.5 In case of TUV certified systems, contractors must ensure the following ;
- All the model numbers of modules supplied shall be TUV

approved.
- All software modules or firmware's shall be TUV
Page 317 of 564
approved.
- The relays used within the PLC shall be TUV SIL 3

approved only
- The system shall be engineered considering all guidelines provided in the
TUV certification of the system. A copy of which shall be furnished to owner /
PMC for information.
- The configuration and assembly of the complete system shall be carried out
either by manufacturer's or by an agency which have carried out the engineering
of same make of TUV approved system in the past and has been authorised by
the PLC vendor in writing with still maintaining their responsibility for safety
such as authorisation certification shall be provided by contractor in such a case.
- All maintenance and operation related features as per TUV report are
to be demonstrated during factory acceptance and site acceptance test.
4.3.6 Three (3) field transmitters where used to initiate interlock/ shutdown shall be
wired to separate TMR/QMR analog input card of PLC & 2 out of 3 voting
logic shall be configured on the analog inputs to enhance the system
availability. The isolator's repeaters shall be used for all 3 inputs for connecting to
DCS. Each isolator repeater shall be powered through separate feeder.
4.3.7 PLC shall have the capability to allow hot swapping of I/O as well as processor
modules without causing any interruption to the process. Hot slot shall be
provided for all TMR cards & hot slot with I/O module shall be provided for QMR
cards.
4.3.8 PLC shall have built in capability to identify & analyze the sequence of events with a
time stamping resolution of 1 millisecond or less at I/O card level.
4.3.9 The PLC scan time shall be of the order of 250 millisecond or better. In case
any equipment requires faster scan time the same may be adopted for that
application. Ladder logic and functional block diagram shall only be used for
programming the PLC complying to IEC 61131.
4.3.10 Six (6) PLC engineering station with operator functionality with key board and one
(1) common colour laser A3 paper printer shall be provided . Engineering station
shall be a desk top PC with 20.1"TFT monitor, latest CPU & other hardware and
shall operate on Microsoft windows XP platform. IEC 61131 toolset shall be
loaded on the engineering station to provide programming interface.
The PLC engineering station shall have full graphic capability and shall
provide all
shutdowns / interlock related operational views to the operator including forcing
facility and power flow on ladder logic. The PLC engineering workstation shall have
necessary software & hardware required for SOE functionality such as event
logging, data retrieval and report generation.
4.3.11 The system shall have an automatic and on demand data back-up facility for
the preservation of all data during a planned / unplanned outage. The entire control
software shall be backed up including vendor software, control database, user-
built programs, source code and data files.
Back-up copies produced on bulk devices shall be removable for remote storage. On
line backup shall not degrade system performance.
4.4 SHUTDOWN INTERLOCK ALARMS & PLC-DCS INTERFACE
4.4.1 For all 2 out of 3 voting logics, in addition to individual and voted alarm, contractor
shall provide a maintenance alarm indicating discrepancy shown by any of inputs.
Page 318 of 564
4.4.2 Common alarm of each initiated shutdown will be hard wired from 'DO' of PLC to a
hard wired alarm annunciator on auxiliary console. Contractor shall submit the list of
hard wired alarms for Owner's /PMC's approval.
4.4.3 For all trip initiating alarm inputs, PLC to provide 'DO' to Aux. Console for hardwired
annunciation. In addition common interlock alarm (XA) to be provided on Aux. Console
annunciator. Also, DCS dynamic graphics to include these common alarms along
with status indication of all initiating inputs (with colour change), through serial link on
interlock graphic display.
4.4.4 Soft commands from DCS to shutdown interlock shall not be acceptable. Wherever
pump stop commands or interlock trip commands (HS) are shown from DCS on P&ID's,
these shall be considered on hardwired Aux. Consoles in control room and shall be
wired to digital input of PLC. Interlock reset switch shall be provided on auxiliary console
and shall be hardwired to digital input of PLC.
4.4.5 Critical pumps & compressors trip alarms and other alarms shall be hardwired to alarm
annunciator on auxiliary console.
4.4.6 No hardwired Maintenance Override Switch (MOS) shall be used. This shall
be incorporated in PLC Operator Station by soft tag. However, for enabling initial start
up, process bypass switches if required shall be considered by LSTK-1 contractor on
Auxiliary Hardware Console.
4.5 INTEGRATED ASSET MANAGEMENT SYSTEM
4.5.1 In order to aid maintenance of field transmitters and smart positioners, a common " Asset
Management system" (AMS) has been envisaged for all units connected to the control
system. This system shall interact with all smart transmitters and smart positioners
to provide following
4.5.1.1 Monitoring of device (smart transmitters, FF transmitters and smart positioners / control
valves) status on-line.
4.5.1.2 All maintenance related data like diagnostics alarms, transmitter range, settings etc.
4.5.1.3 Trend data for all devices.
4.5.1.4 Facility to re-range, configure and calibrate field transmitters and smart positioners remotely.
4.5.1.5 An audit trail for a complete historical record of all configuration, calibration and device
alerts.
4.5.1.6 Data on predictive maintenance such as list of transmitters experiencing dynamic error
band etc.
4.5.1.7 Advanced diagnostic features like device step response, device signature, dynamic
error band etc.
4.5.2 Documentation like various trend reports. Diagnostics reports, predictive maintenance
reports, audit reports, historical data and device specification sheets in addition to those
available with selected software as stand-alone.
4.5.3 Definition, engineering, configuration, loading and compilation of all reports whether
specifically indicated in this specification or available as standard with selected
software shall be in the scope of contractor.
4.5.4 For the purpose of sizing the system, contractor to consider the snap shot of all the
Page 319 of 564at an interval of one hour with a time period of minimum 40 days. However,
data
all the final report data or audit report data shall be stored at least one year, after
which it could get stored on the streamer tape or compact disc automatically with a
message on the system.
4.5.5 The system shall be of latest technology and shall be capable of interacting with the "Hart
Protocol" version used with the
transmitters.
4.5.6 The system shall be supplied complete with all hardware and software
necessary for making the system complete.
4.5.7 The system shall be able to perform read and write function on the transmitters
and positioners. However write protection facility shall be provided with multiple
password and system warning.
4.5.8 The software shall be cornerstone. Asset Management System (ASM) or

equivalent compatible with all the smart instruments supplied as a part of this
package.
4.5.9 Additionally separate configuration PC each for HART shall be provided.
4.6 FIELD - RACK ROOM INTERFACE
4.6.1 Marshalling cabinets shall be supplied for DCS / PLC to provide required isolation
and interconnection between various field signals and I/O subsystem. These shall
be located in the rack room. Unitwise separate marshalling racks shall be considered
for DCS & PLC systems.
4.6.2 In general, intrinsically safe philosophy shall be followed for all inputs /
outputs in hazardous area. Contractor must select external barriers, wherever
applicable, on entity concept. All barriers shall be isolating type. All barriers
should be provided with dual power supply. In case power rail system for barriers
are used, then fused terminals shall be provided for all analog and digital signals from
field and dual power supply to power rail to be provided
4.6.3 Isolators shall be of latest / enhanced available versions with 3-port isolation of
proven quality and of reputed make. Specifications similar to series 5000 of M TL or
equivalent model of P & F isolators shall be considered as minimum. Approval
of actual model number shall be obtained from Owner/ PMC before proceeding and
any change required from the model selected shall be carried out by contractor
without any implication.
4.6.4 Interposing relays shall be considered for digital input & output signals to & from
MCC as well as for interface with field mounted flameproof instruments & accessories
such as field switches & field indicating lamps etc. All relays shall be provided with
free wheeling diodes. Only SIL-3 certified relays shall be used. Minimum no. of
contacts for all relays shall be 2.
4.6.5 Isolators and relays shall be channel mounting type only (PCB mounted shall be
avoided) in view of ease of maintenance. Stacked terminals shall not be used for the
incoming field side termination. These shall be channel mounted type, suitable for
2.5 square mm conductor size. Terminals for internal wiring may be of stacked type
(with minimum separation between stacking of 10mm) PCB mounted and with
prefabricated cable connector for connections with I/D subsystem. All terminals and
termination assemblies shall be of reputed make such as Phoenix contact.
Page 320 of 564
2
4.6.6 Panel internal wiring shall be with stranded copper conductors of minimum 0.5 mm
in size and colour coded for various voltage levels and signal types (Refer standard
specification 44NC-4600-0000/J.SS/0110) for easy identification and shall be segregated
and separately routed to avoid effects of induced voltages.
4.6.7 Following types of cabinets shall be supplied. Unitwise separate cabinets for DCS & PLC
shall be considered. All cabinets shall of RITTAL make only. All cabinets shall
be
800/1200(w) x800 (D) X2100 (H) mm only. Contractor shall ensure that all cabinets shall
be packed & shipped in single sections only and no two cabinets shall be combined
in view of limited entry / passage sizes of control room building.
4.6.7.1 Analog marshalling cabinets

Isolating IS interface units for 4-20 mA DC analog inputs & outputs shall be housed
in these cabinets. These isolators shall be capable of supporting bi-directional digital
communication with SMART field devices using universal HART protocol. Analog
signal isolators shall be powered by 24 V DC & shall be of single Input/Dutput channel type
only. Isolator with built in signal repeater shall be used on analog inputs which are
required to be connected to PLC as well as DCS.
In all analog marshalling cabinets provision shall be kept for mounting hand
held
configurator / fieldbus tester for smart / Fieldbus
transmitter.
4.6.7.2 FF cabinets: - H1 Cards and other hardware like power conditioners, advance diagnostic
modules etc; are located in these cabinets.
4.6.7.3 Marshalling cabinets for digital input signals
Digital input signals shall be housed in these cabinets. These inputs shall be
connected by IS barriers suitable for proximity detector input (NAMUR) or directly
potential free / relay contact. These inputs shall be powered by 24 V DC & shall be
of single input channel type only.
4.6.7.4 Marshalling cabinets for digital output signals

Digital output signals shall be housed in these cabinets. These output shall be
connected by IS barriers suitable for solenoid valves or directly potential free / relay
contact. These outputs shall be powered by 24 V DC & shall be of single output channel
type only.
4.6.7.5 Instrument Electrical Interface cabinet
Separate Cabinet shall be provided for termination of electrical cables from MCC/PCC s to
control system.
4.6.7.6 Relay cabinets for feed back signals from MCC

Potential free MCC contacts shall be wired in the 24 V DC coil circuit of interposing relays.
Contact of the interposing relay shall be wired to digital input of PLC and/or DCS
(as required) in the 24 V DC interrogation circuit. Each relay shall be with
2NO+2NCchange over contacts & contact rating shall be 5 Amps @ 240VAC/110 V DC.
Terminals & wiring carrying 110 V DC shall be segregated from 24 V DC wiring
&
terminals. Fuse type terminals shall be
used.
4.6.7.7 Relay cabinets for command signals to MCC
Page 321 of 564

Interposing relay shall be used to provide potential free closed contact

representing enable command for wiring in the 240 V AC/110VDC control circuit of
MCC for electrical drive wherever required. 240 V AC shall be sourced from MCC.
The coil rating of the interposing relay shall be 24 V DC. Each Relay shall be with
2NO+2NC change over contacts & contact rating shall be 5 Amps @ 240 V AC for LT
drives and 15Amps @ 110
V DC for HT drives. Terminals & wiring carrying 240 V AC/110 VDC shall be
segregated from 24 V DC wiring & terminals. Fuse type terminals shall be used.
4.6.7.8 Power supply distribution cabinet

Separate Power supply distribution cabinet is required to be provided for various
voltage levels i.e. 110 VAC, 24 V DC & 240 V AC. Power supply distribution cabinets
shall house circuit breakers, switch fuse units (Only for current / voltmeters), bus bars,
termination & wiring as well as bulk power supplies as required.
4.6.7.9 System Cabinets

System cabinets supplied by system vendor shall house racks for installing controller
sub system, I/O subsystem, power supplies & other system components along
with their wiring.
All system cabinets (DCS, PLC) shall be provided with toughened glass door at front
side;
all other specifications of cabinet shall be specified elsewhere in feed
document
4.6.8 The ferruling philosophy/type shall be decided during detail engineering based on
overall philosophy for the refinery. Unless otherwise specified, cross-direct ferruling
concept shall be used.
4.6.9 Cabinet lighting shall be 230 V AC non-UPS only and the lamps shall be white
threaded type. One no. additional socket for 230 V AC shall be provided in each
cabinet for use of other testing devices.
4.6.10 All field cables shall be first terminated in separate TB (marshalling terminals) and
further the same shall be connected to the barriers / relays.
4.6.11 Marshalling cabinets for high powered trunk based Fieldbus system and 4-20mA
signals shall be segregated.
4.7 INSTRUMENT - ELECTRICAL INTERFACE
4.7.1 Digital output commands from PLC shall be in the form of normally closed contact
which opens on stop command. ( Relays de-energised on stop command).
4.7.2 Instrument control cables shall be used for carrying all control signals to and from MCC.
Signal segregation and proper distances shall be maintained in cables carrying 240 V
AC/ 110 V DC and analog signals. Contractor shall clearly define inter-departmental
scope and shall be responsible for co-ordination within departments.
4.7.3 110 V AC UPS C power shall be provided from UPS and battery.
4.7.4 Digital inputs to DCS

Following potential free contacts shall be provided at
MCC
- Contact of the contactor for run status feedback of each
Page 322 of 564
drive
- Contact for stop status (indicating stop command from control room, field or
logic operation)
- Contact of the electrical fault relay for each drive indicating electrical
trip
These contacts shall be wired to digital inputs of DCS through interposing relays for
status indication on DCS.
4.7.5 Analog inputs to DCS

4 to 20 mA DC analog signals shall be provided at variable speed drives (VSD)
representing motor current and/or speed as applicable. These signals shall be
connected to analog inputs of DCS for indication / derived alarm.
4.7.6 Analog outputs from DCS

4 to 20 mA DC analog signals shall be provided at marshalling rack for speed control
of
V
S
D.
4.7.7 Digital outputs from PLC

A potential free contact of interposing relay shall be provided at the rack room for
issuing stop command from emergency shutdown logic (as shown on P & I D) to MCC /
VSD.
4.7.8 Substation interconnection with PLC/DCS are to be made through unit multipair cable only.
It should have dedicated laying route inside cellar room. All these cables should
enter cellar through dedicated MCT blocks.
4.7.9 Separate Multi pair cables shall be laid for Motor run contacts to PLC / DCS. Similarly
for Start & stop Commands from PLC, separate Multipair cables shall be laid. All
these cables shall be laid in Electrical Cable Trench. RCC partition shall be
provided in the Electrical cable trench for separation of these signals. Separate
Junction boxes shall be considered for these signals & the same shall be provided at
MCC end.
4.7.10 Electrical/Instrumentation Interface system to be submitted by contractor for PMC/OWNER

approv
al.
4.8 COMPRESSOR CONTROLS
4.8.1 General
4.8.1.1 Contractor shall follow requirement of the instrumentation related portion of the
following standards in the design of compressor instrumentation.
API standard 617-(Centrifugal compressors for general refinery service- latest
edition)
API standard 618-(Reciprocating compressors for general refinery service-latest
edition)
4.8.1.2 DELETED.
4.8.1.3 DELETED.
4.8.1.4 The logic for the compressors shall be executed only in unit PLC.
Page 323 of 564
4.8.1.5 Anti-surge controller with performance monitor, speed governor, etc. as required shall be
housed on auxiliary console & located in control room.
4.8.1.6 All process variables & alarms related to compressor, steam turbine & other associated
equipment shall be made available for monitoring, data acquisition, report generation,
diagnostics and analysis on the main plant distributed control system.
4.8.1.7 In general, instrumentation & controls indicated against 4.8.2 & 4.8.3 below shall be
provided as minimum. Contractor / equipment vendor shall add other instrumentation as
required for safe operation of the compressors.
4.8.2 Centrifugal compressors
4.8.2.1 DELETED.
4.8.2.2 Machine monitoring system for turbine and

compressor
For machine monitoring, all sensors shall be connected to series 3500 rack in control
room and repeat indication to be provided in field. Localized purged enclosures shall be
considered only for BN 3500 LCD Display unit. TDXNet shall be provided. Data manager
is not envisaged. Alarm & trip contacts and analog repeat indication to DCS shall be
hardwired, in addition Redundant RS 485 port shall be provided for
modbus communication to DCS.
4.8.2.3 Surge Protection

CCC make 3 ++ redundant anti surge controller with performance controller shall be
provided to achieve following functionality and shall have minimum features as
indicated below.
- Advance surge control methods to allow compressor to safely operate closer to
its surge limit without recycling.
- Built in loop-decoupling algorithms to allow controller to be tuned faster.
- Fast response time: controller shall be capable of calculation & adjoining compressors
proximity to surge control line at least every 50 milliseconds by automatically
adapting to changing inlet conditions.
- Controller shall be capable of selectively executing combination of closed loop
& adaptive open loop response to avoid surge with additional safety response to limit
the surge after single cycle( if at all it occurs) in order to prevent further surges.
- Bump less transfer between manual & automatic operating modes
- Automatic start up and shut down logic.
- Input fault detection & fall back strategies to keep compressor on line in the event
of transmitter failure with alarm out put for remote.
- Tracking & self test features with alarms
- Anti-surge controller / performance controller shall be provided with serial link
for connecting to DCS.
- Toolbox software shall be provided for anti surge controller
- Anti-surge valve response time maximum. 10 seconds.
Page 324 of 564
DCS shall have facility to work as back-up to anti surge controller when selected
by operator. CCC performance evaluation parameters shall also have DCS back-up.
Contractor shall provide documentations including performance calculations

procedure and anti surge control software configuration.
4.8.2.4 DELETED.
4.8.3 DELETED.
4.9 FIRE & GAS SYSTEM
4.9.1 Integrated Fire & Gas System for entire Coker block, utility packages & tankages, shall be
provided.
4.9.2 F & G system shall be PLC based with TMR/QMR configuration & min. SIL 3 certified.
4.9.3 DELETED.
4.9.4 For Detailed specifications of Fire & Gas system refer Specification for F&G System
enclosed as a part of the MR.
4.10 DELETED.
4.11 CCTV SYSTEM
4.11.1 The scope of supply for the CCTV monitoring system shall include:-
- High resolution charge coupled device (CCD) day and night colour cameras.
- Auto iris zoom lens, pan and tilt, near and far focus, screen wiper, ON/OFF control
equipment, colour monitor and DVR
- Automatic computer based switching device including quad splitter.
- Ceiling hung CCTV monitor such that these can be suitably matched with control room
aesthetics by dimensions appearance etc.
- Coaxial cables, control cables, connector etc of required type and size.
- DVR located in control room
Complete supply of CCTV system for entire coker block including heater package & for
Cooling water system & IA compressor package is in the scope of contractor.
4.11.2 The functional and specification requirements of the CCTV system shall be as per
standard specification 44NC-4600-0000/J.SS/0101 "Standard Specification for
Instrumentation work". However in addition following requirements shall be taken care by
contractor.
- The video signals of the cameras shall be terminated on a matrix switcher and Quad
splitter through an interface junction box.
The control action on the camera (viz. Zoom, pan, tilt, focus, wiper and washer control
etc) and display action on monitors (manual and auto sequencing) shall be carried out
by operator initiated commands from the CCTV keyboard.
- The video outputs of cameras shall be sequentially displayed on monitor. The

sequence of scan interval shall be selectable from control unit/box, using quad splitter
unit.
- Control box shall have the provision to select from any of the video signal inputs
(maximum inputs) of cameras on "Monitor". The control actions on cameras shall be
possible.
Page 325 of 564
- Pan and tilt action shall be programmable from central system (for auto pan and tilt
option)
- The DVR shall be super VHS Tune lapse video cassette recorder with time, data, day
of week, recording mode, camera number, alarm number, self diagnostics and power
outage screen display. The DVR shall have facility for automatic recording, which can
be programmed for each day and in case of an alarm signal, the DVR shall
automatically go into recording mode. The DVR shall also have snap shot recording
facility with selectable snap shot time period.
- Pan/Tilt and zoom control unit & housing shall supplied from OEM (Supplier of Camera)
only.
4.11.3 Contractor to note that CCD Day & Night coloured cameras have been envisaged.
Contractor shall supply all hardware and software necessary for CCTV system as
required.
Minimum required hardware for CCTV system shall be as given below:-
Description DCU LPG Cooling IA

Unit water compressor
system Package
Package
No. nof Cameras 6 Nos. 2 Nos. 2 Nos. 2 Nos.
No. of monitors (32" TFT LCD) 2 No. With 1 No
DCU
No. dof DVRs 1 No. 1 No. 1 No
No. d of control consoles Keyboard with 1 No. With 1 No
Joysi tick DCU
t
Addition to above, one monitor with keyboard shall be provided in shift in-charge's room.
Cameras & field junction boxes along with installation hardware like cable glands etc; for
Heater Package, cooling water system Package & IA compressor package shall be
Free issued to respective package vendors for Installation.
4.11.4 Contractors scope of work shall include but not limited to following.
- Identification of suitable location, actual mounting of cameras in field and monitors in

main control room. Contractor shall get CCTV camera locations drawing approve by
Owner / PMC.
- contractor shall ensure that the interconnecting cables between field mounted
cameras and control room shall be laid & terminated
- The installation of complete hardware, all control room mounted equipment and cable
termination
- The complete commissioning of CCTV

system
- System shall have the capacity for future expansion to add minimum of 2 cameras and
one no. of additional DVR without adding any hardware / software.
4.12 INSTRUMENTATION & SYSTEM EARTHING REQUIREMENTS
4.12.1 DELETED.
4.12.2 DELETED.
Page 326 of 564
4.12.3 DELETED.
4.12.4 Shield wires of all analog instruments will be connected to earth only at control room end.
The instrument side shield shall be properly cut & insulated ensuring that it does not touch
instrument casing or cable gland.
4.12.5 All junction boxes used for 4-20 mA analog, FF, RTD & T/C cables shall be provided with
separate terminal to terminate shields of single run cables & shields of the individual pair
in multi-pair cable.
4.12.6 The junction box body earth terminal shall be connected to local electrical safety earth.
4.12.7 Contractor shall provide a separate earth electrode / pit for UPS grounding.
4.12.8 Rack room mounted system cabinets / marshalling racks (power supplies) shall be
connected to separate redundant earth electrodes / pits.
4.12.9 Each marshalling rack with field signals of analog /RTD /TC type shall be provided with an
insulated earth bus bar to terminate shields of multi-pair cables. This earth bus bar shall
be connected to separate redundant earth electrodes/pits.
4.12.10 For control room mounted operator stations / engineering stations, separate insulated
earth bus bar shall be considered. This shall be connected to separate redundant earth
electrodes / pits.
4.12.11 A separate insulated earth bus bar shall be provided for terminating earth connections of
safety barriers requiring ground connection or ground connection of earth leakage
detectors. These isolated bus bars shall be connected to separate high integrity earth
electrode.
4.12.12 The requirement of earth earth pits for control system shall be as follows:
Earth pit E1 - for rack room mounted system cabinets / marshalling racks body earth
(Includes panel mounted bulk power supply)
Earth pit E2 - for Instrumentation earth ( For circuit ground, shields, drain wire etc;)
Above earth pits shall be constructed each with dual ground electrodes. This earthing
system shall have a resistance to earth of 5.0 ohms or less. Refer Drawing No. 44NC-
4600-0000/J.01/0017 for Typical earthing schematic for control room
4.12.13 Two nos. of insulated earth bus bars shall be provided for each control system of rack
room for signal earth and cabinet / DC earth for further connection to E2 & E1,
respectively.
4.12.14 One no. of separate insulated earth bus bar shall be provided below false floor of console
room for console earth and further connection to E1.
4.12.15 All cabinets, panels & doors shall be connected together using 10 sq. mm. copper wire
and shall be connected from both ends to insulated earth bus bar as indicated in clause
4.12.13 above. System DC bus ground shall be connected to earth by separate earth
conductor (shall not be connected to chassis ground loop).
4.12.16 All signal earths from individual cabinets / panels shall be directly connected to insulated
earth bus bar using 10 sq. mm. copper wires as indicated in clause no. 4.12.13 above.
Page 327 of 564

4.12.17 All consoles shall be connected together using 10 sq. mm. copper wire and shall be
connected from both ends to insulated earth bus bar as indicated in clause 4.12.14
above.
4.12.18 Redundant earth connection cables shall be used to connect these bus bars to the earth
pit using 35 sq. mm. as minimum. The resistance of these conductors shall be less than
0.5 ohms. Sizing of earthing conductor shall be based on 1/3 of maximum current.
4.13 REQUIREMENT DF SPARE TERMINATIDN & SPARE IIDS.
4.13.1 For Analog inputsIoutputs, FF inputs, and digital inputs which are routed through
isolators, at least 20% spare IID channels shall be accommodated within the installed
modules & shall be completely wired (including installed isolators) up to the marshalling
terminals.
a) Actual Required IID x 1.2 = No. of installed modules (or next integer)
No. of channels Imodule
(e.g. 200 *1.2 I 32 = 7.5 hence 8.0)
b) No. of installed Modules X No. of channels module = No. of isolators (Installed &
wired) (e.g. 8 * 32 = 256)
4.13.2 Space shall be available for installing additional 20% spare isolators of each type.
Provision of isolator mounting rail shall be made for these future spares. Marshalling
terminals shall be installed to accommodate termination requirement of all channels of
all isolators including future spares.
( e.g. 128 * 0.2 = 25.6 hence 26 ) Space for 26 isolators for
future. Marshalling terminals ( e.g (128 + 26 ) * 2 = 308 Terminals
installed )
4.13.3 In addition to above, spare slots to accommodate 20% more IIDs or minimum
one module of each type shall be available in the IID rack.
Actual required IIDx 0.2 = No. of spare slots in IID rack (or next integer)
No. of channelsImodule
(e.g. 200 * 0.2 I 32 = 1.25 hence 2.0 )
4.13.4 Density of IID modules in a IID racks shall be decided such that total current consumption
(internally drawn) of all channels in all the used modules shall not exceed 70% of the back
plane current for that rack & current consumption inclusive of spare module (in future
spare slot) shall not exceed 80% of the back plane current for the rack.
4.13.5 For digital outputs, at least 20% spare channels shall be accommodated within the
installed modules & shall be completely wired including interposing relays. In addition to
above, spare slots to accommodate 20% more outputs or minimum one module shall be
available in the IID rack.
4.13.6 Space shall be available for installing additional 20% spare relays of each type.
Provision of relay mounting rail shall be made for these future spares. Marshalling
terminals shall be installed to accommodate termination requirement of all relays including
future spares.
4.13.7 DELETED.
Page 328 of 564
4.14 POWER SUPPLY DISTRIBUTION
4.14.1 DELETED.
4.14.2 Two no's new 110 VAC UPS one for Coker unit along with sub packages,
utility packages, like IA compressor package, cooling water system package &
other UPS dedicated for F & G system shall be supplied & installed as per
electrical specification. UPS system shall be part of DCS system & supplied by DCS
system Vendor.
Following additional number of feeders with indicated rating for Instrumentation
load for field & control room mounted cabinets shall be provided by Contractor.
These cabinets
W ill be supplied by others
1) Coke Decoking package
a) 3 No's 1.5 KVA each, Redundant
Feeder b) 3 No's 2 KVA each,
Redundand Feeder
2) Coke Unheading Package
a) 3 No's 1.5 KVA each, Redundant Feeder
3) Cooling W ater System Package
Feeder b) 3 No's 2 KVA each,
Redundant Feeder
4) IA Compressor & Dryer Package
a) 4 No's 2 KVA each, Redundant Feeder
5) Heater Package
Feeder b) 1 No's 4 KVA, Redundant
Feeder
c) 1 No 1 KVA, Redundant Feeder
d) 3 No's 100 VA each, Single
Feeder e) 3 No's 200 VA each,
Single Feeder f) 2 No's 500 VA
each, Single Feeder
4.14.3 System wise power supply distribution shall be arranged by contractor as

per requirement. 20% installed spare feeders shall be considered for each supply
level.
4.14.4 24 V DC power supply shall be derived from 110 V AC UPS power supply.
4.14.5 110 V DC Power supply as required shall be specified in electrical specifications.
4.14.6 Contractor shall take care of 240 VAC distributions as indicated in engineering
design basis.
4.14.7 Refer Drawing No. 44NC-4600-0000/J.01/0015 & 44NC-4600-0000/J.01/0016 for Power

Distribution
schematic
Page 329 of 564

5.0 CONTROL ROOM ENGINEERING
5.1 COKER CONTROL ROOM BUILDING
5.1.1 DELETED.
5.1.2 The DCS operating stations shall be located inside console room & engineering
work stations shall be in the engineering room & rack room.
5.1.3 The DCS / PLC cabinets shall be located in rack room.
5.1.4 DELETED.
5.1.5 DELETED.
5.1.6 DELETED.
5.1.7 The rack room shall house all cabinets, racks and panels like marshalling cabinets,
barrier cabinets, system cabinets, power supply distribution cabinets, etc. and shall
have
solid flooring with cut-out for panel cable entry from the cable cellar below.
5.1.8 The Engineering, Console and Computer (OPC Server) room shall have trench /
false floor arrangement for cable routing.
5.1.9 In console Room false flooring shall be provided in Console area & rest area shall be with
Granite Flooring.
5.1.10 Contractor shall prepare a separate drawing indicating cable duct / tray routing in cable
cellar. System cables shall be routed in conduits. CCTV monitor cables shall be routed
in conduit above false ceiling.
5.1.11 Contractor shall prepare MCT layout drawing indicating cable number of each & every
cable entering the control room as part of control room detailed engineering
document.
5.1.12 Control room & rack room layout shall indicate the spare space for future consoles &
marshalling panels & provision of required support structure / light fittings shall be
made while constructing the false flooring & false ceiling.
5.1.13 DELETED.
5.1.14 Detailed Control room & Rack room layout shall be developed by contractor &
drawings shall be prepared indicating dimensional details of all consoles & marshalling
panels along with panel to panel & panel to wall clearances.
5.2 OTHER REQUIREMENTS
5.2.1 Cable entry to all equipments inside rack room shall be with bottom entry through
cable cellar.
5.2.2 The cable in cellar shall be routed in pre-defined main trunk ducts below the roof level.
The cables upto the respective cabinets shall be routed from main trunk ducts
through feeder/branch trays and opening in the roof to respective racks in rack room.
5.2.3Page 330 Cable

of 564 entry to all equipments inside console, Engineering and Computer (OPC Server)
room shall be with Bottom entry through false floor.
5.2.4 Multicable Transit Blocks (MCT)
5.2.4.1 The cable entry into cable cellar shall be through Multi Cable Transit blocks (MCT) only.
The MCT shall be sized, supplied and installed at site by contractor.
5.2.4.2 Suitable cut-out based on the sizes given with this specification for installation of MCT
frames on the blast proof wall of control room shall be provided for MCT blocks. In case
any additional entry or modified entry is required after the cellar wall is cast the same
shall be taken care by of by the contractor. .
5.2.4.3 The MCT frame shall be SS plate of 10MM thickness,.
5.2.4.4 The MCT frames shall be of standard RGB type of M/s Brattberg or G type of Roxtec or
equivalent and of stainless steel or galvanized steel construction including frames,
stay plates, wedges bolts etc. The MCT block shall be provided with centre core
with adjustable 00 with peeling off arrangement
5.2.4.5 The actual sizing shall be the responsibility of contractor based on the actual no.
of cables. The sizing defines the minimum requirement.
i. Gontractor shall size the MCT considering 40% installed spare for each
cable size /00.
ii. Gontractor shall provide 20% spare usable insert blocks in each cable
size/0.0. as loose
supply.
iii. The power cables for instruments shall be suitably separated from the
other cables and shall be routed through separate MCT blocks. In general,
the MCT frame considered for instrument shall not be used for electrical
cables.
iv. The MCT shall be installation as per the recommended practice of supplier.
No spare space shall be left uncovered in the frame. The same shall
be provided with MCT block with secured centre core. The size of
quantity installed spare block on MCT shall be proportional to the
blocks used for cables.
The electrical power and control cables shall not be routed through instrument
MCT's. Separate MCT's may be used for the same.
Additionally MCT frames & blocks shall be sized supplied & installed by contractor
for cooling water system Package & IA compressor Package
For analyser shelter MCT sizing /supply shall be carried out in line with
above requirements by LSTK-3 contractor.
5.2.5 DELETED.
5.2.4 DELETED.
5.2.5 Control Room Atmosphere:

Operator area, rack areas and other rooms shall be air conditioned for proper operation of
equipment installed.
Page 331 of 564

5.2.5.1 The temperature, humidity, air cleanliness i.e. dust, H2S contents etc shall be within the
limits for proper operation of control system installed and for personnel inside the room.
Temperature shall be 23 +/- 1 Deg. C and Humidity shall be 55 + 5%
5.2.5.2 The AC requirements shall be suitably worked out to meet the heat dissipation of various
equipment & operating personnel likely to be present.
5.2.5.3 Hydrocarbon detectors (minimum 2 nos.) shall be provided with an alarm on DCS.
5.2.6 Lighting
5.2.6.1 It is recommended to have an optimum brightness as required by DCS vendor. For details
of the lighting refer electrical specification attached elsewhere in this document. In
general, illumination level shall be as follows:.
Rack room area : 600 lux
Console area : 800 lux
5.2.6.2 Lighting in control room shall be designed for Anti- Glare property. Contractor may use flat
TFT screens and concealed lighting.
5.2.6.3 Direct lighting and reflections from lighting should be taken off from operator's view. The
de-fuser of the light source should produce a good effect such that it should not make an
image on TFT display. The lighting arrangement should be carried out in such a way so
as to avoid darkness behind control equipments.
5.2.6.4 Suitable number of power receptacles shall be provided near the equipment for
maintenance.
5.2.6.5 Provision should be made available for Emergency lighting in the control room in case of
power failure.
5.2.7 Colour & painting

The colour for the floor, wall and ceiling shall be same as existing for aesthetic looks.
Contractor shall take special care with respect to aesthetics of console area to match the
colour / type and if required.
5.2.8 Laying of the cables within control room building
5.2.8.1 Vendor shall provide necessary cable duct inside the cable cellar and Cable duct / tray as
required in console/ engineering/ training room in control room for laying of cables. The
duct shall be properly supported by contractor from the bottom of the cellar roof and duct
shall be covered from all the sides. The duct width shall cover the cutout portion of
the floor. The duct material shall be of GI material.
5.2.8.2 The signal and power cables should be segregated as far as possible. The cable
layout shall be such that there is a uniform distribution of cables. The cable entry points
should be carefully chosen to achieve a good layout and distribution of cables to various
points.
5.2.8.3 The planning of cable layout should be such that the cables to/from electrical/instrument
Page 332 cabinets
of 564 should be brought out separately to allow maintenance by electrical
or instrument personnel without any difficulty and with independence. No electrical

power cables except UPS & DC shall be routed through control room. All incoming
cables for UPS shall not be routed through cable cellar room.
5.2.8.4 All the cables should be brought to the control panels / cabinets and terminated with
a proper clamping and with weatherproof double compression type cable glands. No
seal fittings shall be used.
5.2.8.5 Cables (internal and external) shall be colour coded for ease of maintenance and type of
conductor and insulation proposed shall be to the equipments required.
5.2.8.6 Cables shall have sufficient mechanical strength and shall be guarded against
electrostatic, electromagnetic and radio-frequency interference. Each cable shall be
properly identified inside the control room.
5.2.8.7 Ultrasonic rat repellent shall be provided for the entire control room, rack room,
cable cellar and wherever false flooring is provided.
6.0 INSPECTION AND TESTING
6.1 All instruments and systems oriented items shall undergo factory testing and
inspection by contractors authorised representatives, TP I/ owner and PMC.
6.2 In no case items shall be released without proper inspection / verification.
6.3 The inspection and testing shall be carried out as per related specifications, international
codes and practices / standards, approved documents and / or any other document
attached along with specifically suggesting testing to be carried out at manufacturers
works.
6.4 The material shall be despatched only after obtaining written despatch clearance.
6.5 No system or system oriented item & analysers shall be despatched without integrated
factory testing witnessed by representatives of contractor / owner / PMC. The testing
procedures shall be detailed out by the contractor based on testing requirements
indicated in individual system specifications and shall be approved by Owner / PMC.
Contractor must certify that the system is actually ready before calling the Owner /
PMC for FAT. Also all the necessary documents and literature are to be submitted
before calling for FAT.
6.6 Testing and inspection for all items shall be carried out as per approved factory testing
procedures. For items where no testing is witnessed by PMC / Owner, following test
certificates shall be forwarded for review before despatch of such equipment.
Verification of certificates as applicable for the material certificates, NDT reports like
radiography / X-ray / Die-penetration, special testing reports etc, statutory certificates
for Intrinsic safety and explosion proof certificates of conformity etc.
Visual verification for quantity, quality and workmanship
Page 333 of 564

Hydro testing and pneumatic testing as applicable
Functional and performance testing including calibration, accuracy, repeatability

testing.
Seat leakage tests for control valves and hydraulic pressure test, actuator cycling and
fail condition tests.
Test certificates for pressure relief valves set pressure, reseat pressure and seat
leakage test
Radiographic test for control valves, pressure relief valves.
6.7 Contractor shall detail out performance specifications which shall be verified by contractor
or contractor appointed agency/ Owner / PMC during factory testing.
6.8 Testing procedures shall be developed by contractor based on relevant codes,

international standards and practices followed for various items unless otherwise
indicated separately.
6.9 DELETED.
6.10 Contractor shall submit all test records / test results for records to owner / PMC as bound
volume along with the test procedure for each test carried out.
6.11 DELETED.
6.12 DELETED.
6.13 DELETED.
6.14 DELETED.
7.0 DELETED.
8.0 LOOP CHECKING AND COMMISSIONING
8.1 Contractor shall carry out site testing, calibration, loop checking and commissioning as
per the guidelines indicated in standard specification for instrumentation work 44NC-
4600-0000/J.SS/0101.
8.2 Contractor shall be responsible to develop detailed procedure for site testing, calibration,
loop checking and commissioning along with all necessary calibration sheet / loop sheet
formats as required. The same shall be submitted to owner / PMC for approval.
8.3 Contractor / DCS vendor shall be responsible to carry out DCS / PLC installation, testing
and commissioning activities as per the guidelines given in standard specification for DCS
44NC-4600-0000/J.SS/0102.
8.4 Contractor shall be responsible for calibration of all field instruments independently.
Before proceeding for loop checking, the calibration results of individual elements shall be
recorded on the pro-forma which shall be approved by Owner / PMC for correctness of
installation, measurements and calibration results.
8.5 Contractor shall be responsible for providing all assistance to control system sub-vendor
Page 334 during
of 564 loop checking. This shall include providing signals from the field instruments and
checking valve operation with respect to the output from control system to enable control
system vendor to verify loop performance.
8.6 Contractor's responsibility includes demonstration / proving of measuring signal levels of

field instrument outputs to control room in the respective identified pair of cable. In case of
any problem, rectification / re-calibration of field instruments, if found defective during loop
checking shall be contractor's responsibility.
8.7 Loop testing shall be conducted to check the functional performance of all elements
comprising the loop, thereby ensuring proper inter-connections and operations.
8.8 After the loop test is complete, contractor shall connect back any terminations and
connections removed for loop checking.
8.9 contractor shall be responsible to co-ordinate with all package system vendors during
calibration and loop checking.
8.10 For special instruments such as analysers, package instruments, etc. contractor shall
ensure presence of vendor's technical personnel during field testing, calibration and loop
checking.
8.11 Contractor shall be responsible for pre-commissioning and commissioning activities and
provide sufficient man power with tools & tackles required for the successful
completion of project.
9.0 SYSTEM ACCEPTANCE TEST
9.1 The owner will take over the system including (all systems oriented items like DCS/PLC,
Analyzers, field instruments etc.} from the contractor after the final acceptance test
attended by Owner/ PMC, which is defined as successful uninterrupted operation of the
integrated system for three weeks.. Uninterrupted Operation shall be defined as follows:
All control schemes including Complex schemes shall be taken in Auto / cascade
mode
All controllers shall be optimally tuned for both normal & turndown condition.
All interlocks shall be taken on line without Bypassing the interlocks
All constants, timer values shall be configured as per licensor / OEM

recommendations.
System Vendor's personnel shall be present during the test. Any malfunctioning of the
items supplied by the contractor shall be replaced /repaired as required. Once the system
failure is detected, the acceptance test shall start all over again from the beginning. The
warranty period commences from the day owner takes over the contractor supplied
equipment.
10.0 DELETED.
11.0 DELETED.
Page 335 of 564

12.0 DELETED.
13.0 DELETED.
14.0 TRAINING
14.1 Contractor shall provide training to owner personnel in the field of operation, engineering
and maintenance for the system oriented items and special instruments. The number of
persons required for training shall be as follows:
Course
No. of
System Duration
Persons
(minimum)
DCS System
15 10 days
(H/W & S/W Maintenance & Engineering)
PLC System
15 5 days
(H/W & S/W Maintenance & Engineering)
DCS System -Operations 30 3 days
IAMS System (including FF / HART Maintenance
20 3 days
System)
Analyser (each Make & Type)- Operation &
7 2 days
Maintenance
CCTV System ( Operations, engineering and
5 2 days
maintenance)
For each special instruments like mass flow
meters, W obbe Index Meter, Nucleonic Instruments 10 2 days
Anti-surge controllers etc.
14.2 Contractor shall work out detail schedule of training programme and shall co-
ordinate with owner for the schedule.
14.3 Above includes training only at manufacturer's works. The number of days of
training required shall be based on the standard courses available with the
manufacturers. However for all system oriented items, a minimum of 2 week of
training shall be considered for each system.
14.4 All the training shall be provided by the manufacturer's experts in the respective fields.
Efforts shall be made to arrange factory training for the owner personnel at manufacturer
works prior to factory acceptance test. This shall be adhered more closely for items being
procured from abroad.
.
14.5 Vendor shall also be responsible for any other requirements necessary to train
the engineers deputed by owner within a time limit so that they acquire the
necessary expertise to operate and maintain the instruments / systems equipments
supplied.
14.6 The contractor shall also be responsible to provide training to owner personnel at site
for above items
15.0 DELETED.
16.0 TEST EQUIPMENTS
The following Test Equipments shall be provided:

Page 336 of 564
SI. No. DESCRIPTION MAKE QUANTITY

i. 4 % Digit IS Mulitmeter Fluke or equivalent 8 nos.
ii. *Loop Calibrator & Simulator(with PC interface) ALTEK or equivalent 04 nos.
iii. *mV, T/C & RTD Calibrator (with PC interface and ALTEK or equivalent 04 nos
both measuring & feeding ) Type : K,T,R,S & B
&Pt100
iv. Digital Clip on Ammeter (Low Range) Yokogawa or equivalent 01 no.
v. Earth Resistance Tester Yokogawa or equivalent 01 no.
vi. Megger Yokogawa or equivalent 01 no.
vii. *Portable IS Pressure Calibrator (with PC interface) Scandura / Druck 02 nos.

with integrated hand pump /equivalent
0-25 Kg cm2 A
0-100 Kg/cm2 (eXternal generator)
viii. Instrument Technician Tool kit 04 nos.
iX. *Pneumatic Test Bench with following Scandura / Druck
Pressure Calibrator(with PC interface) /equivalent
a) Very High Range : 0-250 Kg/cm2 01 no.
b) High Range : 0-100 Kg/cm2 02 no.
c) Low Range : 0-1 Kg/cm2 Absolute 01 no.
Vaccum pump (240 V AC) with Digital 01 no.
Display unit
Manometer 02 no.
Inclined Manometer 02 no.
X. * Temperature Bath (Type K ) with suitable Ametek / equivalent 01 no.
mounting table - Range 0-250 / 0-650 / 0-800 Deg C
Xi. Dead Weight Tester with mounting table Budenberg or equivalent 01 no.
- Dual range 0-40 Kg/ sq.cm & 40-400 kg/sq.cm
Xii. Solenoid Tester Encom or equivalent 01 no.
Xiii. Soldering And De-soldering Station 01 no.
(with automatic temperature control)
Xiv. Ferrule Printer 01 no.
(with Memory and computer interface)
(100 meters of sleeve and 10 nos. of Cartridge tape)
Xv. Crimping tool Dowell or equivalent 01 no.

Xvi. Instrument Test Bench with
Power Supply 24 V DC(5A & 10A) 01 no.
4-20mA loop indicator
Vice for Instrument
Xvii. Computer & Laser Printer (for Calibrator HP / DELL or equivalent 01 no.
Interface) with necessary table
Note:
1. All test equipments must have at least one-year validity test certificates, traceable to
Accredited Standard Laboratories.
2. For * items, computer interface (RS 232C) must be provided with necessary software and
hardware. The centralised computer must be able to carry out calibration, report generation
and history record. All necessary software, hardware and commissioning of the system is in
vendor's scope.
3. A steel cupboard with lock & key shall be provided to house all the calibrator supplied
above.
Page 337 of 564
17.0 DELETED.
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Page 358 of 564
DISTRIBUTED CONTROL SYSTEM Part A - Section: V
RESID UPGRADATION PROJECT A133-000-16-51-SOW-1500 Rev. A
CPCL LTD Page 1 of 5
SECTION-V
(SCOPE OF WORK)

No by by

Page 359 of 564
1.0 SCOPE OF WORK

1.1 The scope of work for DCS shall comprise of the following:
SR. DESCRIPTION VENDOR PURCHASER
NO
Design & system Engineering of specified system including
1. coordination with various contractors/ package vendors during system
engineering
Manufacture/ supply of all hardware & software for complete DCS
including PLC, FF system, F&G system, operator console, engineering
consoles, OPC server, Instrument Asset Management System,
2. Documentation Node, , Alarm Information Management System,
Client PC, Giant Screen and UHN to meet specified functional
requirements. The scope shall include system configuration, system
integration, factory testing & acceptance of the system.
Manufacture & supply of auxiliary cabinets/ panels/ consoles as per
material requisition including marshalling cabinets, relay cabinets,
MCC Interface cabinets, power supply distribution cabinets, cabinets
for mounting free issue items, control panels, hardwired consoles,
3.
consoles for other free issue items like PCs/ HMI, ASC , PA system
etc. along with all accessories & instruments, barriers, alarm cards,

terminals, relays, power supply distribution cabinets with accessories
duly mounted, wired & tested to meet specified MR requirements. The
scope shall include their engineering, wiring, testing, integrated factory
testing & acceptance.
Supply of Fieldbus junction boxes, surge protectors, advanced
diagnostic module, MCT, Corrosion detectors/transmitters, Special
4. tools and tackles and hardware for free issued items like cabinets,
consoles, cables, tables, chairs etc, as per Special Instruction to Vendor
(A133-000-YE-SP-1508) and job specifications.
Supply of all type of Interconnecting cabling & wiring including
5. power cabling within control room for all vendor supplied equipments
and all the free issued equipments in control room.
Supply of serial link communication cables with connectors within
control room, between DCS/PLC to all vendor supplied equipments
6. and to free issued equipments and fibre optic cables with HDPE
conduit between control room and analyzer shelter/fire station/local
control room

Page 360 of 564
Packing, forwarding, transportation, custom clearance, insurance,

7. storage at site including unloading, keeping under safe custody and
shifting of to control room.
Installation of all bidder supplied instruments and equipment including
8.
cabinets, consoles, racks, equipments, free issued instruments/ panels
as specified and any other item indicated specifically in the MR

including:
Installation of all types of vendor supplied cables cabling including
a)
those required for interface with free issue item/ Packages PLC in
MCR and vendor supplied fibre optic cables to analyzer shelter and fire

station.
Glanding, ferruling & termination of all interconnecting cables/ wires
b) for Package/ Free issued items in Main Control Room and vendor
supplied/installed fibre optic cables in Fire station, Analyzer Shelter .
Glanding, ferruling & termination of all types of field cables,
c)
interconnecting cable, system cables, power cables including those for
packages, free issued items in control room and special fiber optic

cables in analyzer shelter and fire station..
d)
Laying of all types system cables & Prefabricated cable including
those for the packages, free issued items in control room.

Supply and installation of of cable duct, cable trays with all its
e) accessories and structural supports including bends, structural channel
frame in control room including in cellar area.
f)
Coordination with various contractors and Owner/ PMC/EIL during
installation, cable core identification and termination.

g)
Powering of all equipments in control room including free issue
panels/ equipments and interconnecting power cabling in MCR

h) Supervision of installation & termination of FBJBs
Field-testing, loop checking which shall include interlock simulation,
commissioning & final acceptance of complete system. This includes
9. coordination with various contractors (through
Purchaser/PMC/Owner), package vendors, other PLC vendor for the
above-mentioned activities.
10. FAT and SAT as per MR

Page 361 of 564
11.
Supply of consumables and commissioning spares as per MR
requirements.

12.
Submission of quote for two years recommended operational and
maintenance spares as per MR.

13. Documentation including As-built
14. Training for Owner Personnel at works and at site
15. Warranty for the complete system
16.
Post Warranty Maintenance Contract ( If ordered by Owner at a later
date)

1.2 As part of engineering, bidder shall develop documents required for the system engineering of the
project, as detailed below:
a) For all the units, bidder shall develop functional schematics, network/ segment drawings,
dynamic graphic display drawings based on the Piping and Instrumentation Diagrams
(P&IDs) and the guidelines for preparing graphic display, which will be provided to the
successful bidder. Instrument details, shutdown logic diagram/C&E diagram and cable
schedule (non-FF) shall be provided by Purchaser .
b) In addition to above Instrument details, shutdown logic diagram, wiring diagram/cable
schedule for package items such as compressors, pumps, feed filters etc. shall be supplied by
purchaser ,based on the input received from respective package vendor.
c) All the above Documents shall be provided to successful bidder only.
d) The successful bidder shall execute Non-disclosure agreement with Owner. The format for the
same will be provided to successful bidder.
1.3 The detailed scope of work shall be as per this MR.
1.4 Attachments to Section-V are as below:
a) I/O Summary and sizing consideration (Annexure-VII)
b) System Configuration Diagrams
System Configuration Diagrams (Dwg.No.A133-086-16-51-MD08 sheet 1 of 4 to sheet 2

of 4)
c) F&G System configuration diagram (Dwg.No.A133-086-16-51-MD08 Sheet 3 of 4)
d) 110 V AC UPS Power Distribution Diagram (Dwg. No: A133- 000-16-51-3101)
e) 110 V AC Non DCS UPS Power Distribution List (Annexure-VIII - Table - I)
f) 230 V AC Power Supply Diagram (Dwg. No. A133-000-70-16-51-3102)
g) 24 V DC Non UPS Power Distribution List (Annexure-IX - Table - I)
h) Control Room Layout (Dwg.No.A133-000-16-51-1101)

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i) Control Room Ground & Basement Floor plan ( A133-086-16-49-0009)

j) Control Room -Terrace floor plan, Section (A133-086-16-49-0010)
k) Control Room Elevations, Sections (A133-086-16-49-0011)
l) Overall Plot Plan (Doc. No 44NC-4600-0000-/L-01/0001/A1)
m) Vendor Data Requirements (Doc. No. A133-000-YE-SP-1511)
n) Fieldbus design and implementation criteria(Annexure-X)
o) Vendor List (Annexure-XI)
p) Mandatory spare parts (Annexure-XII)

Page 363 of 564
Part A - Section: V
RESID UPGRADATION PROJECT Annexure VII to
A133-000-16-51-SOW-1500 Rev. A
CPCL
Page 1 of 9
SECTION-V
(I/O SUMMARY AND SIZING CONSIDERATION)
C 11.03.14 Revised & Issued with MR RK NZ AR
B 01.02.14 Revised & Issued with MR RK NZ AR
A 17.01.14 ISSUED with MR RK NZ AR

Rev.
No

Page 364 of 564
Part A - Section: V
A133-000-16-51-SOW-1500 Rev. A
CPCL
Page 2 of 9
NAME OF VENDOR:
1. Bidder shall be responsible for the correct sizing of DCS; its related sub-systems and nodes and other components as indicated in system architecture
drawing attached with the MR.
2. Bidder shall consider the following while sizing and loading the system:
a. Serial link connectivity with the system shall be as per details given in this document. The sub-system shown connected directly to system
communication sub-system through serial interface must have dedicated interface units as shown in configuration diagram. All PLCs
supplied by bidders shall be interfaced through dedicated redundant links. Consider all PLC I/Os and diagnostic messages for sizing of
interface node. Consider typically 2000 points per package PLC for sizing serial interface module and gateways
b. For serial interfaces following criteria may be followed:-
i. Loading due to data transfer via serial link for machine monitoring systems, anti-surge control systems etc. shall be considered.
Consider typically 200 points per such links for sizing I/Os. List of such interfaces is given in Table-V.
c. Input/ Output Summary table enclosed as Table I to Table IV are the actual I/O counts required.
d. The I/O summary does not include installed spares, future spare space requirements and system spares. As such bidder shall consider the
following while sizing
a) Additional 20 % installed spares and 20 % future space requirement and as defined elsewhere in this MR. For F&G PLC system,
additional 20% installed spares and 30% future space shall be provided. The installed spares shall also include barriers, relays, and
terminals, I/O modules, communication modules, and processor as per specifications.
b) Bidder shall consider additional I/O for inputs and outputs related to systems like alarms for UPS failure, BPS failure,
cabinets/consoles temperature/ fans failure) as specified in MR specification.
e. I/O module and marshalling cabinets shall be segregated as per Groups indicated below:
Group IA DCU BLOCK
Group IB HEATER PACKAGE
Group II LPG-CFC UNIT
Group IIIA IA COMPRESSOR

Page 365 of 564
Part A - Section: V
A133-000-16-51-SOW-1500 Rev. A
CPCL
Page 3 of 9
Group IIIB CW PACKAGE

Group IVA 086-C-07 PLC
Group IVB 086-C-10 PLC
f. DCS and PLC controller sub system shall be provided as a minimum as shown in the configuration diagram.
g. During detail engineering and at any stage of the project, if I/O counts on any particular group are found in excess of its requirements, the
same can be adjusted with other groups with approval of purchaser.
3. The requirement of historical trending should be considered for all tags.
4. The trending and logging requirement should be considered while sizing the system.
5. I/O ASSIGNMENT PHILOSOPHY
a) The I/O of process equipment (Transmitter A/B/C, Pumps A/B/C etc.) shall not be configured in the same I/O module and shall
be distributed among different I/O modules. Any redundant / duty stand-by machines (e.g. Compressors, pumps) and parallel running
equipment (e.g. heaters) shall be assigned to different I/O modules in different racks.
b) I/O assignment of tags shall match with the cable schedule.
6. 10% spare field bus junction boxes along with all accessories over and above the quantities required as per I/O summary table shall be supplied as loose
items.
LEGENDS
P & F = Pressure & Flow, L & T = Level & Temperature
WB = With Barrier, WOB = Without Barrier

Page 366 of 564
Part A - Section: V
A133-000-16-51-SOW-1500 Rev. A
CPCL
Page 4 of 9
I/O SUMMARY
TABLE - I: I/O SUMMARY (DCS- FIELDBUS)
TRANSMITTERS POSITIONERS FIELDBUS

(CLOSED LOOP) (CLOSED LOOP) TRANSMITTERS
UNIT REMOTE SEGMENTS
(OPEN LOOP)
INDICATORS
P&F L&T P&F L&T
Group IA & IB (DCU & HEATER PACKAGE)
DCU 0 0 0 0 450 20 68
Heater Package 0 0 0 0 154 11 24
Group II (LPG-CFC)
LPG-CFC 0 0 0 0 75 11 15
Group IIIA&B (IA COMPRESSOR & CW PACKAGE)
IA Compressor Package Not Applicable
CW Package Not Applicable
Group IVA&B (086-C-07 & 086-C-10)
086-C-07 Not Applicable

Page 367 of 564
Part A - Section: V
A133-000-16-51-SOW-1500 Rev. A
CPCL
Page 5 of 9
TABLE - II: I/O SUMMARY (DCS- NON FIELDBUS)
CLOSED LOOPS OPEN LOOPS

INPUT OUTPUT INPUT OUTPUT
4-20mA Special
Control Proxim 4-
Blocks Calcul RTD/ Contact
Unit 4-20mA 4-20mA 4-20mA 4-20mA Contacts ity 20mA
To ation TC (WOB)
Switch (WB)
Consider Blocks es
ed
WB WOB WB WOB Switches Switches MCC
WB WOB WB
P&F L&T P&F L&T P&F L&T P&F L&T (WB) (WOB) (WOB)
Group IA & IB (DCU & HEATER PACKAGE)
DCU 148 73 0 0 145 55 0 0 65 406 0 0 136 177 128 - 0 100 110
Heater
44 42 0 0 44 42 0 0 0 250 0 0 55 44 11 - 0 0 11
Package
Group II (LPG-CFC)
LPG-CFC 14 6 0 0 13 5 0 0 0 66 0 0 13 7 17 - 0 13 7
Group IIIA & IIIB (IA COMPRESSOR & CW PACKAGE)
IA
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 - 0 22 0
Compressor
CW Package 3 3 0 0 3 3 0 0 0 53 0 0 33 18 5 - 0 18 11
Group IVA & IVB (086-C-07 & 086-C-10)

Page 368 of 564
Part A - Section: V
A133-000-16-51-SOW-1500 Rev. A
CPCL
Page 6 of 9
TABLE - III: I/O SUMMARY (PLC)
INPUT OUTPUT PBs, HS

EMER.
CONTACTS CONTACTS AND STATUS
4-20mA PROXIMITY RELAYS SW ANN. WIN
Unit SELECT. LAMP
(NOTE-4) SWITCHES MCC SWITCHES SOV MCC OTHER (NOTE-1) (NOTE -2) (NOTE -3)
SW (NOTE -3)
WB WOB WOB WB WB WOB WOB (NOTE-2)
Group IA (DCU)
DCU 177(126) 562 0 123 49 137 285 304 10 318 88
Group IB (HEATER PACKAGE)
Heater Package 175(60) 161 0 44 22 44 22 28 11 22 40
Group II (LPG-CFC)
LPG-CFC 15(6) 18 0 0 9 10 3 16 3 18 44
Group IIIA (IA COMPRESSOR)
IA Compressor 66(15) 33 0 11 6 6 33 9 5 11 22
Group IIIB (CW PACKAGE)
CW Package 18(9) 9 0 3 4 3 17 9 5 11 22
Group IVA (086-C-07)
086-C-07 3(3) 1 0 2 1 1 1 1 1 1 1
Group IVB (086-C-10)
086-C-10 3(3) 1 0 2 1 1 1 1 1 1 1
NOTES:
Note-1: Relays required for multiplication of contacts. Interposing relays shall be provided as per MR. Quantity shall be worked on by vendor as per I/O counts
Note-2: Pushbutton/ selector switches/ emergency switches are taken in the input count. This column is for counting hardware in Hardwired console.
Note-3: This column is for counting hardware in Hardwired Console. Outputs are included in output count
Note-4: All inputs shall be single input from field. The figures shown within bracket are the inputs with 2 out of 3 voting mode of total inputs given in this column.

Page 369 of 564
Part A - Section: V
A133-000-16-51-SOW-1500 Rev. A
CPCL
Page 7 of 9
TABLE - IV: I/O SUMMARY (PLC-FIRE & GAS DETECTION SYSTEM)
DIGITAL
ANALOG INPUT DIGITAL INPUT
OUTPUT PUSH- EMER. STATUS
ANN. WIN.
GAS DETECTION PLC NO. BUTTONS SW. LAMP
4-20mA (NOTE-3)
WB WOB WOB (NOTE-2) (NOTE-2) (NOTE-3)
(2/3/4-wire WB)
F&G#1 115 25 15 30 20 5 10 15
NOTES:
Note-1: Relays required for multiplication of contacts. Interposing relays shall be provided as per MR. Quantity shall be worked on by vendor as per I/O counts
Note-2: Pushbutton/ selector switches/ emergency switches are taken in the input count. This column is for counting hardware in Hardwired console.
Note-3: This column is for counting hardware in Hardwired Console. Outputs are included in output count

Page 370 of 564
Part A - Section: V
A133-000-16-51-SOW-1500 Rev. A
CPCL
Page 8 of 9
TABLE- V: SERIAL LINK TO DCS
Sr. No From System Location Type of Serial Link No. of Serial links Single/ Dual
Group I (DCU & Heater Package)
A Foreign Device Interfaces through DCS Serial Interface Card

1. Machine Monitoring System (086-G-03A/B) MCR Modbus RTU 1 Dual
5. Machine Monitoring System (086-K-01)) MCR Modbus RTU 1 Dual
6. WoodWard Speed Governor System MCR Modbus RTU 1 Dual
7. Anti-surge/Performance Controller (086-K-01) MCR Modbus RTU 1 Single
8. Stack Analyser Shelter of Heater Package Field Modbus RTU (FO Link) 1 Dual
9. UPS / Data Concentrator System Sub-Station Modbus RTU 1 Dual
10. Fire Alarm Panel MCR Modbus RTU 1 Single
11. SPARE-1 MCR Modbus RTU 1 Dual
B Foreign Device Interfaces through dedicated Serial Communication Gateway

1. DCU PLC Subsystem ( Note-1) MCR By Bidder 1 Dual
2. Heater Package PLC Subsystem (Note-1) MCR By Bidder 1 Dual
3. LPG-CFC PLC Subsystem ( Note-1) MCR By Bidder 1 Dual
4. CW Package Subsystem (Note-1) MCR By Bidder 1 Dual
5. IA Compressor Subsystem (Note-1) MCR By Bidder 1 Dual
6. Coke Decoking Package PLC Subsystem (Note-1) MCR By Bidder 1 Dual

Page 371 of 564
Part A - Section: V
A133-000-16-51-SOW-1500 Rev. A
CPCL
Page 9 of 9
Sr. No From System Location Type of Serial Link No. of Serial links Single/ Dual
7. Coke Un-heading Package PLC Subsystem (Note-1) MCR By Bidder 1 Dual

8. 086-C-07 PLC Subsystem (Note-1) MCR By Bidder 1 Dual
9. 086-C-10 PLC Subsystem (Note-1) MCR By Bidder 1 Dual
Note 1: The DCS and PLC shall preferably be of the same make and family enabling bi- directional communication through the common communication bus.
In case, the PLC system is not of the same make/ family as that of the DCS, then vendor shall provide dedicated and redundant bi-directional serial
interface gateways for each PLC processor for interfacing the same with the DCS communication bus. The serial interface gateways shown for foreign
devices (Package PLC) interface shall however be provided.

Page 372 of 564
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.
NEW DELHI
Page 373 of 564
DCU BLOCK
REV.
DATE
LPG-CFC UNIT
REVISION
CW PACKAGE/
IA COMPRESSOR
BY
CHK
APPROVED
APPROVED
DRAWING NO.
REV.
PMC DOC. CONTROL CODE : J24
NEW DELHI
Page 374 of 564

DCU BLOCK
REV.
LPG-CFC UNIT
DATE
REVISION
CW PACKAGE
BY
IA COMP. PACKAGE
CHK
APPROVED
APPROVED
DRAWING NO.
REV.
NEW DELHI
Page 375 of 564

REV.
DATE
REVISION
BY
CHK
APPROVED
APPROVED
DRAWING NO.
REV.
Page 376 of 564
110VAC AC UPS & NON DCS POWER DISTRIBUTION LIST Part A - Section: V
DISTRIBUTED CONTROL SYSTEM Annexure VIII to
RESID UPGRADATION PROJECT A133-000-16-51-SOW-1500 Rev.A
SECTION-V
(110 V AC UPS & NON DCS POWER DISTRIBUTION LIST)
A 17.01.2014 Issued with MR RK NZ AR

Rev.
No
Page 377 of 564Rev.1

Format No. EIL-1641-1924 Copyright EIL All rights reserved
Table 1
110V AC (UPS) non DCS Feeders Distribution List
Legend
(R)- Redundant Feeder
Main Control Room
CABLE
Sr. No FEEDER DECSRIPTION FEEDER SIZE
RATING FEEDER (mm2) CABLE OD
(VA) REQD (No's) TOTAL (VA) (mm)
A 110V AC UPS non DCS load in field from DCS PDB in MCR
I CONTROL ROOM
1 WG compressor (086-K-01)
1.1 Machine Monitoring System ( MMS) 1500 1(R ) 1500
1.2 WoodWard Governor Speed Control System 2000 1( R) 2000
1.3 Anti Surge Controllers( ASC) 50 6 ( R) 300
2 Charge Heater Pumps( 086-G-03A/B)
2.1 Machine Monitoring System ( MMS) 750 2( R) 1500
3 CCTV System 8000 1 8000
4 Giant Screen 4000 1 4000
5 Machine Monitoring System for 086-G-08A/B 500 2 ( R) 1000
8 Misc 1000 1( R) 1000
9 Misc 1000 1 (R ) 1000
10 Misc 500 2(R) 1000

110VUPS POWER SUPPLY DISTRIBUTION TO FIELD

FIELD
1 LCP for wet gas compressor package (086-K-01) 1000 1 1000
2 PLC system package for Bridge Crane System 2500 1 2500
3 LCP for Charge Heater Pumps(086-G-03A/B) 1000 2 2000
4 Instrument Air Compressor Package for LPG-CFC 1000 1 1000
5 Ultrasonic Flow Meter 30 8 240
6 Mass Flow Meter 50 9 450
Nucleonic Level Instruments( 2x300) + Trans for coker
7
Fractionator(1 x 500) 1100 1 1100
9 Composition analyzer 1000 1 1000
10 TOC analyzers 750 1 750
11 PH/ Conductivity Analyzers 100 1 100
12 Local Control Panel for Fire Water System 500 1 100
13 Ultrasonic Flare Flow Meter (Flare) 50 1 50
14 MMS display unit for 86-G-08A/B 100 1 100
18 Woodward Governor for 86-G-03B 50 1 50
19 Woodward Governor for 86-G-05B 50 1 50
20 Misc 500 1 500
21 Misc 410 1 410

Page 380 of 564
24V DC NON UPS POWER DISTRIBUTION LIST Part A - Section: V
DISTRIBUTED CONTROL SYSTEM Annexure IX to
SECTION-V
(24 V DC NON UPS POWER DISTRIBUTION LIST)

Rev.
No

Page 381 of 564
24V DC NON UPS POWER DISTRIBUTION LIST Part A - Section: V
DISTRIBUTED CONTROL SYSTEM Annexure IX to
Table 1
24 V DC non UPS power distribution list
FEEDER RATING FEEDER REQD

Sr. No FEEDER DECSRIPTION Location
(VA) (No's)
1. Misc. MCR 20 20
2. Misc. MCR 15 10

Page 382 of 564
1 2 3 4 5 6 7 8 9 10 11 12 13 14 16
DCU PLANT
A
A
INST. DUCT BANK
FOR ROAD CROSSING
B
B
NOTES :-
C
C
D
D
E
E
izLrqr vkjs[k ,oa blesa fufgr fMt+kbu bathfu;LkZ bafM;k fyfeVsM dh LkaifRr gSA ;s ek= m/kkj fn, x, gSa vkSj m/kkjdrkZ us ;g Li"V Lke>kSrk fd;k gS fd u rks mUgsa iqu% eqfnzr fd;kk tk,xk] u udy dh tk,xh] u
m/kkj fn, tk,axs] u iznf'kZr fd, tk,axs vkSj u gh Lkhfer vkSj futh iz;ksx ds vykok budk dksbZ vU; iz;ksx gksxk vkSj ;g iz;ksx m/kkj nsus okys }kjk m/kkjdrkZ dks fyf[kr :i esa nh xbZ Lkgefr Lks gksxk A
F
GIANT SCREEN
G
G
LEGENDS/ABBREVIATIONS :-
H
H
I
I
J
J
K
K
L
L
CONTROL ROOM-GROUND & BASEMENT FLOOR PLANS
CONTROL ROOM-TERRACE FLOOR PLAN, SECTION
CONTROL ROOM- ELEVATIONS, SECTIONS
CONTROL ROOM LAYOUT(CONCEPTUAL) FOR COKER BLOCK M
M
DRAWING NO. TITLE

REFERENCE DRAWINGS
CABLE ENTRY DETAIL (THROUGH MCT-1)

PMC DOC. CODE : J33
E 24.01.14 COMMENTS INCORPORATED & RE-ISSUED FOR APPROVAL RS NZ AR
D 12.11.13 COMMENTS INCORPORATED & RE-ISSUED FOR APPROVAL RS NZ AR
M
N
C 07.11.13 COMMENTS INCORPORATED & ISSUED FOR APPROVAL RS NZ AR

B 28.10.13 REVISED AND ISSUED FOR COMMENTS RS NZ AR
A 15.10.13 ISSUED FOR COMMENTS RS NZ AR
DATE REVISIONS BY CHKD APPD
CHENNAI, INDIA
N
O
O
(A Govt. of India Undertaking)
CABLE ENTRY DETAIL (THROUGH MCT-2)

P
P
SCALE JOB NO. UNIT DIVN. DEPT. DWG. NO. REV.
1
Page 383 of 564
2 3 4 5 6 7 8 9 10 11 12 13 14 14 15 15 16 16
3-1641-0501 REV.2 A1-841x594

Page 384 of 564
Page 385 of 564
Page 386 of 564
Page 387 of 564
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned and on the borrower's express agreement that they will
not be reproduced, copied, exhibited or used, except in limited way permitted by a written consent given by the lender to the borrower for the indended use. EIL-1651-726 Rev.0 A4-
VENDOR DATA REQUIRMENT
With Final
Description AFTER PURCHASE ORDER
Proposal Documentation
(Prints) / As Built
Prints Date Needed
1. Vendor drawings / documents schedule - X(r) -
2. Control Room Layout - X(r) X
3. Hardwired Console Layout - X(r) X
4. Cabinet / Rack General Arrangement - X(r) X
5. Marshalling Panel Drawings - X(r) X
6. Cabinet / Rack Wiring Diagram - X(r) X
7. Overall dimensional drawing (including weight and clearance - X(i) X
req. for all eqp.)
8. Control Room equipment / panel foundation details (channel - X(i) -
base drawing)
9. System Architecture Drawing (DCS, PLC, IAMS, AIMS X X(r) X
System)
10. Cable Schedule (for Vendor's scope of cabling) - X(r) X
11. UPS Power Consumption and Non-UPS Power Consumption X X(i) X
12. Power Supply Loading Calculations X X(i) X
13. Ventilation and Air-conditioning requirements X X(i) X
14. Air purity requirement for control room X X(i) -
15. Recommended illumination level X X(i) -
16. Functional Schematics - X(r) X
17. Network / Segment Diagrams (General Note-3) - X(r) X
18. Communication Network Drawings - X(r) X
19. Nest loading details input / output assignment - X(r) X
20. Functional Description / Control Narratives for Fieldbus - X(r) X
Segments
21. Loop Wiring Diagram (including packages) - X(r) X
22. Peripheral Connection Wiring Drawings - X(r) X
23. Power Supply Distribution Diagram - X(r) X
24. Interconnection Cable Details - X(i) X
25. System Grounding Details - X(i) X
26. Dynamic Graphic Display Drawings - X(r) X
27. Formats for Detail Engineering and Software Configuration - X(i) -
28. Software Functional Diagram - X(r) X
29. Overview and Group-view Requirements - X(i) -
30. Display print-outs including graphics, log and MIS report - X(i) -
31. Logging and Log format requirements - X(i) -
32. Trend and Trend group requirements - X(i) -
33. Bill of Materials X X(r) X
34. Logic / Ladder Diagrams - X(r) X
35. Serial Interface Details - X(i) X
36. Special S/W Details, Serial Link int. add. map details, inc. 3rd - X(i) X
party int.,OS
37. Factory Testing and Acceptance procedure - X(r) -
38. Site Testing and Acceptance procedure - X(r) -
1 13/03/2014 RK ZH AR REQ. NO. : A133-000-YE-MR-1500

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ORDER NO. :
REV DATE BY CHKD APPVD VENDOR :
PLANT : RESID UPGRADATION PROJE SPECIFICATION REV

UNIT : 000
NEW DELHI A133-000-YE-VD-1500 1
CLIENT M/S CPCL
Page 388 of 564
39. Test reports and log books - X(i) -

40. Special test equipment and tools requirement for X X(i) -
maintenance
41. Test Plans & Test Reports for each item of Hardware to be - X(r) X
supplied
42. Communication Bus loading calculation X X(i) X
43. Sub-system loading calculation X X(i) X
44. CPU loading and Sizing Calculations X X(r) X
45. Catalogues including technical information X X(i) X
46. Hardware Specifications - X(r) X
47. System Configuration and Programming Manuals - - X
48. Functional Design Specification - X(i) X
49. Cable Cellar & Control Room Duct / Tray Layout Drawing - X(r) X
50. Brought Out Items Vendor List - X(r) X
51. MCT Sizing and Layout X X(r) X
52. Overview and group-view Requirements X X(r) X
53. Logging and Log Format Requirements X X(r) X
54. Trend and Trend group Requirements X X(r) X
55. System Installation Manual - X(i) X
56. System Operation and Maintenance Manuals - - X
57. MODBUS Memory Map - X(r) X
58. Listing of assembled prog. w/ labels and symbol tables in - X(r) X
assembler/compiler lan
59. Mandatory Spares Summary - X(r) X
60. Spare Summary for Consumables - X(r) X
61. Recommended Spare Parts for 2 Year Continuous Operation X X(r) -
62. SOE/First Out Tag assignment - X(r) -
63. Earthing Pit Details - X(i) -
64. Earthing Detail Drawings - X(r) -
65. TUV / SIL Certificate for PLC with complete reports X X(r) X
66. Training Course Manual - X(i) X
67. Soft Copy (CD) of Final Documentation (General Note-4) - - X
NOTES :
1. Fold all drawings to 216mm X 279mm and roll transparencies.
2. Vendor to provide all printed matter to ENGINEERS INDIA LIMITED (EIL).

ATTENTION -
Vendor Drawing Control

10th Floor EI House, 1, Bhikaji Cama Place, New Delhi-11006
LEGEND:

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ORDER NO. :

UNIT : 000
CLIENT M/S CPCL
Page 389 of 564
Categories preceeded with * will be approved for fabrication by Engineers India Limited.
The remaining drawings are needed for information only.
A/C = As compiled A/R = As required W/S = With shipment W = Weeks
IMPORTANT
While submittimg drawings and documents for review as indicated in vendor data requirement,
vendor must ensure the following :
1. A blank space measuring 75 mm W x 38 mm H shall be provided on all vendor drawings

(on the front side) for marking review codes etc. by ENGINEERS INDIA LIMITED.
2. The review of the drawings shall be done as applicable, under the following review codes :
a) Review Code 1 : No Comments.
b) Review Code 2 : Proceed with manufacture / fabrication as per commented drawing.
Revised drawing required.
c) Review Code 3 : Document does not conform to the basic requirements as marked.
Resubmit for review.
3. Review of the vendor drawings by EIL would be only to check compatibility with basic design and
concepts and would in no way absolve the manufacturer / fabricator of his responsibility to meet the
applicable codes, specifications and statutory rules and regulations.
4. For drawings / documents indicated as FOR INFORMATION in the vendor data requirement,
vendor must clearly mark FOR INFORMATION ONLY on the submitted drawings / documents.
GENRAL NOTES:
1. Any drawing / document not included in the llist above but required during erection, commissioning or for
reconfiguration of the system shall also be supplied by the Bidder on demand.
2. X indicates required. Suffix Codes mean the following:

(i) For Information
(r) For Review
3. For fieldbus instruments, network / segment digram shall include:

a) Title Block containing network name.
b) All network / segment connections including H1 card, bulk power supply, Fieldbus Power Supply, Field
devices, terminations, junction boxes, terminators.
c) All segment and field device tagging. All spur cables shall be labeled with the instrument tag number. All
cable distances (with voltage drop calculation results if needed).
d) LAS and back-up LAS shall be identified.
e) Bidder shall furnish segment timing cycle map and associated calculations as official document in electronic
format.
f) Bidder shall furnish the drawing for cable route between rack room to console room, engineering room for
operator consoles / equipment / printers / engineering consoles etc. (the console area is in fixed flooring and
bidder shall accordingly plan and furnish the detail route drawing).

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ORDER NO. :

UNIT : 000
CLIENT M/S CPCL
Page 390 of 564
4. The soft copy of documentation shall be in editable form (CAD, Excel, Database etc.)
5. The control room layout also includes the equipment / items / cabinets which are free issued to Bidder.
6. Bidder shall note the following regarding no. of copies to be provided at each stage for respective
documents:
a) Document required with Proposal: 6 copies
b) Documents required After Purchase Order: 6 copies
c) Final Documentation / As Built: 10 copies

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ORDER NO. :

UNIT : 000
CLIENT M/S CPCL
Page 391 of 564
ANNEXURE-X
FOUNDATION FIELD BUS Document No.
DESIGN CRITERIA A133-086-16-51-FFS01 Rev A
OF CPCL Page 1 of 15
FOUNDATION FIELDBUS DESIGN CRITERIA

ANNEXURE-X TO DCS MR
PROJECT : COKER BLOCK (EPCC-1) RESID UPGRADTAION PROJECT,
CPCL, CHENNAI
OWNER : CHENNAI PETROLEUM CORPORATION LIMITED
PMC : JACOBS ENGINEERING INDIA PRIVATE LIMITED
CONTRACTOR : ENGINEERS INDIA LIMITED
JOB NO. : A133
DOC NO. : A133-086-16-51-FFS01
PMC DOC.CONTROL CODE: J07
A 20.12.13 Issued For Review PS NZ AR

No by by

Page 392 of 564
ANNEXURE-X
1.0 SCOPE
This specification defines the basic guidelines for the design and implementation of Foundation
Fieldbus System Design requirements for RESID UPGRADATION PROJECT (RUP) CPCL, Chennai,
DCU/LPG-CFC Treating Unit of LSTK-01 Coker Block The requirement specified herein are the
minimum requirements to be considered by bidder to ensure uniformity basic design and shall not be
considered as final requirements. The FF design shall be further validated by Bidder during detailed
engineering and any variation/ changes required based on DCS system requirements and actual field
installation, operational philosophy etc. shall be considered by bidder without any implications Any
deviation from the philosophies, criteria and/or standards within this procedure shall be subject to
approval by the Owner / PMC/Purchaser.
2.0 PURPOSE
The purpose of the specification is to define the Foundation Fieldbus System Design requirements
for Coker Block (DCU & LPG CFC Unit).
Ensure consistency across the entire project

Minimise the design effort required by all parties
Minimise the validation requirement
Minimise commissioning related problems
Simplify the overall Fieldbus implementation process.
3.0 DEFINITIONS AND ABBREVIATIONS
3.1 Definitions
3.1.1 Foundation Fieldbus Definitions
The following represent definitions of Fieldbus terms used within this specification.
Term Definition
Bus A H1 Fieldbus cable b e t w e e n a host and field devices

connected to multiple segments, normally through the use of
repeaters.
Common File Format (CFF) A software file used by the Host to know the device detailed
FF capabilities without requiring the actual device.
Device Description (DD) A Device Description (DD) provides an extended description of

each object in the Virtual Field Device (VFD), and includes
information needed for a control system or host to understand
the meaning of data in the VFD.

Page 393 of 564
ANNEXURE-X
Fieldbus A Fieldbus is a digital, two-way, multi-drop communication link

among intelligent measurement and control devices. It serves
as a Local Area Network (LAN) for advanced process control,
remote input/output a n d high-speed f a c t o r y automation
applications.
FISCO Fieldbus Intrinsic Safe Concept. Allows more power to an IS
segment for approved FISCO devices, allowing for more devices
per IS segment.
H1 H1 is a term used to describe a Fieldbus network operating at

31,25 kbits/second.
HIST Host Interoperability Support Testing performed by the

foundation t o approve Host conformance to the FF
specifications.
Interchangeability Interchangeability is the capability to substitute a device from

one manufacturer with that of another manufacturer on a Fieldbus
network without loss of functionality or degree of integration.
Interoperability Interoperability is the capability for a device from one

manufacturer to interact with that of another manufacturer on a
Fieldbus network without loss of functionality.
ITK Interoperability Test Kit used by the Foundation to tick mark

devices Link A Link is the logical medium by which FF
devices are interconnected. It is composed of one or more
physical interconnected segments. All of the devices on a link
share a common s c h e d u l e , w h i c h i s administered by that
link's current LAS.
Link Active Scheduler A Link Active Scheduler (LAS) is a deterministic, centralized bus
scheduler that maintains a list of transmission times for all data
buffers in all devices that need to be cyclically transmitted. Only
one Link Mas t er ( LM) d e vi ce on an H1 Fieldbus Link can be
functioning as that link's LAS.
Link Master (LM) A Link Master (LM) is any device containing Link Active
Scheduler (LAS) functionality that can control communications
on an H1 Fieldbus Link. There must be at least one LM on an
H1 Link; one of those LM devices will be elected to serve as
LAS.
Resource Block (RB) A Resource Block (RB) describes characteristics of the FF

device such as the device name, manufacturer and serial
number. There is only one Resource Block (RB) in a device.
Schedules define when Function Blocks (FBs) execute and
when data and status is published on the bus. Segment A
Segment is a section of an H1 Fieldbus that is terminated in its
characteristic impedance. Segments can be linked
Repeaters to form a longer H1 Fieldbus.Each
s e g m e n t c a n i n c l u d e up to 32 H1 devices.
Segment Segment is defined as network or part of network that serves as

Page 394 of 564
ANNEXURE-X
The primary communication highway for connected field bus

devices
Spur A Spur is an H1 branch line connecting to the Trunk that is a

final circuit. A Spur can vary in length from 1 m (3.28 ft.) to
120 m (394 ft)
Standard Function Block (FB) Standard Function Blocks (FBs) are built into FF devices as
needed to achieve the desired control functionality. Automation
functions provided by Standard FBs include Analogue Input (AI),
Analogue Output (AO) and Proportional/Integral/Derivative (PID)
control. The Fieldbus Foundation has released specifications
for 21 types of Standard FBs. There can be many types of FBs
in a device. The order and definition of Standard FB parameters
are fixed and defined by the specifications.
Terminator A Terminator is an impedance-matching module used at or

near each end of a transmission line. Two Terminators must be
used on each H1 segment.
Tick Marked Tick marked FF devices are those with validated compliance
with FOUNDATION Fieldbus specifications: ITK. The resource
block contains the device approved ITK level.
Topology The Segment structure; Tree, Daisy Chain, etc. are

examples.
Transmitter A Transmitter is an active FF device containing circuitry,

which applies a digital signal on the bus.
Trunk/Home-run A Trunk is the main communication highway between devices

on an H1 Fieldbus network. The Trunk acts as a source of
main supply to Spurs on the network.
3.2.1 Abbreviations
The following list gives the used abbreviations in this document.
Abbreviation Description
AI Analogue Input
AO Analogue Output
AMS Asset Management System
AWG American Wire Gauge
CFF Common File Format
DCS Distributed Control System
DI Discrete Input
DD Device Description

Page 395 of 564
ANNEXURE-X
DO Discrete Output
EPC Engineering, Procurement & Construction
FB Function Block
FF Foundation Fieldbus
FGS Fire & Gas Detection System
FISCO Fieldbus Intrinsic Safety Concept
HART Highway Addressable Remote Transmitter
HIST Host Interoperability Support Testing
INtools Control & Instrumentation Database System
I/O Input/Output
IS Intrinsic Safety
ITK InteroperabilityTest Kit
LAN Local Area Network
LAS Link Active Schedule
MAI Multiplexed Analogue Input
MOV Motor Operated Valve
MVC Transmitter Measurement, Validation and Comparison
PID Proportional / Integral / Derivative Control
PLC Programmable Logic Controller
PRM Plant Resource Manager
UPS Uninterrupted Power Supply
STANDARDS AND SPECIFICATIONS
The following standards and specifications are to be referenced as part of this

document.
FF-103 Common File Format

FF-131 Standard Tables
FF-524 Device Descriptors File
FF-569 Host Interoperability Test (HIST) FF-581 System Architecture
FF-586 Ethernet Presence
FF-588 Field Device Access (FDA) Agent
FF-589 HSE System Management
FF-593 HSE Redundancy
FF-801 Network Management
FF-803 HSE Network Management
FF-816 31.25 kbit/s Physical Layer Profile/FISCO FF-870 FB Message Spec.
FF-880 System Management
FF-890 Function Block Application Process Part 1 (Architecture)
FF-891 Function Block Application Process Part 2 (10 Standard FBs) FF-892
Function Block Application Process Part 3 (Advanced FBs) FF-893

Page 396 of 564
ANNEXURE-X
Function Block Application Process Part 4 (Multiple I/O FBs) FF-894

Function Block Application Process Part 5 (Flexible FBs)
FF-900 Device Descriptor Language
FF-902 Transducer Block Application Process Part 1 (Basics)
FF-903 Transducer Block Application Process Part 2 (Details Profile)
FF-940 Communication Profile
FF-941 HSE Profile
4.2 International Society of Automation (ISA)
ISA 50.02 Fieldbus Standard for Use in Industrial Control Systems

Part 2 Physical Layer Specification and Service Definition
Part 3 Data Link Service Definition
Part 4 Data Link Protocol Specification
Part 5 Application Layer Service Definition
Part 6 Application Layer Protocol Specification
4.3 International Electro-technical commission (IEC)
IEC 61804 Function Blocks for Process Control and Electronic Device
Description Language
IEC 61158 Industrial Communication Networks- Field Bus Specifications
Part-1 Overview and guidance for the IEC 61158 Series
Part-2 Physical layer specification and service definition
Part-3 Data Link Service definition
Part-4 Data Link protocol specification
Part-5 Application Layer service definition
Part-6 Application Layer protocol specification
5.0 FIELDBUS SYSTEM OVERVIEW
5.1 Overall System Configuration
5.1.1 General
Foundation Fieldbus (FF) is a digital, two way, multi-drop communication system

providing a Local Area Network (LAN) for intelligent instruments connected to a network
can communicate with each other and to host control system via a single twisted pair
cable. Control functionality is implemented in host control system.
FOUNDATION Fieldbus system shall be based on the 31.25 kbits/s (H1FieldBus)

physical layer per ISA S50.02.
For the operator, use of FF technology for monitoring is transparent, but can give
access to considerably more data for maintenance or process diagnostics than the
conventional HART devices.
Page 397 of 564
ANNEXURE-X
For the project facilities, FF technology i s a p p l i e d f o r t h e n o n - c r i t i c a l o p e n

loops associated with monitoring in the DCS. The field bus loops are
identified as explained in the P&IDs.
The Fieldbus devices have to be fully interoperable with the DCS, including maximizing
of associated advanced diagnostic features coupled to Asset Management system
capabilities within DCS system to ensure interoperability all the devices must be
supplied with the file and firmware revisions.
5.1.2 Design Requirements
As standard, a tree topology shall be used.
Multi barrier philosophy shall be applied for this project. Refer t o t y p i c a l schematic
diagram of the topology attached to this document.
A segment consists of H1 card connected to a trunk junction box (L2) via a 12 pair
trunk cable. The junction box has 36 terminals to connect the 12 pair trunk cable and
12 one pair trunk cables. Out of which max. 9 ~ 10 one pair of trunk cables will be
installed and other will be left as spares .Each trunk cable between trunk junction
box( L2) & Spur Junction Box ( L1) shall be two pair .One Pair shall be spare
One pair trunk cables will be connected to the spur box to which maximum three
multi barriers can be connected. Each multi barrier can have maximum 4 (four)
devices connected to it. With this maximum 12 (twelve) devices can be connected to
one spur box. However, min. one (1) per multi barrier in totality three (3) will be left
as spare per spur box.
The segment design with number of devices for each segment for each type above shall
comply with all of the following criteria and the number of devices shall be limited meeting
the following criteria:
(1) Device Current consumption & FF power supply.
(2) Segment Length (Ohms law)
(3) Loop response time requirements
While designing the segment, the number of devices is limited based on Current
consumption of fieldbus devices, field barrier assemblies and the FF power supply current
limiting values.
The actual power supply details shall be provided to bidder during detailed engineering. The
make of the field barrier and accessories installed within the FF junction boxes shall be
same as and compatible with the fieldbus power supply devices supplied by Bidder. The
make and model for the FF power supply devices shall be informed at a later stage during
detailed engineering
Repeat signal for indication in Local Control Panel/Field mounted remote indicators shall
form part of same segment to which the primary transmitter is connected.
Bidder shall provide all standard function blocks for all FF devices as per FF guidelines
5.1.3 HARDWARE
Each FF network is known as a segment, the design of which is subject to

various hardware and software restrictions. The main components of this segment are:
Page 398 of 564
ANNEXURE-X
Link Active Scheduler (LAS)

H1 card (interface to DCS) - Redundant configuration
Power supply - Redundant Configuration
Power conditioner - Redundant configuration
Trunk cable (also called a home run or main run depending on the Supplier) Device
coupler (SPUR box)
Spur cables (connecting field devices to the device coupler)
Two terminators (usually one at the rack room and one at the device coupler) FF field
devices (Transmitters)
5.1.4.1 H1 Card Requirements
Fieldbus segments interface to the host system via FF interface cards (known as
H1cards) that have, two or four ports, i.e. each card can interface to two or four
segments and their connected field devices. Diagnostic data from the field device is
communicated to the AMS over the same network as used by the associated devices
and via the FF interface cards. V e n d or to indicate number of segments that can be
interfaced.
Redundant H1 interface card shall be provided for all segments in the DCS system.
5.1.4.2 Field Device Power.
As a standard philosophy the FF devices shall be bus-powered rather than

locally powered. Redundant bulk power supplies shall be used to power several
segments, but to be compatible with signal conditioning, the power supply to each
segment must be conditioned to provide impedance matching with the bus.
The power supply must be able to supply all of the devices on the connected buses
with spare capacity for expansion and for powering other temporary devices that
may be connected e.g. hand held tools, etc. The verification that the power
consumption of each segment and selected power conditioner are compatible is to
be carried out using a segment verification tool.
The selection of suitable power supply units and power conditioners shall be
the responsibility of contractor /DCS vendor to ensure the best compatibility with the
DCS.
Minimum voltage allowed at multi barrier input shall be 16 V.

The minimum voltage allowed at each device shall be 10V (other than multi barrier).
5.1.4.3 Power Conditioner
As a practice only active power conditioners to be used in a redundant

configuration serving one segment per pair of conditioners. In case active power
conditioners not available in redundant configuration the passive power conditioner
shall be used. The power conditioner shall be with advanced diagnostic modules
communicating via separate communication line (e.g. RS-485 or Ethernet) or data link.

Page 399 of 564
ANNEXURE-X
The common alarm from the power conditioners units shall be connected to the
common cabinet alarm.
5.1.4.4 Distance Constraints
The maximum allowed length of a Fieldbus segment is of 1900 meters using Type A
cable (Individual Shielded, twisted pair). This total segment length shall be computed
by adding the length of the main trunk line and all the spurs that extend from it.
Therefore, Total Segment Length = Trunk + All Spurs
5.1.4.5 Trunk/ Spur Cable
Cable Type
The cable type and characteristics are major factors that determine the allowable
bus length and the number of devices that can be connected.
Type A cable shall be used for all sections of FF segments. Multi-pair and single-
pair cables shall be with multistranded.
Cable Description Wire Size

Type A Twisted pairs with individual shield 1.13 mm2,
& overall shield to IEC 61158-2 minimum
The FF cable shall be single Pair, Two pair & Twelve Pair. Single pair shall be used for
Spur Connectivity only. For Trunk Multipair cable shall be used .At least one pair shall be
Provided as spare. All cables shall be armored. Parameters for FISCO shall be as
defined in IEC 61158-2.
The cable characteristics for the Multipairs cable and single pair cable shall be similar.
The outer sheath colour of single pair and multipair field bus cables shall be Orange
with blue longitudinal strips. The number of longitudinal strips shall be minimum
3(Three).
5.1.4.6 Wiring
IDC (Insulation Displacement Connector) terminals shall be used in junction boxes,

I/O cabinets and segment/spur boxes.
Within the segment/spur boxes IDC terminals with knife terminals shall be used to be
able to disconnect and connect each segment device for maintenance and testing.
Wiring termination shall be marked to connect appropriate positive or negative wire of

the trunk or spur.
5.1.4.7 Earthing

Page 400 of 564
ANNEXURE-X
The conductors of the twisted pair trunk and spur cables shall not be connected to earth
at any point in the network. Failure to observe this requirement will most probably
cause all devices on the network to lose communications.
The screens shall only be connected to earth at one place, which shall be at the
H1 interface cabinet end of the network.
At the instrument the screen needs to be cut and a sleeve shall be installed at the
cable end to prevent the screen touching metal parts.
5.1.4.8 Surge protection
The spur block shall have built-in lightning surge protection.
5.1.4.9 Spur Box and Spur Block
For I.S. segments the multi-barrier will be used. Three (3) Multi-barriers shall be
mounted in a spur box. Each multi-barrier can have four (4) I.S. outputs for FF field
devices i.e. 12
Nos connections for spur cable 1No. dedicated connection for trunk cable. . However
total no of devices shall be limited to 9 nos /spur box. The voltage on the multi-barrier
shall be minimum 16V.
Spur box is provided with built in Fieldbus termination.
Spur Block shall have built-in current limiting and short circuit protection functionality.
Fuses shall not be used for short circuit protection.
The enclosure of Spur Box shall be explosion proof; EExd IIC T3 and terminals are on
din rail mounting. Spur box shall have dual compartment one separate for isolation -for
isolating power supply & other for field barriers, surge protectors & terminals.
Cable entries (NPT(F).Vendor to supply NPT(M), EExd certified, SS, double

compression cable glands for spur box. The unused entries of spur box shall be
closed with SS plugs.
Certificate for Junction box as well as internal component shall be provided

from
BASSEFA, PTB, FM, CMRI, CMRS, in addition CCOE, Nagpur approval is required.
5.1.4.10 Location
Spur boxes will be located near the connected instruments; Trunk boxes will be located
at pipe-rack grade level.
5.1.4.11 Terminators

Page 401 of 564
ANNEXURE-X
Each segment shall be provided with two terminators, one at beginning at

power conditioner and the second at end of the segment in the spur block, for the
project this shall be in the spur block.
Care shall be taken that the dipswitches in conditioners are set in correct position.
5.1.5 FF Field Devices
5.1.5.1 FF Field Device Compatibility
Devices proposed shall be registered with FF as having passed the current version of
the Interoperability Test Kit (latest ITK or, as a minimum, ITK4.01) and also bear the
FF tick mark. ITK test shall be carried out by vendor for specific models, which are not
tested.
Vendor shall ensure compatibility with field device.

All FF devices shall be provided with standard function blocks as per FF guidelines
- Shall have as a minimum multiple FF compliant analog input (AI) blocks, AO

blocks, PID control blocks and VCRs (Virtual Communication Relationship)..
Multiple AI blocks shall provide flexibility in using transmitter data for calculations and
alarming, while VCRs used for communication between function block, both within a
device as well as amongst different devices shall be sufficient to execute all inter
block data transfers.
- Shall have input selector block for voting or averaging applications
- Shall provide back up Link Active Scheduler (LAS) so as to improve the reliability and
security of the FF network.
- Shall have software download capability for upgrades or product enhancement via
Fieldbus segment with the segment in operation.
- Shall have guided routine (methods) for calibration and restoration of sensor
defaults
At commissioning of the field devices, once the device is connected to the segment for
the 1st time, the information shall be downloaded from the DCS to the instruments
and not uploaded from the instruments. Vendors of field instruments shall supply
required information electronically for installation in the DCS.
The FF master database shall recide in the Host, so changing parameters in the
device shall not be done, also not during operations.
5.1.6 Number of devices per segment
For I.S. segments, multi-barriers shall be used, the devices per I.S. segment shall be:
3 multi-barriers per segment with each 4 devices (However, total no. of devices
shall be limited to 9).
Page 402 of 564
ANNEXURE-X
5.1.7 Test Points
Terminals shall be supplied with test points to test the segment where required. The
test point terminal shall be provided with plug on test connection possibility.
Within the I/O cabinet test points shall be provided to allow for segment testing.
Test points shall be easy accessible.
5.1.8 SOFTWARE
5.1.8.1 Segment Execution Time
In general, macro cycle time of 1000 msec shall be considered unless other specified.
The segment shall be designed with 50% of the macro cycle time can be used for
schedule data transmission and minimum 50% of the macro cycle time shall be allocated
for unscheduled communication.
5.1.9 Link Active Scheduler (LAS)
The H1 card is designated the Link Master on a segment and, to provide

segment integrity, back-up LAS shall be configured. The back-up LAS shall reside in
the back-up H1 card.
Field devices shall be specified with LAS capability. In case LAS capability is
standard feature in the field device, the LAS functionality in the device shall be
provided in deactivated state.
5.1.10 Download Requirements
The DD and CFF files from each field device include the device standard manufacturer
settings. These files shall be adopted by DCS vendor in the control system
for commissioning and download in the device, once connected to the segment.
Field device firmware /software shall be provided by vendor/supplier in electronic format

to allow DCS vendor for implementation in the control system.
Software changes applicable to field devices shall be upgradable and downloadable from
HOST.
Special attention shall be paid to the management of software versions of field

devices, including instruments to be provided by package units suppliers.
Selected DCS & Field inst. suppliers shall support the DTM/FDT files/protocol; this type
of protocol provides open communication between the host and the FF device.
Diagnostic parameters from the FF device can be in detail obtained and advanced
device diagnostics is available in the host..

Page 403 of 564
ANNEXURE-X
A selection of field devices will be tested in combination with the segment

simulation during the FAT.
The FAT shall be performed in accordance with the DCS vendor procedure for FAT as
per agreed by Owner/PMC and consist of the following as a minimum:
HOST SYSTEM
Factory staging
Functionality test.
Redundancy Switchover Test.
Network Test.
OTHERS
Network/Segment Check.
Device Check.
Data Reconciliation
Commissioning of the FF device shall be based on downloading of the configuration

parameters from the host to the FF device, once connected to the segment.
As downloading takes considerable time, the commissioning procedure shall
take into account batch downloading, in this case it is advised to perform the
commissioning of the field devices in several steps, e.g. step 1 connect device and
link to system this will be done for a batch of devices in sequence, step 2 batch
downloading to connected devices, step 3 start loop checking of the device.
The installation, testing and commissioning shall consist of the following as a

minimum and agreed during detailed engineering.
Cable Test
Network segment Checkout
Connected Field Device Check.
Loop Check
8.0 SITE ACCEPTANCE TEST PLAN(SAT)
Site acceptance test procedure shall be furnished by bidder to

purchaser/PMC/Owner for review.

Page 404 of 564
ANNEXURE-X
9.0 FF SCHEMATIC DIAGRAM

Page 405 of 564
ANNEXURE-X

Page 406 of 564
Page 1 of 5
APPROVED VENDOR LIST
(INSTRUMENTATION)
ANNEXURE-XI, SECTION-V TO DCS MR
A133-000-YE-MR-1500
Page 407 of 564

Page 2 of 5
S.NO. VENDOR NAME COUNTRY
EMERGENCY SHUT DOWN SYSTEM / PLC (QMR)

1 Yokogawa India Ltd. India
2 Honeywell Automation India Ltd. India
EMERGENCY SHUT DOWN SYSTEM / PLC (TMR)

1 ABB Ltd. (Bangalore) India
2 Invensys Software Systems (s) Pte Ltd. Triconix (Invensys) India
3 GE Fanuc Systems Pvt. Ltd. India
4 GE Fanuc Automation North America Inc. USA
5 ICS Triplex (c/o Industrial Control Services PLC) UK
LOOP INDICATOR
1 Honeywell USA
2 Emerson Process Management Singapore
3 Yokogawa Japan
CABINET
1 RITTAL
MACHINERY MONITORING SYSTEM

1 Bently Nevada Inc. USA
ANTISURGE / PERFORMANCE CONTROLLERS

1 CCC USA
ETHERNET SWITCHES
1 CISCO USA
SPEED CONTROLLER
1 Woodward USA
LARGE SCREEN DISPLAY (GIANT SCREEN)

1 Barco or equivalent Belgium
2 Delta
3 Planer
ALARM PANEL / ALARM ANNUNCIATOR
1 ICA India
2 ICS Triplex UK
3 IDEC Izumi Corp. Japan
4 IIC India
5 Procon Instrument (P) Ltd. India
6 Rochester Inst. UK
Page 408 of 564

Page 3 of 5

PUSH BOTTON / LAMP / ELECTRIC SWITCHES
1 IDEC-Izumi USA
2 R. Stahl (P) Ltd. India
3 Teknik India
FOUNDATION FIELDBUS CABLES

1 Belden Canada / India
2 Lapp Group UK
3 Leoni Special Cables (I) Pvt. Ltd. India Mumbai
4 Northwire Inc. USA
5 Rockbestos Supprenanat Cable Corporation USA
6 Truck India Automation Pvt. Ltd. India - Pune
FIBRE OPTIC CABLES & ASSOCIATED ITEMS

1 AVAYA
2 AMP
3 NORDX
4 KRONE
DISTRIBUTION BOARDS / CIRCUIT BREAKER & FUSES

1 Larsen & Toubro Ltd. India
2 Siemens India
3 Kaycee India
MULTICABLE TRANSIT
1 Brattberg Sweden
2 Roxtec Germany
TERMINAL BLOCK
1 Elemex India
2 Phonix India
ELECTROMECHANICAL RELAY
1 Omron Germany
2 Phoenix Contact India
3 Weidmuller
INSTRUMENT CABLE TRAYS / DUCT (GI)
1 VSL Instruments India
2 Indian Cable Trays India
3 Reliance Cable Trays India
4 Sadhana Engg Corporation India
5 Profab Engineers India
Page 409 of 564

Page 4 of 5

JUNCTION BOXES (FLAMEPROOF)
1 Baliga Lighting Equipment (P) Ltd. India
2 Flameproof Equipment Pvt. Ltd. India
3 Flexpro Electricals Pvt. Ltd. India
4 FCG Power Industries Pvt. Ltd. India
CANOPIES (FRP)
1 Fibrochem
2 Sabre-Nison consultants Pvt. Ltd.
INTERFACE DEVICES
1 MTL5000 SERIES
2 P&F EQU. MTL 5000 SERIES
SIGNAL CABLES
1 Associated Flexibles & Wires (P) Ltd. India
2 KEI Industries Ltd. India
3 Universal Cables Ltd. India
4 Brooks Cable Works India
5 Cords Cable Industries India
6 Delton Cables Ltd. India
7 Elkay Telelinks Ltd. India
8 Polycab Wires Pvt. Ltd. India
9 Radiant Cables Pvt. Ltd. India
10 Thermo Cables Ltd. India
CABLES CONTROL PVC

1 Associated Flexibles & Wires (P) Ltd. India
2 KEI Industries Ltd. India
3 Universal Cables Ltd. India
4 Brooks Cable Works India
5 Cords Cable Industries India
6 Delton Cables Ltd. India
7 Elkay Telelinks Ltd. India
8 Polycab Wires Pvt. Ltd. India
10 Thermo Cables Ltd. India
CCTV
1 Electronic Corporation of India Ltd. India
2 Nelco India
3 Philips India Ltd. India
Page 410 of 564

Page 5 of 5

CAMERA
1 Pelco
2 Hernis
3 Bosch (UL Listed)
CCTV MONITOR
1 Pelco
2 Sharp
3 Sony
CCTV ACCESSORIES (DVR, MATRIX CONTROLLER, ETC.)

1 Pelco
2 Sanyo
3 Sony
FIELDBUS POWER CONDITIONERS

1 MTL
2 P&F
3 TURK
BULK POWER SUPPLIES

1 LAMADA
2 COSEL
3 Delta Electronika BV
4 Mitsubishi Electric
5 Weidmuller
CABLE GLANDS
1 Comet Brass Products
2 Ex-protecta
3 Baliga Lighting Equipment Pvt. Ltd.
SOLENOID VALVES
1 Asco (I) Ltd. India
2 Herion werke Germany
3 Thomson Valves Ltd.
Page 411 of 564

MANDATORY SPARES LIST Part A - Section: V
DISTRIBUTED CONTROL SYSTEM Annexure XII to
SECTION-V
(MANDATORY SPARE PARTS LIST)
B 11.03.2014 Revised & Issued with MR RK NZ AR
A 17.01.2014 Issued with MR RK NZ AR

Rev.
No

Table 1
Mandatory Spares List
Sr. No PART DECSRIPTION QUANTITY REQUIRED
1 DCS, PLC These spares are in addition to 20% installed spares.

5% or minimum 2 modules of each type (processor module, I/O module, communication module, power
A Modules supply module etc.) being used inclusive of those used in consoles. This shall include spare modules for
hardwired instruments also.
10% or minimum 2 nos. of Safety Barriers, Signal Converters, Trip Amplifiers etc.
20% or minimum one no. of each type of Fuses, MCBs, Auxiliary Relays.
2 nos. of bulk power supply unit of each rating.
10% or minimum 2 nos. of communication system components such as hubs, switches, routers etc.
whichever is higher.
B PCs One no. PC of latest version to be supplied as spare.

5% of minimum 1 no. of Disks, disk drives, CRT, switches, lamps, push buttons, etc. whichever is higher.
Consumable spares including Laser printer cartridges, paper or any other consumable items supplied along
C Consumables
with the system required for a minimum of 6 months duration after system acceptance.
2 F&G PLC Subsystem As per Clause No. 22 of Specification for F&G System, attached in Section IV of this MR.
3 CCTV
A Camera Station 1 no.

B Camera 1 no.
C Lens with zoom 1 no.
D Water tank with tube, bracket 1 no.
E Receiver and drive 1 no.
F Keypad including joy stick 1 no.
4 UPS As per requirements specified in Part-B of this MR.
5 MCT Blocks 10% of each type of MCT Block used.
Notes:
1. Above-mentioned mandatory spares list defines the minimum requirement. Contractor to provide any additional items as recommended by manufacturer.
Contractor to submit mandatory spares list to Owner / PMC for approval.
2. All spare items required for commissioning shall be supplied by contractor.
3. Next rounded figure to be considered wherever % is specified. Example: For total 11 Nos. Instruments with 10% spares basis, 2 Nos. spares shall be provided.
4. For the items not covered in the list, 10% or minimum 1 no. (whichever is higher) of each type of electronic card & one fuse set shall be provided.

DISTRIBUTED CONTROL SYSTEM Part A - Section: VI
SECTION-VI
(VENDOR PROPOSAL OUTLINE)

No by by

Page 415 of 564
1.0 GENERAL
1.1 Bidder shall submit a proposal containing, as a minimum, information described in this section.
Bidder's proposal should be organized into tabbed and indexed volumes.
1.2 Bidder to note that all the volumes of proposal shall be submitted in soft copies through EIL eDMS
portal only. Incomplete proposals and proposals not conforming to this specification are likely to be
rejected.
1.3 Bidder must prepare their proposal as per the sections indicated. Each section shall contain the
information as asked specifically. The proposal not prepared in the described format shall be considered
incomplete.
2.0 PROPOSAL CONTENTS
2.1 The technical proposal shall comprise of the following sections:
a) SECTION I- Synopsis of the Proposal
b) SECTION II- Bidders Capability
This section shall be used by the Bidder to establish their capability in the field of Distributed
Control Systems. The details shall be forwarded as under:
Introduction
Company profile
Bidders experience (in PTR format)
System engineering capability
Sub-vendor list (for all bought-out items)
Bidders Organisation chart
Miscellaneous
c) SECTION III- Project Execution
This section shall be used by the Bidder to provide details about execution of the project DCS.
The details shall be forwarded as:
Proposed project management
Man-power Deployment Chart
Bio-data of Key persons
Estimated engineering and delivery schedule including bar chart.
Methodology of execution
Bidders responsibility chart
In case of an Indian company as vendor with foreign collaborator / principal, specify:
Work to be carried out by Indian vendor
Responsibility of system engineering
Overall system responsibility
Source of supplies
Sub-vendors Responsibility Chart
Page 416 of 564
To be filled separately for each bought-out item.

Sub- vendors Manpower deployment chart
To be filled separately for each bought-out item.
Logistic Support Certificate
To be submitted separately for each bought-out item.
d) SECTION IV- System Description/ Operation
This section shall include the following details separately for each system item i.e. DCS, PLC,
IAMS etc.
i) System proveness
Completely filled PTR format for the offered system.
To be submitted separately for each major bought-out system item like PLC, IAMS
etc.
ii) A drawing showing the offered system architecture and all subsystems offered by the
Bidder.
iii) A single line diagram showing interconnection of all hardware functional modules
subsystem-wise, e.g. I/O modules, controller modules, communication subsystem
interface module etc. for each system item.
iv) Detailed functional description for each system item explaining how the system meets
each of the functional requirements specified in the requisition.
v) Bidder shall explain as to how the engineering console, back-up engineering console
and Database Station meets all the functional requirements specified in the
requisition.
vi) Bidder to explain redundancy levels and methodology of change-over at each
processor level i.e. I/O module, Processor module and communication at Processor
and network level (for controller, console, PLC)
vii) Bidder to explain availability of Diagnostics at various levels with the system.
viii) Bidder to explain data storage and retrieval capability of the system.
ix) Bidder to explain with respect to offered hardware and software explaining how Time
Synchronisation of Complete System from external clock is achieved.
x) Display selection on Giant screen from each operator console indicating the hardware
& software being offered to meet their requirement.
xi) Bidder to forward detailed explanation as to how they propose to meet the 20% future
expansion requirements with respect to hardware and software as specified under job
specification attached with MR..
e) SECTION V- Technical Specifications
This section shall include the following details separately for DCS, PLC, IAMS, etc.
i) Bidder shall complete all the data sheets supplied as project specification filling up all
the information required to be filled by Bidder (denoted by * or **)

Page 417 of 564
Bidder shall include printed literature to support the data filled. In addition, Bidder
shall clearly explain as to how each subsystem fits into the functional requirements
specified in the requisition
ii) Bidder to furnish the following documents
A. Sizing calculation for controller and data acquisition sub-system considering
loading and scan time requirements specified in the MR.
B. Sizing calculation for PLC processor considering loading and scan time
requirements.
C. Sizing calculations for HMS hardware and software.
D. Communication network sizing calculation.
iii) Storage Capacity
A. Trending Capability (No. of points with respect to sample time and maximum
storage time)
Real-time Trend
Historical Trend
B. Data Base and History Memory Sizing
C. Calculations for 30 days Historical Trending for all analog points at the rate
of 1 (one) minute sample time.
iv) SOE Capacity Calculations with respect to number of tags and storage time.
v) Bidder to specifically indicate the availability of the following system alarms:
A. For DCS and PLC
Channel failure alarm of main as well as back-up I/O module.
Module failure alarm of main as well as back-up module.
Availability of PLC system alarms on DCS operator console.
Power supply failure alarm.
Fan failure and cabinet temperature high alarm
Main and redundant bus failure alarm
I/O channel latent fault (permanent open / short) detection and alarming
for PLC only.
Barrier failure diagnostic
Disc failure alarm. In case of dual disc configuration, Main as well as
Redundant disc.
Redundant device failed to take-up
B. For SOE
Failure of I/O module
Failure of Processor module
Power Supply Failure alarm
Fan Failure and Temperature high in cabinet alarm
Page 418 of 564
vi) Bidder to furnish following details

A. Update rate on DCS console.
B. Update rate for data from PLC to DCS console and vice versa.
C. Console switch over time in case of Redundant Console electronic type
systems.
D. Switch-over and Switch-over time for redundant gateways and third party
interfaces
vii) Bidder shall include any other information not mentioned in the data sheets but
important or required to be furnished to support and explain the functional
requirements for the system. The additional information shall be provided on separate
sheets and shall be attached to appropriate data sheet.
viii) Bidder shall furnish all the data and drawing required as per the "Vendor Data
Requirements". Bidder shall also furnish data for power consumption, ventilation and
air conditioning requirements, and air quality requirements as per the enclosed
format. Since this information is being used for engineering, Bidder must certify the
correctness of the data provided.
ix) Bidder shall include the detailed description and capabilities of all the software
offered.
x) Bidder shall include separate lists for mandatory spares, recommended spares for two
(2) years normal operation, test equipment and tools, and consumables.
f) SECTION VI- Deviations
Bidder shall list out deviations, if any.
The list shall indicate Document name, Document no., Page no., Clause no., Requirement,
Deviation asked Technical reason for Deviation, Remarks, if any.
Bidder should not give any explanation or comment on the specification.
g) SECTION VII- Quality Assurance, Factory Testing and Field Acceptance
i) Bidder shall enclose "Vendor Standard" procedures including the test facilities
available with them to perform the following:
A. Quality Assurance
B. Factory Acceptance
C. Field Testing
D. Field Acceptance
Bidder shall provide the procedure being adopted by them to demonstrate scan time,
loading, resolution time (for SOE) etc.
ii) Bidder shall enclose the details of simulation method of all process inputs.
iii) Bidder shall also enclose the detailed schedule for factory testing, installation, loop
checking, field testing, commissioning and field acceptance of the system.
h) SECTION VIII- Post Warranty Maintenance Contract

Page 419 of 564
Post Warranty Maintenance Contract details for five years as per specification attached with
MR.
Bidder must confirm the requirements specified here in this MR.
i) SECTION IX- Testing and Maintenance
Training course contents for:
Operating personnel
Hardware and Software engineers (Module level and component level maintenance
training)
Hardware and software maintenance
Schedule of training at Bidders works and at the user's site should be enclosed.
j) SECTION X - Price Details
This section shall contain all the pricing information including Bill of Materials, as per the
commercial section of the MR.

Page 420 of 564
Document Number
AC UPS FOR DCS PACKAGE A133-086-16-50-SP-1500
Rev. A
Page 1 of 9
AC UPS FOR DCS PACKAGE
PROJECT : COKER BLOCK (EPCC-1)

RESID UPGRADATION PROJECT, CPCL, CHENNAI
PURCHASER : CHENNAI PETROLEUM CORPORATION LIMITED
PMC : JACOBS ENGINEERING INDIA PRIVATE LIMITED
CONTRACTOR : ENGINEERS INDIA LIMITED
JOB NO. : A133
A 17.01.2014 Issued for Bids VB ANPS SA

Date Purpose
No by by by

Page 421 of 564
Document Number
Rev. A
Page 2 of 9
Item Tag No. /

Description Quantity
No. Item Code
1.0 Design, manufacture, testing at manufacturer's works,
packing, supply and delivery of UPS system in compliance
with attached data sheet no. A133-000-16-50-DS-1500 Rev A
and Standard Spec. 44NC-4600: ESS 025 Rev 0.
1.1
UPS Systems (IGBT type) of following ratings comprising of,
but not limited to the following:
i Rectifier transformer
ii Battery chargers/rectifiers
iii Transistorized inverters
iv Filter circuits
v Required no. of static switch assemblies
vi Bypass transformer with static voltage stabilizer
vii Make-before-break switch for manually bypassing the
inverters & static switches
viii Ni-Cd Battery bank (Common set rated for 100% of
required AH capacity), along with required accessories
and battery management system
1.1.1 UPS-01 * kVA ,110 V, 50 Hz, Single Phase Parallel Redundant UPS 1 Set
with bypass transformer, static voltage stabilizer and battery
banks. (For DCS/ ESD System) (Loc.: Coker Block Control
Room)
1.1.2 UPS-03 * kVA ,110 V, 50 Hz, Single Phase Parallel Redundant UPS 1 Set
with bypass transformer, static voltage stabilizer and battery
bank. (For F&G System) (Loc.: Coker Block Control Room)
1.2 AC distribution board with incomer Air circuit breaker/
Switch and various switch-fuse outgoing feeders of ratings as
per MR requirements.
1.2.1 AC-01 110V, * A, 50Hz, 1 phase for use with Item 1.1.1 above. 1 No.
1.2.2 AC-03 110V, * A, 50Hz, 1 phase for use with Item 1.1.2 above. 1 No.
1.3 Cell Booster
1.3.1 Cell Booster of adequate rating suitable for battery AH 1 No.
capacity for item 1.1.1
1.3.2 Cell Booster of adequate rating suitable for battery AH 1 No.
capacity for item 1.1.2
2.0 Recommended spares for two years of trouble-free
operation along with quantity and unit rates for the following:
2.1 For item no 1.1.1, 1.2.1 & 1.3.1 above Unit rates
2.2 For item no 1.1.2, 1.2.2 & 1.3.2 above Unit rates
3.0 Mandatory spares for the following:
3.1 Item no. 1.1.1 above Lot
3.2 Item no. 1.1.2 above Lot
4.0 Installation, Testing & Commissioning at site of the
following UPS system, including all labour and materials,
transportation to site and supply of all commissioning spares
4.1 Item no. 1.1.1, 1.2.1 & 1.3.1 above Lump sum
4.2 Item no. 1.1.2, 1.2.2 & 1.3.2 above Lump sum

Page 422 of 564
Document Number
Rev. A
Page 3 of 9
Item Tag No. /

Description Quantity
No. Item Code
5.0 All supporting arrangements and base frames for the UPS
system to be installed in cavity floor, as per the attached
standard no. 7-51-0335 Rev.2
5.1 For item no 1.1.1 & 1.2.1 above Lump sum
5.2 For item no. 1.1.2 & 1.2.2 above Lump sum
6.0 Training to Owners engineers for operation and maintenance Lump sum
of UPS system (See note-31)
7.0 Unit rate of items for addition/ deletion purpose, as per note- 1 No.
11 below
* Vendor to decide.
Notes:
1. All test equipments & tools required for installation, testing and commissioning at site
shall be brought by vendor at his own expense.
2. Each UPS unit shall have dual parallel redundant modules. Each module shall consist
of rectifier transformer, rectifier-cum charger, inverter, filter circuit, static switches,
bypass transformer, facility for manual transfer between inverter supply and bypass
line, facility for bypassing inverter, static switch for maintenance, ACDB and Batteries.
3. The rating of each UPS system (UPS-01/ UPS-03) shall be decided by the vendor
considering the total package load (DCS-ESD/ F&G) and other loads as specified in
Instrumentation Part of MR. In addition to the above, the following Owners/
Purchasers loads shall be considered for DCS/ESD UPS (UPS-01) sizing:
1. Purchasers heater package load 30 kVA

2. Owners LLI package loads 40 kVA
3. Owners OSBL loads 25 kVA
4. Non DCS load 35 kVA
5. Electrical load 6 kVA
4. The crest factors and sizing criteria as given elsewhere shall be considered for UPS
sizing. 20% spare capacity for UPS system shall be provided for future use.
5. UPS rating shall be limited to 130 KVA. In case rating is more than 130 KVA, two
number UPS of equal rating shall be considered without time and cost implication to
Purchaser.
6. In addition to requirements specified in Spec. No. 44NC-4600: ESS 025 Rev. 0

following shall also be taken care in the offered UPS system:
a. UPS system shall comprise of 2 nos. Chargers & 2 nos. Inverters (each rated for 100%
capacity) and a common battery set (rated 100% AH capacity).
b. In the event of failure / non availability of one section of UPS (Charger + Inverter),
suitable arrangement shall be provided such that the battery bank gets connected to
the other healthy section of UPS so that the healthy charger continues to charge the
battery bank as well as continues to feed the 100% of load through the healthy
inverter.
c. In the event of AC mains failure, while one of the inverter is not available, suitable
arrangement shall be provided such that the battery bank gets connected to the
healthy inverter and continues to feed the 100 % load.

Page 423 of 564
Document Number
Rev. A
Page 4 of 9
d. UPS system shall comprise of three incomers, Purchaser will provide three incoming
cables, two for UPS incomer-1, incomer-2 and third for UPS bypass.
7. Vendor shall furnish the calculations for sizing the UPS Systems along with heat loss
and battery sizing calculations for each UPS. The individual load details for DCS and
other package loads shall be complete with load crest factors.
8. Backup time to be considered for sizing of battery for UPS of DCS system shall be
1 hour while that for F&G system shall be 48 hours.
9. Battery and Charger/Inverter sizing calculations shall be subject to Purchasers review

and batteries and chargers/Inverters of approved rating/ capacity shall be supplied
without any cost/ time implication.
10. The final UPS ratings shall be decided based on approved UPS sizing calculation.
Higher UPS rating if required due to change in DCS and other instrumentation loads
shall have no cost and time implication to Purchaser.
11. MR SR. NO. 07.00
Bidder shall quote unit price for addition/ deletion of modules and components at a
later date, for the equipments specified at MR item nos. 1.2.1 and 1.2.2. The price shall
include all accessories, wiring, mounting etc. as required. The items identified below
are the minimum envisaged:
i) Outgoing feeders from ACDB:

a. 10 A Switch fuse
b. 16 A Switch fuse
c. 32 A Switch fuse
d. 63 A Switch fuse
e. 125 A Switch fuse
f. 10 A Switch fuse with isolation transformer
g. 16 A Switch fuse with isolation transformer
h. 32 A Switch fuse with isolation transformer
i. 63 A Switch fuse with isolation transformer
j. 125 A Switch fuse with isolation transformer
12. List of mandatory spares (MR item no. 3.0) for each UPS system shall be as follows:
Quoted:
Sr. No. Part Description Quantity Required Yes/No/Not
Applicable.
A. UPS (One set of spares for each rating of UPS)
1 SCR of all types & ratings 10% with min. 1 No. for
each type & rating
10% with min. 1 No. for
2 IGBT of all types & ratings
each type & rating
3 PCBs of all types 1 Set
4 Control fuses 20% for each rating of fuse
5 Power fuses 20% for each rating of fuse

Page 424 of 564
Document Number
Rev. A
Page 5 of 9
Quoted:
Sr. No. Part Description Quantity Required Yes/No/Not
Applicable.
6 Switching module with static switch 1 Set
7 Power supply card 1 Set
8 Operating console card / control logic card 1 Set
9 Cooling fans 1 Set
10. Indicating Lamps 10% with min three nos
11. Indicating Lamps covers 2 nos of each colour
B. BATTERY (One set of spares for each type & rating of Battery)
1 Complete Battery cell 5 Nos
2 Vent plugs per set 5 Nos
3 Acid level indicator (float) per set 5 Nos
4 Inter cell connector per set 5 Nos
5 Nut , bolts and washer per set 5 Nos
13. UPS unit shall be able to withstand without deterioration mechanical and thermal
effects of the short circuit current. It shall also be able to withstand continuous over
voltage of 10 % and surges from the power distribution, switching surges and over
voltages due to system faults up to a maximum of 2.5 kV peak value.
14. The tentative list of feeders (actual requirement excluding spare feeders) required for
Purchasers/ Owners loads and NON DCS loads are as specified below. Vendor to
provide the same in addition to the other feeders required for DCS loads and other
loads specified elsewhere in the MR. Spare feeders shall be provided additionally as
specified elsewhere in this MR.
Incomer Switch Fuse

kVA
S. No.
Rating Feeder Type Quantity Rating Rating Remarks
Rating
(A) (A) (A)
ELECTRICAL:
1. Later Normal 12 0.5 10 Later
HEATER PACKAGE:
2. Later Redundant 8 1.5 32 Later
3. Later Redundant 1 4 63 Later Actual feeder
4. Later Normal (*) 2 2 32 Later numbers/rating
5. Later Normal (*) 2 5 63 Later will be finalized
LONG LEAD ITEMS ( LLI): during detail
6. Later Redundant 6 1.5 32 Later engineering and
7. Later Redundant 6 2 32 Later the same shall
8. Later Redundant 2 5 63 Later be complied by
9. Later Normal (*) 1 4 63 Later vendor without
10. Later Normal (*) 1 5 63 Later any cost and
OSBL COOLING PACKAGE: time
11. Later Redundant 3 1.5 32 Later implications.
12. Later Redundant 3 2 32 Later
13. Later Normal (*) 1 4 63 Later
OSBL IA COMP. PKG
14. Later Redundant 4 2 32 Later

Page 425 of 564
Document Number
Rev. A
Page 6 of 9
15. Later Normal (*) 1 2.5 32 Later

NON-DCS FEEDERS:
16. Later Redundant 2 1 16 Later Actual feeder
numbers/rating
17. Later Redundant 1 1.5 32 Later will be finalized
18. Later Redundant 1 2 32 Later during detail
Normal (*) engineering and
19. Later 5 1 16 Later
the same shall
20. Later Normal (*) 1 1.1 16 Later be complied by
21. Later Normal (*) 1 2.5 32 Later vendor without
Normal (*) any cost and
22. Later 1 4 63 Later
time
23. Later Normal (*) 1 8 125 Later implications.
(*) denotes feeders to be provided with isolation transformer.
15. A minimum of 20% spare outgoing feeders (subject to minimum of one of each type
and rating) shall be provided in each ACDB. Instrument load >= 1KVA shall be fed
through UPS ACDB.
16. UPS system construction shall be such that each charger, inverter module can be
made fully isolated for maintenance. No common devices/wiring should be installed.
Further there shall be no common device between main & redundant units (e.g. master
oscillators etc.) in order to ensure that the failure of the same does not cause
shutdown of more than one unit.
17. Special tools and tackles required for the maintenance of the equipment, if any, shall
be supplied along with each UPS system.
18. The offered UPS systems shall be completely suitable for the Inrush Current and Load
Crest Factor of DCS and other loads.
19. The vendor shall limit the maximum harmonic content in input current within
permissible limits to ensure that no undue harmful effects are caused on other
equipments operating on same bus. Input harmonic current limits shall be as per IEEE
519.
20. Galvanic Isolation shall be as per Instrumentation requirement.
21. Provision shall be provided for online discharge of battery bank on load.
22. Isolator shall be provided for battery bank isolation near battery.
23. Paint shade for the UPS system shall RAL 7035.
24. Fault diagnostic units shall be complete with PCs of reputed make. The PCs shall be
loaded with the vendors licensed software. Software shall also be supplied in CD
ROM. Serial ports shall be provided in FDU/ PC to integrate the system with DCS and
Purchasers interface.
25. Battery bank shall be supplied with battery management system (auto filling of
electrolyte, condition monitoring of individual cell of the bank through operators
console etc.).

Page 426 of 564
Document Number
Rev. A
Page 7 of 9
Battery management system panel for UPS Battery Sets shall be located in Coker
Block Control Building.
26. All cables shall be FRLS, heavy duty type, 650/ 1100 V grade with Aluminium/ Copper
conductor, PVC insulated, extruded FRLS PVC inner sheathed, armoured and
extruded FRLS PVC overall sheathed and shall comply to latest revision of IS:1554
(Part-1) and IS-10810 (Category-AF). Cables upto size 16 mm sq. shall be with Copper
conductor and Aluminium or Copper conductor for cables above 16 mm2. All outgoing
cables from UPS ACDB shall be of copper conductor. All interconnecting
wiring/Cabling between different shipping sections of the UPS shall be supplied by the
vendor and shall be done internally through the panel. Supply, laying and termination
of FRLS power and control cables as per specification 44NC-4600: ESS 008 between
UPS, ACDB & Battery shall also be in vendors scope. Cable sizing calculation shall be
furnished by vendor post order for approval prior to cable ordering.
27. Fuse disconnecting switch shall be provided for each outgoing feeder of the UPS and
the fuse shall be of fast clearing type (semiconductor type). Fuse rating shall be
selected to achieve co-ordination to protect the UPS during short circuit. The rating of
the largest branch circuit shall not exceed 25% of the system rating. The distribution of
DCS and Non-DCS loads shall be designed accordingly.
28. All alarms & status of UPS shall be communicable through serial link on modbus
protocol over RS-485 port. Following minimum shall be considered:
Current signal
Voltage signal
Fault summary contact
ON/OFF status for HMI.
Duly wired contacts for the above signals shall be provided and terminals for the same
shall be clearly identified.
29. ACDB shall not be more than 8m in length. If required in such case, ACDB shall be
split into two sections.
30. AC incomers cable size to the UPS as well as for outgoing feeders of ACDB used by
client will be furnished post order. The panel shall be suitable for terminating these
cable sizes.
31. Training shall be provided to ten Purchasers Engineers for a period of five days at
CPCL site, by UPS manufacturers representative. Training shall also be provided to
Purchasers personnel in the field of operation, engineering and maintenance of UPS
system at manufacturers works. The no. of days of training required shall be based on
standard courses available with the manufacturer.
32. Battery Load Cycle test shall be carried out by vendor at Site for each of the supplied
UPS system.
33. All shipping sections shall be of single panel only (for facilitating entry from corridor/
door).
34. FIELD TESTING & COMMISSIONING
a) A visual inspection at both ends of all intermediate joints to ensure that terminal
chambers and other enclosures are clean, joints tight and sound, wiring correctly
dressed and labeled and no obvious faults are present.
Page 427 of 564
Document Number
Rev. A
Page 8 of 9
b) After visual inspection, all the covers shall be replaced and cover screw (and gaskets,
if any) checked to be present and tight.
c) Electrical tests generally shall include:
i) An insulation test for each winding and circuit with a separate test for each core of
power circuit.
ii) Continuity test for all power, control circuits, windings etc.
iii) Earth continuity test for all circuits.
d) After the above tests and inspection are completed, control circuit shall be tested for
correct operation under all operating combinations and proved correct before applying
power to main circuits.
e) Capacity test shall be carried out on UPS / batteries / battery charger after installation
at site.
f) After completion of tests a joint test report shall be prepared for each test carried out
on each equipment and shall be signed by authorized representative. A copy of such
test reports shall form a part of completion report.
35. LIST OF ATTACHMENTS:
A133-000-16-50-DS-1500 Rev. A Data sheet for UPS system

A133-000-16-50-VR-1500 Rev. A Vendor Data Requirement
44NC-4600-0000/E.01/0007/A4 Rev 0 Typical Single Line Diagram for UPS
A133-000-16-50-VL-1500 Rev A Vendor list for Electrical Equipments and
Components
44NC-4600: ESS 025 Rev 1 Specification for UPS system
44NC-4600: ESS 008 Rev 1 Specification for medium and high voltage
heavy duty cables.
44NC-4600: ESS 026 Rev 1 Specification for Electrical Equipment
Installation
44NC-4600: ITP 025 Rev 1 ITP for UPS System
7-51-0335 Rev 2 Typ. Installation details of Electrical Panels
on False Flooring

Page 428 of 564
Document Number
Rev. A
Page 9 of 9
TECHNICAL COMPLIANCE STATEMENT

(TO BE SIGNED BY VENDOR'S PRINCIPAL CORPORATE LEVEL SIGNATORY ON COMPANY LETTERHEAD)
I, ON BEHALF OF M/s CONFIRM THAT THE PROPOSAL OF ------
----------------------------------------------QUOTED BY M/s FOR CPCL,
RESID UPGRADATION, CHENNAI (INDIA) AGAINST MATERIAL REQUISITION
/TENDER/PACKAGE No. A133-000-YE-MR-1500 (ELECTRICAL PART) IS IN
TOTAL COMPLIANCE TO THE SCOPE AS WELL AS ALL THE TECHNICAL
SPECIFICATION AND NO DEVIATION, VARIATION OR RESERVATION
WHATSOEVER HAS BEEN MENTIONED IN THE TECHNICAL OFFER. IT IS
FURTHER AGREED THAT THE TECHNICAL DETAILS FURNISHED IN OUR
OFFER WILL BE REVIEWED BY EIL/GAIL DURING DETAILED ENGINEERING
STAGE AFTER ORDER AND ANY CHANGE REQUIRED TO MEET THE
REQUIREMENTS OF ENQUIRY SPECIFICATION INCLUDING AMENDMENT(S)
(IF ANY) WILL BE INCORPORATED BY US WITHOUT ANY PRICE AND TIME
IMPLICATION.
(SIGNATURE WITH SEAL)

Page 429 of 564
DOC. NO. A133-000-16-50-DS-1500
DATA SHEET FOR REQN. NO. A133-000-YE-MR-1500
STATIC UNINTERRUPTIBLE POWER
SUPPLY UNIT (U.P.S.)
APPD. BY SA
PROJECT NO 44NC - 4600 CHKD. BY ANPS
PROJECT LOCATION MANALI PRPD. BY VB
PROJECT TITLE RESID UPGRADATION PROJECT DATE 17.01.14
CLIENT CPCL REV. A B 0 1
A TYPE
B DESIGNATION
C CLIMATIC CONDITIONS
1 DESIGN AMBIENT TEMPERATURE 45 C
2 ALTITUDE ( ABOVE MSL ) 3.5 MTRS
3 RELATIVE HUMIDITY 80 % MAX
4 ANNUAL RAINFALL 1378 mm.

5 ENVIRONMENT CORROSIVE AND HUMID
D SUPPLY CONDITIONS
1 INCOMING SUPPLY SPECIFICATION
1.1 NOMINAL VOLTAGE 415 V 10 %
1.2 FREQUENCY 50 Hz 3%
1.3 NO. OF PHASES / WIRE 3 PHASE / 4 WIRE

1.4 SYSTEM GROUNDING EFFECTIVE / NON EFFECTIVE
1.5 FAULT LEVEL MVA , Ph , SYMM.

1.6 MODE OF SUPPLY TO UPS V TP
415 V TPN
V SP ( P - P )
V SPN
2 BYPASS SUPPLY SPECIFICATION
2.1 NOMINAL VOLTAGE 415 V 10 %
2.2 FREQUENCY 50 Hz 3 %
2.3 NO. OF PHASES / WIRE 3 PHASE / 4 WIRE
2.4 SYSTEM GROUNDING EFFECTIVE / NON EFFECTIVE
2.5 FAULT LEVEL MVA , Ph , SYMM.
2.6 MODE OF SUPPLY TO UPS V TP

415 V TPN
V SP ( P - P )
V SPN
E RATING & PERFORMANCE
1 RATED OUTPUT CAPACITY KVA
2 RATED OUTPUT VOLTAGE 110 V

3 NO. OF PHASES 1
4 OUTPUT SYSTEM SP / SPN / TP / TPN
5 RATED FULL LOAD P.F. 0.8 LAG
6 PERMISSIBLE VOLTAGE VARIATION %
7 PERMISSIBLE FREQUENCY VARIATION %
8 MAXIMUM PERMISSIBLE TOTAL HARMONIC
DISTORTION ( THD ) %
9 MAXIMUM PERMISSIBLE RMS VALUE OF ALL
HARMONICS %
10 MAXIMUM PERMISSIBLE RMS VALUE OF ANY
HARMONICS %
11 METHOD OF CHANGEOVER TO STANDBY
SUPPLY ( BYPASS ) STATIC BYPASS / MANUAL CHANGEOVER THROUGH SWITCH
APPLICABLE STANDARD SPECIFICATION : E SS 025

DOC. NO A133-000-16-50-DS-1500
APPD. BY SA
E RATING & PERFORMANCE ( CONTD.. )
12 TRANSIENT RESPONSE
12.1 PERMISSIBLE MAX. VOLTAGE DIP ON
APPLICATION OF 100 % LOAD %
12.2 DESIRED MINIMUM RECOVERY IN VOLTAGE

DIP ON APPLICATION OF 100 % LOAD % IN SECS.
12.3 PERMISSIBLE MAX. VOLTAGE RISE ON
REJECTION OF 100 % LOAD %
12.4 DESIRED MINIMUM RECOVERY IN VOLTAGE
RISE ON REJECTION OF 100 % LOAD % IN SECS.
13 OVERLOAD 125 / 150% FOR 10/1 MINS. (RESPECTIVELY)

14 CURRENT LIMITING FEATURE
14.1 CURRENT LIMITATION % OF FULL LOAD VALUE
14.2 TRANSFER OF ADDITIONAL LOAD DEMAND TO
BYPASS SUPPLY THROUGH STATIC BYPASS
SWITCH REQUIRED / NOT REQUIRED
15 TYPE OF COOLING NATURAL / FAN

16 CABLE ENTRY TOP / BOTTOM
17 CABLE SIZE LATER
F BATTERY
1 TYPE VENTED TYPE LEAD ACID
SEALED TYPE LEAD ACID

POCKET PLATE (+VE PLATE) TYPE NI - CAD Y
SEALED TYPE NICKEL - CADMIUM
2 BATTERY CELL CONTAINER MADE OF STEEL / NICKEL PLATED / HIGH IMPACT RESISTANT PLASTIC
3 MOUNTING / LOCATION INTEGRAL WITH INVERTER ASSEMBLY

WITH SEPARATE PANEL
IN A SEPARATE BATTERY ROOM Y

4 BATTERY VOLTAGE V ( TO BE DECIDED BY VENDOR )
5 CAPACITY OF EACH BATTERY SET AH ( TO BE DECIDED BY VENDOR )
6 NO. OF BATTERY SETS ONE / TWO AS PER SKETCH NO. B - E50 -
7 DURATION FOR WHICH EACH BATTERY SET
SHALL SUPPLY INVERTER FULL LOAD ON LOSS
OF MAINS SUPPLY 1 HR FOR DCS/ESD UPS ; 48 HRS FOR F&G UPS

8 CELL VOLTAGE AT THE END OF DUTY
SPECIFIED IN CLAUSE NO. 7 ABOVE V
9 TIME OF CHARGING THE BATTERY SET TO HOURS , IF THE BATTERY SET IS CHARGED WITH NO
FULL CAPACITY FROM FULLY DISCHARGED LOAD ON INVERTER

CONDITION AFTER THE DUTY SPECIFIED IN HOURS , IF THE BATTERY SET IS CHARGED WITH FULL
CLAUSE NO. 7 ABOVE. LOAD ON INVERTER
G CONTROLS ** (AS PER ATTACHED SPEC 44NC-4600 : ESS 025 AND SHALL BE INDICATED BELOW)
1 BATTERY FLOAT / BOOST CHARGE SELECTOR

SWITCH ON CHARGER UNIT
2 STATIC BYPASS SWITCH
3 REGULATED TRANSFORMER / SERVO
STABILIZER IN BYPASS CIRCUIT
4 UPS TO BYPASS MANUAL CHANGEOVER

SWITCH

DOC. NO. A133-000-16-50-DS-1500
APPD. BY SA
H INDICATION ** (AS PER ATTACHED SPEC 44NC-4600 : ESS 025 AND SHALL BE INDICATED BELOW )
1 AC MAIN POWER INCOMING INDICATING LAMPS
2 AC MAIN POWER BYPASS CKT.INDICATING LAMPS
3 BATTERY CHARGE DISCHARGE / DISCHARGE
AMMETER
4 UPS OUTPUT AC VOLTMETER
5 UPS OUTPUT AC AMMETER
6 UPS OUTPUT FREQUENCY METER
7 BYPASS CIRCUIT AC VOLTMETER
8 BYPASS CIRCUIT AC AMMETER
9 BYPASS CIRCUIT FREQUENCY METER

10 DC VOLTMETERM
I ALARMS ON UPS PANEL ** (AS PER ATTACHED SPEC 44NC-4600 : ESS 025 AND SHALL BE INDICATED BELOW)
1 MAINS FAILURE ALARM
2 CHARGER FAILURE ALARM

3 LOW DC VOLTS ALARM
4 HIGH DC VOLTS ALARM
5 DC EARTHFAULT ALARM
6 BATTERY CIRCUIT BREAKER TRIPPED ALARM
7 INVERTER FAULT / FAILURE ALARM
8 INVERTER THYRISTOR FUSE FAILURE
9 COOLING FAN FAILURE ALARM

10 OVERLOAD ALARM
11 OVER TEMPERATURE ALARM

12 LOAD TRANSFERRED TO BYPASS ALARM
13 OUTPUT VOLTAGE ERROR ALARM
14 OUTPUT FREQUENCY ERROR ALAR
15 CONTROL POWER FAILURE ALARM
16 COMMON ALARM FOR REMOTE
** BIDDER SHALL OFFER ANY OTHER ALARMS, CONTROLS
AND INDICATIONS WHICH ARE RECOMMENDED FOR SAFE
OPERATION / EASE IN MAINTENANCE AND OPERATION
AND FAULT FINDING.
J APPROVAL , INSPECTION & TESTING AS PER APPROVED VENDOR QUALITY PLAN
K NOTES & ADDITIONAL REQUIREMENTS
1. ALL UNFILLED DATA SHALL BE FILLED BY THE VENDOR IN LINE WITH MR REQUIREMENTS.
2. VENDOR SHALL SUBMIT DULY FILLED-IN DATASHEETS SEPARATELY FOR EACH OFFERED UPS SYTEM.

Page 1 of 20
STANDARD SPECIFICATION FOR

STATIC UNINTERRUPTIBLE POWER SUPPLY UNIT (U.P.S)
DOCUMENT NO: 44NC-4600 : ESS 025
Rev No. Issue Date Pages Rev Description Prepared Checked Approved
By By By
0 03 May 2010 20 Issued for Engineering VSL PPP RBD
Page 433 of 564

STANDARD SPECIFICATION : 44NC-4600: ESS 025 DATE : 03 May 2010
STATIC UNINTERRUPTIBLE POWER SUPPLY UNIT (U.P.S) PAGE : 2 OF 20
REVISION NO : 0
TABLE OF CONTENTS
1.0 SCOPE 3
2.0 BASIS OF DESIGN 3
3.0 SERVICE CONDITIONS 4
4.0 DETAILS OF DESIGN 4
5.0 TESTING AND INSPECTION 17
6.0 SPARES 20
7.0 DRAWINGS AND DATA 20
8.0 QUALITY ASSURANCE 20
9.0 DEVIATIONS 20
Page 434 of 564

REVISION NO : 0
1.0 SCOPE
This specification covers design, manufacture, testing and supply of Static Uninterrupted
Power Supply (UPS) system comprising the following major equipment.
Rectifier/charger
Batteries
Static inverter
Electronic static switch and regulated transformer (where specified) in bypass
circuit.
Manual maintenance bypass switch.
Metering + protection equipment and annunciation, synchronising equipment & all
logics.
Outgoing feeders / Distribution boards as specified elsewhere.
2.0 BASIS OF DESIGN

2.1 The equipment shall comply with the requirements of latest issue of relevant Indian
standard specifications/ equivalent specifications of the country of origin/ IEC
specifications including amendments and addenda. Some of the applicable IS/ IEC/BS
specification are listed below:
IEC: 146 : Semi-conductor converters

IS: 3700 : Essential rating and characteristics of semi-conductor devices.
IS: 3715 : Letter symbols for semi-conducting devices
IS: 4411 : Code of designation of semi-conducting devices.
IS: 5001 : Guide for preparation of drawings for semi-conductor devices.
IEC: 146 : Semi-conductor converters
IS: 3700 : Essential rating and characteristics of semi-conductor devices.
IS: 3715 : Letter symbols for semi-conducting devices
IS: 4411 : Code of designation of semi-conducting devices.
IS: 5001 : Guide for preparation of drawings for semi-conductor devices.
IS: 5469 : Code of practice for the use of semi-conductor junction
devices.
IS: 10918 : Vented type Nickel Cadmium batteries
IS: 13947 : LV switchgear & control gear
IS: 13314 : Solid state inverters run from storage batteries.
IS: 1651 & : Stationery cells and batteries, Lead acid type (with tubular
positive plates).
IS 1652
IS: 8320 : General requirement and method of tests for Lead Acid storage
batteries.
IS: 7204 : Stabilised power supplies D.C. output
Page 435 of 564

REVISION NO : 0
IS: 2147 : Degree of protection provided by enclosure for low voltage
switchgear and control gear.
IS: 13703 : L.V. fuses
IS: 1248 : Direct acting indicating analogue electrical measuring

IS: 12021 : Specifications for control transformers for switchgear and
control gear for voltages not exceeding 1000 V AC.
IS: 5 : Painting
BS: 4417 (IEC : Semiconductor rectifier equipments
146)
IS: 8623 (IEC 439) : Factory built assemblies of switchgear & control gear for
voltages up to & including 1kV and 1200V DC
IS 694(IEC 228) : PVC insulated cables for switchgear and control gear wiring
BS 9720 : Custom- built transformers and inductors of assessed quality
IS2208 & IS9224 : Cartridge fuses for voltages up to & including 650V
BS 2709 (IEC119) : Electrical performance of semiconductor rectifiers
2.2 The equipment shall also conform to the provisions of Indian Electricity rules and other
statutory regulations currently in force.
2.3 In case of any contradiction between the standards listed in 2.1 and this specification, the
requirements laid down in this specification shall prevail.
3.0 SERVICE CONDITIONS

The UPS system shall be designed to operate under the conditions as specified in the
data sheet.
4.0 DETAILS OF DESIGN

4.1 The UPS system shall be an integrated system comprising static rectifiers, battery, static
inverters, static switches, manual by pass switch, AC distribution board, voltage stabiliser
in by pass, isolating and protection devices and all other equipment/ accessories required
for completeness of the system whether specifically mentioned herein or not, but
necessary for completeness and satisfactory performance of the system.
4.2 The UPS system shall be suitable to feed all loads connected to output which are
primarily instruments, DCS, computers, disc drives and other SMPS equipment leading to
high crest factor of the load. However, manufacturer shall check the suitability of the
system for the specific application mentioned in data sheets. (e.g.: Motor starting duty
with motor started on DOL/Star-delta/soft starter/VSD etc.)
4.3 The UPS system shall be based on latest generation technology having proven
performance of satisfactory operation for similar applications. The inverter shall be
transistorised type. All components shall be of a quality and reliability that satisfies the
requirements of a secure AC power to vital equipment performance, controlling,
monitoring and safe guarding function in continuously operating petrochemical process
units, petroleum refineries, gas processing facilities and utility installation. Components
shall be capable of withstanding the thermal and dynamic stresses resulting from internal
and external short circuits and circuit switching operations etc.
Page 436 of 564

REVISION NO : 0
4.4 The design of the UPS shall be such as to minimise the risk of short circuits and shall
ensure personal and operational safety.
4.5 The vendor shall be responsible for design, engineering and manufacturing of the
complete system to fully meet the intent and requirements of this specification and
attached data sheets/ drawings.
4.6 The UPS shall be single phase or three phase system as indicated in the data sheets.
4.7 INPUT POWER SUPPLY
4.7.1 The UPS shall be suitable for input power supply as defined in the data sheet. If not
specified therein the UPS shall be suitable for the following input power supply.
Voltage : 415 10%
Frequency : 50 Hz 5%
In addition to above variations, the input voltage may be subject to transient comprising
voltage dip to 20% of normal voltage during motor start-up and voltage interruption during
short circuit. UPS system shall be designed to operate satisfactorily while deriving the
input power from an emergency diesel generator set.
4.8 UPS CONFIGURATION & OPERATIONAL REQUIREMENTS
The UPS system shall have one of the following basic configurations as specified in data
sheet and drawings:
4.8.1 Single UPS with Bypass (Refer Scheme - I)
In UPS system having this configuration a single rectifier and inverter shall be provided.
Under normal conditions when AC mains power is available the rectifier shall
simultaneously feed DC power to inverter as well as for float/ boost charging of the
battery. The AC supply to loads shall be fed from inverter output.
In case of any fault in inverter / manual stop or inverter overload, the load shall be
automatically transferred to stabilised by pass supply and retransfer of load from
stabilised bypass supply to the inverter shall only be in manual mode.
In case of AC input power failure or battery charger failure, the battery shall supply power
to inverter without any interruption. Actual autonomy period remaining for the batteries
shall be indicated, when inverter draws power from batteries. Upon restoration of normal
AC power, the rectifier shall automatically restart, walk in and shall gradually assume
both inverter and battery charging loads. This shall be fully automatic function without
causing any interruption to critical loads. The charger shall be designed for
simultaneously feeding complete inverter load and for float/ boost charging the battery to
its rated capacity within 10 hrs. Charger shall be equipped with automatic On Line as
well as manual charging facility.
Whenever the UPS is to be taken out for maintenance, the manual maintenance bypass
switch shall enable load transfer to standby supply without any interruption in power to
critical loads. Transfer / Retransfer of critical loads shall be accomplished by automatically
synchronising the UPS to the standby supply and paralleling the inverter with standby
power supply source, before closing or opening of bypass switch as appropriate.
4.8.2 PARALLEL REDUNDANT UPS WITH BYPASS (Refer Scheme - 2)
Page 437 of 564

REVISION NO : 0
In UPS system having this configuration, two sets of rectifiers and inverters and two sets
of batteries shall be provided. Under normal conditions, when AC mains power is
available, both the rectifiers shall operate in parallel and supply DC power for float/ boost
charging the battery and simultaneously to inverters. In case of failure in one rectifier, the
other rectifier shall feed the complete load and the battery without any interruption. In
case of incoming supply failure or failure of both rectifiers, the battery shall feed the
inverters without any interruption. Each rectifier shall be designed for simultaneously
feeding complete inverter load and float/ boost charging of the battery to its rated capacity
with in 10 hrs. Each rectifier shall be equipped with automatic On Line as well as
manual charging facility.
Normally both inverters will be synchronised with each other and with stabilized bypass
supply. Two inverters shall operate in parallel and share the load equally. When a
disturbance/ fault occurs in any one of the inverters, the faulty unit shall automatically get
disconnected and the entire load shall be fed from the other inverter. In case both the
inverters develop a fault, the complete load shall be transferred to stabilized by pass
supply through the static switches and retransfer of load from stabilized by pass supply to
the inverter shall only be in manual mode. All other applicable features as mentioned in
Cl 4.8.1 also shall be incorporated.
4.8.3 HOT STAND-BY REDUNDANT UPS WITH BYPASS
In UPS system having this configuration, the arrangement of rectifiers/ inverters and the
operating philosophy is same as described in Cl.5.2.2 above, except that only one
inverter shall be operating at one time. The other inverter shall not be sharing the load
but shall be synchronised with the running inverter & stabilized bypass supply and remain
ready to accept the load in case of fault in the running inverter. Retransfer of load from
stabilized bypass supply to the inverter shall only be in manual mode. All other applicable
features as mentioned in Cl 4.8.1 also shall be incorporated.
4.8.4 In all UPS configurations, the facility for uninterrupted manual transfer in either direction
through static switches shall also be provided.
4.8.5 For ease of maintenance, it shall be possible to isolate inverters and static switches from
load through manually operated make before break switches. In case of larger rating
UPS, where it is not possible to provide one power switch with make before break feature,
combination of breakers with the control scheme having make before break logic may be
provided which ensures momentary paralleling before tripping of selected breaker.
4.9 UPS DESIGN & PERFORMANCE REQUIREMENTS
4.9.1 Incoming AC supply shall be converted to DC through phase-controlled rectifiers. The
rectifiers shall operate according to the constant voltage current limiting principle and
shall incorporate a Soft Start feature to gradually accept load on initial energising.
4.9.2 The rectifier section of the UPS system shall be capable of precise regulation to prevent
damage to the battery. The output voltage of rectifiers DC bus without the battery shall
be stabilised to within 1% of set value during load variation between 0 to 100% of the
rectifiers and specified mains input supply voltage variation.
4.9.3 Suitable protection shall be provided in the control circuits to guard against instability of
phase controlled rectifiers due to electrical oscillations, which may be present in the input
supply as caused by emergency DG set.
4.9.4 UPS shall be designed to ensure that the harmonic component in the input currents are
limited so as not cause under harmful effects on other sensitive equipment operating on
the same supply bus. Suitable filters/ harmonic traps shall be provided as required.
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4.9.5 The UPS system including the stabilised by pass shall be galvanically isolated form input
power supply system by providing double wound transformers. All transformers shall be
natural air-cooled, dry type suitable for location inside panel. All rectifiers shall also have
a double wound transformer at its input.
4.9.6 An R.F. filter shall be provide at the input and output of UPS to suppress the radio
frequency interference to permissible limits as specified in IEC.
4.9.7 Transient/ surge protection circuit shall be provided in the input circuit to rectifiers to
protect the UPS from surges & voltage spikes.
4.9.8 The UPS system shall be designed to draw power from main supply at a minimum power
factor of 0.85 while working at rated load in normal operating UPS configuration. Vendor
shall furnish variation of power factor when load varies from no load to full load.
4.9.9 The UPS shall be provided with automatic sequence and power walk in circuit(s) with
adjustable time delay up to 15 sec. such that the rectifiers and inverters can start
operating automatically when incoming AC power is restored allowing the UPS to be
loaded automatically.
4.9.10 Facility shall be provided to enable testing of rectifier independently without disconnection
of inverter.
4.9.11 Facility for initial charging of batteries shall also be provided. The inverters shall be
disconnected during initial charging of the battery.
4.9.12 Batteries shall be indoor, stationary type, Lead-acid or Ni-Cd type as specified in data
sheets. Unless specified otherwise in the data sheet, Lead acid battery shall be tabular
plate type (positive plate) and Nickel Cadmium battery of pocket plate type (positive
plate).
4.9.13 For battery sizing, the following factors shall be considered unless specified otherwise in
the data sheet:
a. Load Power Factor of 0.8
b. Minimum ambient temperature specified in Data sheet or 15C if not specified.
c. Battery Current Inverter rated kVA
Inverter efficiency * End cell voltage * No. of cells

d. Aging factor 0.8
e. Back up time of half an hour in case of mains power failure unless specified
otherwise in data sheet.
f. Minimum end cell voltage for lead acid battery 1.75 V per cell and Ni-Cd battery
1.0 V per cell
g. Battery state of charge factor.
4.9.14 The rectifiers/ chargers shall be designed to completely charge the battery in a maximum
time of 10 hours after complete discharge. Facilities shall be provided to initiate battery
boost charge operation by Manual & Automatic means. An auto charging sequence
should be provided for the boost and float charging based on current sensing. In addition
to above, the charging shall be transferred from boost to float mode after a preset time
adjustable through 0-24 hours timer.
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4.9.15 The rectifiers shall be sized based on the maximum inverter input load when inverter is
delivering its rated output at 0.8 p.f. Lagging and recharge the battery to nominal rated
capacity of the battery. The DC load imposed by the inverters shall be considered under
the worst case where only one rectifier is operating but the UPS load is equally shared by
all the inverters. The rating of each rectifier shall be not less than the value calculated as
follows:
For Lead Acid Batteries = Max. Inverter input current 0.14 AH
For Nickel Cadmium Batteries = Max. Inverter input current 0.2 AH

4.9.16 The DC rectifiers shall sense the battery charging current and adjust the DC bus voltage
to maintain the charging current to preset level. A separate current limit circuit shall also
be provided for adjustment of battery current. The rectifiers shall be protected against
reverse battery connection at DC link voltage bus. Subsequent to a discharge cycle when
battery is connected to rectifier, the battery current shall be monitored, controlled and
limited to set value automatically irrespective of the inverter input current.
4.9.17 The battery may be taken out of service for maintenance, during which period it shall be
possible for the inverter to continue operation by drawing power from the rectifier. Ripple
content at the DC link shall not exceed 2% even with battery disconnected.
4.9.18 Battery shall be provided with a sensitive earth leakage protection.
4.9.19 The inverters shall operate satisfactorily for variation of DC bus voltage from fully
discharged condition of the battery to boost charge voltage of the battery and Invertor
output load current waveform having a relative harmonic content varying between 0 and
50%. The latter waveform having a crest factor not exceeding 2.5 and individual
harmonics not exceeding the following values:
- 3rd harmonic - 44% of fundamental
- 5th harmonic - 33% of fundamental
4.9.20 It shall be possible to vary the inverter output voltage steplessly within 5% of the
specified output voltage. This adjustment shall be possible to be made when the inverter
is in operation.
4.9.21 The steady state output voltage and frequency (free running) variation of inverters shall
not exceed 1% from the set value for specified input power supply conditions from no
load to full load condition and load power factor variation from 0.6 lag to 1.0.
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4.9.22 The UPS output voltage waveform shall be sinusoidal. The total harmonic distortion of
voltage waveform at inverter output shall not exceed 4% of the RMS value of the
fundamental considering any linear load up to maximum rated output of UPS system at
rated power factor and not exceeding 15% under non-linear load. Vendor shall submit
with offer empirical data indicating the increase in THD with rising crest factor of load.
4.9.23 The UPS system shall be able to operate satisfactorily on rated loads (in kVA) with power
factors in the range of 0.6 lag to 1.0, if not specified otherwise in the data sheet. Vendor
shall furnish a graph showing the effect of variation in load power factor in this range on
UPS output parameters. The overall efficiency of the UPS system shall not be less than
80% at rated load and 0.8 p.f.
4.9.24 The UPS shall have capacity to deliver a minimum overload of 125% for 10 minutes and
150% for 60 sec., if not specified otherwise in the data sheet. UPS shall be provided with
current limit circuit to avoid excessive loading beyond its permissible overload withstand
capability.
4.9.25 The inverters shall be phase locked to the stabilized bypass power supply as long as
stabilized bypass supply frequency remains within 4% of nominal. When bypass supply
frequency variation exceeds the above limits, the inverters shall be de-linked from mains.
Free running frequency tolerance limit shall not exceed 1%. Facility shall also be
provided for adjustment of synchronising frequency from 1% to 4% in the steps of 0.5%.
4.9.26 Unless otherwise specified, the voltage variation shall not exceed 10% and complete
recovery to normal steady state shall be within 0.1 sec. The phase angle disturbance
shall be less than 120 3% in case of 3-phase inverter. The above requirement shall be
complied for following transient disturbances.
a) 100% step load and unload (For hot stand by only)
b) 50% step load
c) Momentary interruption in power supply
d) Load transfer to stabilized bypass supply
e) Complete load transfer to other healthy inverter when one of the two parallel
inverters develop a fault.
4.9.27 For 3phase UPS system, the maximum output voltage and angle variation between the
phases should not exceed 6% and 3 degrees respectively even under the condition of
100% unbalanced loading of the 3 phase output.
4.9.28 UPS system shall be suitable both for floating output or earthing of star point in case of
single phase/ three phase system respectively.
4.9.29 The stabilized bypass supply shall be designed to regulate the output voltage within 2%
of the rated voltage over complete range of load from no load to full load and for specified
input supply voltage variation. Voltage stabilizer in stabilized bypass supply shall be of
static type and not servo controlled type.
4.9.30 The stabilized bypass supply shall have a continuous current rating equivalent to the
rated output of the UPS unit and be capable of conducting a current ten times the rated
output for the duration more than the fault clearing time of the type of fuse provided. The
load transfer devices may comprise either continuous rated static elements in both
inverter and stabilized bypass supply or continuous rated electromechanical switching
devices with short time rated static elements.
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4.9.31 Suitable number & configuration of adequately rated static switches must be provided in
the inverter(s)output and stabilised bypass supply to ensure positive isolation of faulty
inverter section such that the other inverter and bypass circuits do not feed into the fault
leading to under voltage/ trip. The short time rating of all the static switches shall be at
least 10 times the rated output for the duration more than the fault clearing time of the
type of fuse provided.
4.9.32 Facility shall be provided to manually and automatically initiate transfer of the load from
inverters to the stabilized bypass supply and manually from stabilized by pass supply to
the inverters. Under voltage and over voltage sensing levels to initiate transfer shall be
adjustable. The maximum transfer time between inverters and bypass supply shall not
exceed 4 msec and 20 msec in synchronous and asynchronous mode respectively.
When the manual maintenance bypass switch (MBS) is operated, it shall be possible to
feed all critical loads from standby power source, whilst providing complete isolation to
UPS and static switch. This shall ensure operator safety during maintenance. It shall be
possible to test UPS operation without affecting critical loads, when MBS is operated.
4.9.33 The criteria for automatic load transfer from inverter to the stabilized bypass supply shall
be as follows:
(a) The load transfer shall only be possible when -
- The stabilised bypass output voltage is within 5% of rated UPS

output voltage and
- The mains bypass frequency is within 4%.
(b) Auto-transfer of the load from inverter to stabilized bypass supply shall be
initiated when:
- Inverter output voltage drops below 95% of nominal output
voltage under steady state condition. The transfer shall be
accomplished before the inverter voltage falls below 90% of the
nominal value under transient conditions.
OR
- Inverter output voltage exceeds 105% of the nominal output
voltage under steady State condition. The transfer shall be
accomplished before the inverter voltage reaches 110% of the
nominal value under transient conditions.
OR
- The inverter output current exceeds its tolerable limits.
(c) The following transfer & retransfer operations shall be provided by static
bypass switch (SBS)
- Uninterrupted transfer to standby power initiated by output
overload, DC voltages out of limits, over temperature.
- Transfer to reserve power with 20 msec delay when the inverter
& standby power source are not synchronised, in order to avoid
damage to loads due to phase reversal.
- Uninterrupted manual transfer to standby power shall be initiated
from control panel.
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- All no break transfer & retransfer shall be inhibited when, voltage
of inverter or standby power is out of limits, or frequency
synchronisation is out of limits.
4.9.34 All beakers shall be adequately rated for continuous rating as well as breaking capacity
as applicable. Paralleling of breaker/ switch/ contactor poles to achieve the required
current rating is not acceptable. All output isolating device shall be double pole type.
The static bypass switch shall be capable of delivering overloads of 150% for 1 minute.
4.9.35 All electronic power devices including thyristors, transistors, diodes etc. shall berated
under operating conditions for approximately 200% of the maximum current carried by the
device. All other electrical components such as transformers, reactors, breakers,
contactors, switches, busbars etc. shall be rated for at least 125% of the maximum
required rating. No electronic device shall be subjected to PIV greater than 50% of its
rated value.
4.9.36 All the thyristors, diodes and other electronic devices of UPS shall be protected with high
speed semiconductor fuses. 12/t co-ordination characteristics between fuse and semi-
conducting power devices shall be furnished.
4.9.37 The outgoing circuits of ACDB shall be protected by semiconductor fuses. Each inverter
shall be designed to clear a fault in any of the branch circuits up to a maximum rating of
25% of the system capacity without the assistance of the stabilized bypass supply. In
case of any fault in branch circuits, the load connected to the healthy circuits shall not get
affected. The fault clearing time shall be less than 4 msec.
4.9.38 All PCBs shall be provided with a transparent epoxy coating for environmental protection
and tropicalisation. They shall be suitably located away from heat sources.
4.9.39 All electronic control and monitoring printed circuit cards shall be suitable for easy
replacement. Monitoring points shall be provided on each of the PCBs and the PCB shall
be firmly clamped in position so that vibration or long usage does not result in loose
contacts. All PCBs shall be placed in a manner to avoid replacement of a PCB by a
wrong spare PCB. Failure of each PCB shall be indicated by visual alarms. Visual fault
diagnostics shall preferably identify faults up to various sections in the card.
4.9.40 Forced ventilation of panel, if provided, shall be supplemented by 100% redundant fans.
In normal operation, normal & redundant fans shall run together. The power supply for
the fans shall be tapped from the inverter output. However, the rating of the UPS as
specified in the data sheet shall be the net output of UPS after deducting power
consumption for fans etc. However in case of non-operation of 50% of running fans the
UPS output shall not be affected. The fans shall be arranged to facilitate removal of faulty
fan for maintenance without taking system shutdown
4.9.41 Maximum noise level from UPS system at 1 metre distance, under rated load with all
normal cooling fans shall not exceed 75 dBA.
4.10 CONSTRUCTION
4.10.1 Rectifier/ charger and inverter, stabilized bypass supply and static switch sections shall
be suitably housed in sheet steel panels complete with all interconnections. The panels
shall be fabricated with 1.6 mm/ 2 mm. Thick cold rolled sheet steel and structural steel.
The panels shall be free standing, fitted with suitable louvers for ventilation and cooling
fans as required. Hinged doors shall be provided at the front and back with dust tight
gaskets. Interpanel sheet steel barriers shall be used. The enclosure shall provide
minimum IP-31 degree of protection, if not specified otherwise in the data sheet. The
maximum and minimum operating height of the switches shall be 1800 mm and 300 mm
respectively.
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4.10.2 Power cables shall be with aluminium conductors and control cables shall be with copper
conductors. All the cable connection shall be from bottom and front of the panel, if not
specified otherwise in the data sheet. A removable bolted gland plate shall be provided
along with double compression type nickel-plated brass cable glands for external cable
connections. Clamp type terminals shall be used for connection of all wires up to 10 mm.
Bolted type terminals suitable for cable lugs shall be provided for wire size above this.
Copper lugs for all external connections shall be provided with the panels.
4.10.3 Busbars (AC & DC) shall be colour coded and live parts shall be shrouded to ensure
complete safety to personnel intending routine inspection by opening the panel doors. All
the equipment inside the panel and on the doors shall have suitable nameplate and
device tag numbers as per the schematic diagram. All wires shall be ferruled and
terminals shall be numbered.
4.10.4 All power and control switches shall be rotary type, mounted on the door and shall be
externally operable. Space heater and 100 W incandescent lamps shall be provided in
each panel. All instruments shall be switchboard type, back connected 72 x 72 mm
square of repute make & analogue / digital type. Analogue instruments scale shall have
red mark indicating maximum permissible operating rating. Separate test terminals shall
be provided for measuring and testing of the equipment to check the performance.
4.10.5 A suitably sized earth bus shall be provided at the bottom of the panels including ACDB
running through the panels line up with provision for earth connection at both ends to
main earth grid. The minimum size of earth bus shall be 25 x 3 mm cooper (or equivalent
aluminium). All potential free metallic parts of various equipments shall be earthed
suitably to ensure safety.
4.10.6 All panels shall be of same height so as to form a panel line-up, which shall have good
aesthetic appearance.
4.10.7 Inside the panels, the controls connection shall be done with 660 V grade PVC insulated
wires having stranded copper conductors, 1.5 mm size wire shall normally be used for
circuits with control fuse rating of 10 amp. or less. For circuit control fuse of 16 Amps. 2.5
mm size wire shall be used. Wire size of 0.75 mm may be used for wiring to electronic
components.
4.10.8 All control wiring shall preferably be enclosed in plastic channels or otherwise neatly
bunched together. Each wire shall be identified at both ends by PVC ferrules. Ferruling
of wires shall be as per relevant IS.
4.10.9 All metal surfaces shall be thoroughly cleaned and de-greased to remove scale, rust,
grease and dirt. Fabricated structures shall be pickled and then rinsed to remove any
trace of acid. The surface shall be prepared by applying a coat of phosphate paint and a
coat of yellow zinc chromate primer. The surfaces shall be made free from all
imperfections before undertaking the finished coat.
After preparation of the surfaces, the panels shall be spray painted with two coats of
epoxy-based final paint or shall be powder-coated. Spray-painted finished panels shall be
dried in stoving ovens in a dust-free atmosphere. Panel finish shall be free from
imperfections like pinholes, orange peels, runoff paint, etc. The vendor shall furnish the
painting procedure along with the bids.
4.11 BATTERY ACCESSORIES
4.11.1 The battery shall be complete with all accessories and devices including, but not limited
to, the following (for each battery):
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1 Lot Battery stand in double row, double tier formation made of treated first
class teakwood assembled without the use of any metal fastenings for lead
acid battery or PVC coated steel stand for NI-Cd battery.
1 Lot Intercell, inter row and interbank connectors and end take offs. These shall
be of lead plated/ PVC sleeved copper.
1 Lot Porcelain cell insulators
1 Lot Stand insulators
2 Nos. Hydrometers suitable for specific gravity readings along with wall mounting
teakwood stand
1 Lot Cell number plates and fixing pins as required
2 Nos. Thermometers with specific gravity correction scale along with wall
mounting teakwood stand.
1 No. Cell testing voltmeter (3V-0-3V) complete with IM long leads
4 Nos. Level testers
2 Pairs Rubber gloves, eye protection goggles
2 Nos. Rubber aprons
1 set Acid/Alkali resistant jugs and funnels
1 set Spanner set
1 set Catalytic caps (for lead acid batteries)
Required quantity of electrolyte for initial filling of the battery set plus
10% extra in non-returnable containers.
1 No. Cell booster shall be provided for each AH capacity of battery cells
supplied with following specification:
Cell booster for charging one to five cells within a duration of 10 hours shall
be supplied. It shall be suitable for charging not only new cells before
being introduced to the battery bank but also any treatment to be given to
the individual weak cells. Quantity of such boosters shall be as defined in
data sheet. Cell booster shall be suitable for 240 V 10%, 50 Hz 3%
input power supply.
Cell booster shall have heavy-duty switch fuse on AC incomer and DC
output, AC voltmeter, DC ammeter and Voltmeter, indicating lamp for AC
power ON. The output voltage and current of cell booster shall be under
manual control. Cell booster shall be portable type with wheels. Each cell
booster shall be supplied with 5 m long flexible copper conductor PVC
insulated cable for AC incomer power supply and DC output connection to
the battery.
4.12 A.C. DISTRIBUTION BOARD
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Sheet steel enclosed AC distribution board shall be provided as part of the complete UPS
package. They shall accommodate AC feeders as indicated in the data sheet. The
distribution board shall be floor mounted, fixed type with compartmentalised construction,
having horizontal and vertical bus bars. All bus bars shall be PVC sleeved. It shall be
possible to operate the switches without opening the doors. Switches shall be provided
with door interlock. Vertical cable alley shall be provided for the termination of outgoing
cables. Suitable supports shall be provided for supporting incoming and outgoing cables.
All outgoing switches shall be air insulated load break type. Fuses on outgoing feeders
shall be fast acting semiconductor type/HRC type (as required based on type of load) and
cable entry shall be from bottom. The gland plate of the distribution board shall be non-
magnetic type.
4.13 ALARM, CONTROL, INDICATION AND METERING REQUIREMENTS
If not specified otherwise in the data sheets, following schedule shall be followed for
alarm, control, indication and annunciation. Any additional devices/ features considered
necessary for reliable operation and maintenance shall also be included in various panels
and it shall be highlighted separately. An illuminated one-line diagram indicating
operational status shall be provided on the front of the panel.
4.13.1 Metering
4.13.1.1 Rectifier
a) Incoming line voltages
b) Input line currents
c) D.C. voltage at each rectifier output
d) D.C. current at each rectifier output
e) Battery current for boost and float charging/ discharging
4.13.1.2 Inverters
a) DC input current at each inverter
b) AC voltage at each inverter output. (AC voltages for 3 phase inverter)
c) AC current at each inverter output. (AC currents for 3 phase inverter)
d) Frequency meter at each inverter output
4.13.1.3 Stabilised Bypass supply

a) Frequency meter for incoming supply
b) Voltmeter with selector switch for incoming supply
c) Ammeter with selector switch for incoming supply
4.13.1.4 ACDB
Following shall be provided for each of the ACDB incomers:
a) Voltammeter (voltmeter selector switch shall also be provided for 3 phase
inverter.
b) Ammeter (ammeter selector switch shall also be provided for 3 phase inverter).
c) Power factor meter
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4.13.2 INDICATIONS
4.13.2.1 a) AC mains ON Rectifier
b) AC mains ON- Bypass
4.13.2.2 Rectifiers (for each rectifier)
a) Rectifier output ON
b) Battery on float charge
c) Battery on boost charge
4.13.2.3 Inverters (for each inverter)
a) DC input ON
b) Load on inverter
c) Inverter synchronised with mains
4.13.2.4 Static switch inhibited (on a/c of poor quality of bypass line).
4.13.3 Audio-Visual alarm (Compete with Accept/ Reset/Test Facilities) separately for each
circuit.
4.13.3.1 a) Mains failure
b) Battery charger failure
c) Battery fault
d) Inverter high temperature
e) Low voltage from inverter
f) Inverter bypassed
g) Inverter overloaded
h) Static switch faulty
i) All power fuse failures
j) Load on bypass
4.13.3.2 2 nos. changeover contacts shall be wired to the terminal strip, 1 no. for common remote
alarm of UPS fault and 1 no. for load on stabilized by pass supply annunciation.
4.13.4 CONTROLS
a) All the switches for starting, shut down and testing sequence
b) Primary input circuit breakers for feeding chargers, bypass line and dc bus from
battery including backup protection.
c) Inverter ON/OFF switch (to initiate inverter operation)
d) Static switch transfer test Push Button.
4.14 RELIABILITY
All necessary care shall be taken in selection, design, manufacture, testing and
commissioning of the equipment for ensuring high system reliability. Vendor shall furnish
the value of MTBF, MTTR and Availability Factor. The above figures shall be
substantiated by tests and field results. Following design consideration shall be taken
into account of ensure maximum availability of the system.
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4.14.1 There shall be no common device, between main and redundant units (e.g. master
oscillators etc.) in order to ensure that the failure of the same does not cause shut down
of more than one unit.
4.14.2 It shall be possible to bring out any individual power circuit for maintenance without
affecting the total UPS supply.
4.14.3 Series-parallel combination of smaller devices to achieve specified rating shall not be
acceptable.
4.14.4 All the components used shall be time tested and standardised. Vendor shall state the
safety factors used in selecting such items as semi-conductor, electrolytic capacitors,
transformers etc.
4.14.5 Vendors shall quote their nearest higher standard size that will meet the requirement of
the specified UPS rating.
4.15 FAULT DIAGNOSTIC UNIT
If specified in the data sheet, each UPS set shall have provision for adding
microprocessor based ON line fault diagnostic unit. This shall supervise the UPS
operation continuously. It shall identify and locate faults immediately so that corrective
action can be taken. Fault Diagnostic unit shall be compatible to hook up with ECS / MMI
through RS232/RS485 interface. The software shall be provided on 3.5 inch floppy.
The fault diagnostic unit shall have provision for following minimum facilities:
Automatic print out facilities for time, input/output voltages, currents, frequency under
the following conditions.
UPS power source change over from mains to battery
UPS power source change over from battery to mains.
Changeover from inverter to stabilized bypass supplies and vice versa.
Changeover from one inverter to other inverter
Change over time in case of inverter to stabilized bypass supply and from one
inverter to other inverter.
Prints-out in case of UPS failure.
Output voltage wave form of UPS
Output current wave from of UPS.
Type of failure incident alongwith diagnostic report.
In addition to the above, any other feature which vendor feels may be useful shall be
provided and highlighted separately.
If any additional equipment (e.g. bin connector, adaptor cards etc.) are required for
connecting this unit with UPS system as well as with ECS / MMI, the same are also to be
included in the vendors scope.
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5.0 TESTING AND INSPECTION

After completion of all work at the manufacturer's works, the UPS System shall be
inspected and tests witnessed by the Purchaser's representative. However, stage
inspection may be carried out from time to time to check progress of work and
workmanship. Battery capacity and other tests may be conducted at battery
manufacturers works.
Prior to start of the tests, the manufacturer shall make all relevant adjustments in the
protection and control circuit components of the rectifiers, inverters as necessary to fulfil
the requirements of this specification. The rectifiers output voltage and current limit
shall be set to the appropriate value for the type and no. of battery cells to be supplied
with UPS.
Following tests shall be carried out on each UPS system.
5.1 INSULATION TESTS
The voltages specified in the following table shall be applied for one minutes to the
circuit indicated:
Table of withstand voltage Control electronics Power electronics Auxiliary circuits

< 60V Un1 Un2
To earth 700 V d.c. 2 x Un1 + 1000 V 2 x Un2 + 1000 V
To control electronics --- 2 x Un1 + 1000 V 2 x Un2 + 1000 V
To power electronics 2 x Un1 + 1000 V --- 2 x Un1 + 1000 V

To auxiliary circuits 2 x Un2 + 1000 V 2 x Un1+ 1000 V ---
(Un1 and Un2 are nominal voltage rating of power electronics and auxiliary circuits
respectively).
D.C test voltages may be applied instead of A.C. the magnitude of D.C. test voltages to be
applied shall be 2 times the above mentioned A.C. (rams) values
Insulation resistance test is required to be conducted before and after insulation tests and
continuous burn-in test for 100 hours at full load with temperature rise measurement.
5.2 INTERCONNECTION CABLE CHECK
The inter connection cables are to be checked for correct wiring, insulation and quality of
the terminations.
5.3 A.C. INPUT FAILURE TEST

The test is performed with the test battery and carried out by tripping a.c. incoming circuit
breakers or by switching off rectifies and bypass supply at the same time. Out put voltage
and frequency variations are to be checked for specified limits.
5.4. A.C.INPUT RETURN TEST
The test is performed by closing a.c. incoming circuit breaker or is simulated by energising
rectifiers and by pass supply. Proper operation of rectifiers starting and voltage and
frequency variations of output are to be checked.
5.5 SIMULATION OF PARALLEL REDUNDANT UPS FAULT
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The test is applicable for UPS with parallel redundant configuration. Fault of rectifier or
inverter are to be simulated and output transients are to be recorded.
5.6 TRANSFER TEST
Transients shall be measured during load transfer from inverter to bypass supply caused
by simulated fault and load manually retransfer after clearing the fault.
5.7 Regulation test
This test shall be carried out by measuring input voltage, input current, output voltage,
output current, DC link voltage, output distortion, input active power, output active power
and frequency at no load, 50% load and 100% load at 0.6 and 0.8 p.f.
Following parameters of rectifiers and inverters are to measured;
Measurement shall be carried out in the rectifier float charge mode and in boost charge
mode. Measurement shall be at nominal a.c. voltage and at no load, 50% load and 100%
of rectifier full load. Rectifier measurement shall comprise of: -
Input voltage, frequency, phase current and input power.
D.C. output voltage and current
Ripple current at the DC link bus shall be recorded after isolating the test battery
Inverter measurement shall also be at no load, 50% load and 100% load of inverter rated
output current and shall be repeated for inverter D.C. input voltages corresponding to
battery float charge operation as well as rated inverter maximum and minimum input D.C.
voltage. Measurement shall comprise of:
Input voltage, input current
Output voltage, frequency and waveform distortion, output power and current.
5.8 UPS EFFICIENCY
This shall be determined by the measurement of the active power input and output at rated
p.f. for 50%, 75% and 100% load.
5.9 CURRENT DIVISION IN PARALLEL UPS
Load sharing between UPS units shall be measured with a dummy load under parallel
redundant UPS configuration.
5.10 LIGHT LOAD TEST
The test is to verify that UPS is correctly connected and all functions operate properly. The
load applied is limited for economic reasons to some percentage rated load. The following
points are to be checked.
(a) Output voltage and frequency and correct operation of meters.
(b) Operation of all control switches and other means to put UPS system into
operation.
(c) Functioning of protective and warning devices.
5.11 Continuous burn-in test for 100 hours at full load and 0.8 power factor with temperature
rise measurement.
The test is required to be performed by connecting resistive load or resistive and inductive
load to the UPS system output. The load shall be placed outside the test room to avoid
influences of its heat upon UPS ventilation.
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UPS system in this test is required to work continuously for 100 hours at full load and
steady state temperature of rectifier transformer, rectifier set, D.C. choke, inverter set,
static switch etc. shall be recorded. The temperature of all UPS panels are also to be
recorded.
5.12 AUXILIARY EQUIPMENT AND CONTROL CIRCUIT TESTS
The correct functioning of all measuring instruments, alarms, indications, protection
devices and controls are to be verified. The functioning of auxiliary devices such as
lighting, cooling fans, annunciation etc. should be checked.
5.13 SYNCHRONISATION TEST
Frequency variation limits of inverter is to be tested by feeding bypass supply incoming line
by variable frequency generator and inverter synchronisation limit to be checked as
specified.
5.14 UNBALANCED LOAD TEST (FOR 3 PHASE UPS ONLY)
Unbalance load at specified limits is applied to the UPS system. The specified voltage and
phase angle variation may be checked for compliance with specified values.
5.15 OUTPUT VOLTAGE UNBALANCE (FOR 3 PHASE UPS ONLY)
Output voltage unbalance shall be checked under symmetrical load conditions and
unbalance load conditions. Phase to phase and phase to neutral output voltage are to be
observed. The voltage unbalance is the ratio of highest phase voltage minus lowest phase
voltage to the average value. Phase angle variation may be measured for phase to phase
and phase to neutral voltages.
5.16 OVERLOAD CAPABILITY TEST

Specified values of short time over load are to be applied for specified time interval. Values
of output voltage and output current are to be recorded.
5.17 SHORT CIRCUIT CURRENT CAPABILITY TEST
Specified short circuit current capability is to be tested by application of a short circuit to
UPS output if necessary via a suitable fuse. Short circuit current is to be recorded.
5.18 SHORT CIRCUIT FUSE TEST
Fuse tripping capability of the UPS system is to be tested by short-circuiting the UPS
system output via a specified rating of fuse.
The test shall be repeated to ensure against fuse non-uniformity. The test is carried out at
an appropriate UPS load under normal operation.
5.19 RESTART
Manual restart to be tested after complete shut down of UPS system.
5.20 OUTPUT OVER VOLTAGE
Operation of output over voltage protection is to be checked.
5.21 PERIODIC OUTPUT VOLTAGE MODULATION
Output recording at different loads and operating condition to be done.
5.22 HARMONIC COMPONENTS
Harmonic components of output voltage are to be recorded at no load, 50% load and 100%
load conditions. Harmonic currents caused by UPS system components in the A.C.
incomer side shall also be recorded.
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5.23 EARTH FAULT TEST
An earth fault is to be applied to the output terminal of UPS system. UPS output transients
are to be measured. An earth fault is also to be applied to the battery terminal and UPS
system output transient shall be measured.
5.24 AUDIBLE NOISE TEST
The audible noise is required to be measured at 1 metre distance from UPS system in at
least 4 to 5 locations and its value shall be within permissible limit.
5.25 In addition to above UPS tests, the battery shall be tested as per applicable standards
including duty cycle tests at battery manufacturer works. Following battery tests shall also
be conducted at site:
(a) Rated storage energy time battery test
(b) Battery ripple current.
5.26 The test schedule and test procedure shall be formulated in line with above. Before call
for the witness of the tests, vendor shall get Jacobs' approval on the test procedures.
Vendor shall also indicate the max. allowable tolerance for each test result, along with the
test procedures.
Vendor shall provide all facilities such as power supply, testing instruments, and apparatus
required for carrying out the tests. Required copies of test certificates for all the tests
carried out along with copies of type test certificates and certificates from Sub-Vendor for
the components procured from them are to be submitted before despatch of the UPS
System.
If tests show that certain requirements of the specifications are not met, vendor shall make
necessary corrections to the equipment so that it satisfies all the requirements before
acceptance is made.
6.0 SPARES
The Vendor shall provide, with his quotation, separate priced lists of recommended
operation and maintenance spares.

The Bidder shall furnish drawings in accordance with Vendor Document Requirements as
attached else where.

8.1 Quality assurance shall follow the requirements of Q.A. documents of Jacobs.
8.2 Quality assurance shall commence at the bid stage and follow through to completion and
acceptance, thus ensuring total conformity to purchasers requirements.
9.0 DEVIATIONS
9.1 Deviations from specifications must be stated in writing at the bid stage.
9.2 In the absence of such a statement, it will be assumed that the requirements of the
specification are met without exception.
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Page 1 of 33
ELECTRICAL INSTALLATION
By By By
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ELECTRICAL INSTALLATION PAGE : 2 OF 33
REVISION NO : 0
TABLE OF CONTENTS
1.0 GENERAL 3
2.0 DESIGN 3
3.0 EQUIPMENT & MATERIALS 5
4.0 CIVIL WORK 7
5.0 OUTDOOR SWITCHGEAR INSTALLATION 8
6.0 INSTALLATION OF TRANSFORMERS 8
7.0 INSTALLATION OF EHV, HV & MV SWITCHGEAR & MOTOR CONTROL CENTRES 9
8.0 INSTALLATION OF BUSDUCT 10
9.0 INSTALLATION OF BATTERIES 10
10.0 INSTALLATION OF NEUTRAL EARTHING RESISTOR 10
11.0 INSTALLATION OF POWER & LIGHTING DISTRIBUTION BOARD 10
12.0 MOTORS 11
13.0 CABLE INSTALLATION 11
14.0 LIGHTING INSTALLATION 15
15.0 EARTHING & LIGHTNING PROTECTION 19
16.0 ELECTRICAL INSTALLATION IN HAZARDOUS AREAS 21
17.0 STEEL WORK 22

18.0 INSPECTION, TESTS & COMMISSIONING OF ELECTRICAL EQPT. 22
AND INSTALLATION
19.0 INSTRUMENT & TOOLS 26
20.0 LABOUR, SUPERVISION, COORDINATION & PROGRESS, LICENCE, 27
STATUTORY APPROVAL
21.0 QUALITY ASSURANCE - QUALITY CONTROL 27
22.0 ACCEPTANCE OF INSTALLATION 28
23.0 ATTACHMENTS / APPENDICES : 28

23.1 APPENDIX I - LIST OF CODES, STANDARDS & STATUTORY 28
REGULATIONS
23.2 APPENDIX II 30
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1.0 GENERAL
1.1 SCOPE
This specification covers the technical requirements for equipment, materials and
installation methods, testing and commissioning of electrical system which will generally
include the following:
i) E.H.V & H.V. Outdoor Switchyards
ii) Power & distribution Transformers
iii) E.H.V., H.V. & M.V. Switchgear
iv) Motor Control Centres
v) Power distribution Boards/Power Control Centres
vi) Lighting Installation, including Lighting Distribution Boards, Lighting Fittings &
Socket Outlets.
vii) Wiring for Power, Control, Lighting & Instrumentation
viii) Earthing & bonding of Electrical Equipment, Anti-static Earthing & Lightning
Protection
ix) Emergency Power Generating Equipment
x) Batteries & Associated Equipment.
xi) Communication Systems
xii) Fire Alarm System
1.2 CODES, STANDARDS AND STATUTORY REGULATIONS

Appendix I to this Specification lists the codes, standards and statutory regulations to be
used. This list is not exhaustive and in general, all equipment materials as well as
design and construction shall be in accordance with the latest issues of Indian and/or
Relevant Standards currently in force.
1.3 RELATED DOCUMENTS

This specification is to be read in conjunction with the other contract Documents that will
include General Conditions of Contract, Special Conditions of Contract.
2.0 DESIGN
2.1 EQUIPMENT AND MATERIALS
Equipment of a major or specific nature, such as Transformers, Switchgear, Motor
Control Centres, Motors, Starting & Control Gear, Generators, Batteries, Rectifiers,
communication Equipment, Fire & Plant Alarm System etc. shall be provided by the
Contractor. Equipments supplied by the Contractor shall conform to the
Purchaser's/Owner's 'Particular Specifications' for such equipment. These specifications
may also be detailed in the Contract Documents. Materials not specifically described
shall be of the best quality, complying with applicable codes, standards or current
engineering practice. Selection of equipment and materials shall also be based on the
technical details, performance figures and recommendations given by the manufacturer
and site condition.
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2.2 ALTERNATIVE EQUIPMENT, MATERIALS OR METHODS

Where the Contractor wishes to use alternative equipment, materials or methods to
those specified, the approval of the Purchaser/PMC shall be sought at the time of
tendering, and shall not be assumed unless specifically confirmed by the
Purchaser/PMC, in writing.
2.3 INSTALLATION DOCUMENTS
The Contractor shall carry out, all electrical installation design including the following:
i) Single Line Diagram for Power and Lighting distribution, Earthing System,
Communication System.
ii) Schematic & Control wiring Diagrams for Circuit Breakers, Motor Control and
other Electrical Controls, including Fire Alarm and Plant Alarm Systems.
iii) Location of items of electrical equipment, including Switchgears, Transformers,
Generating Set(s), Control Batteries, Motor Control Centres, Power & Lighting
Distribution Boards, Motors, Control Stations, Lighting Fittings, Socket Outlets,
Switches, Instruments, Instrument/Control panels, Communication Fire & Plant
Alarm Systems, etc.
iv) Main routes for distribution of power, control, lighting and instrumentation
cabling, earthing system, with size and construction details, of associated
trenches, ducts, overhead cable trays, floor / wall cut-outs etc.
v) Cable Schedule, giving type and sizes of cables, respective termination points,
approximate route length, etc. for all power, control and instrument cables and
for main lighting cables.
vi) Sub-circuiting of distribution boards for power, lighting, socket outlet supplies,
process instrumentation and control.
vii) Layouts of earthing system showing earth electrodes, main earth loops or
earthing system, details of construction and earth connections to equipment, for
both equipment and static earthing systems.
viii) Layout and constructional details for lightning protection system, showing
protected zones.
ix) The classification and extent of hazardous areas.
x) Typical installation details for Power, Lighting and earthing.
xi) Material take-off Schedule (Bill of Materials).
xii) Basis of Design & Design Calculations.
The contractor shall carry out design in accordance with Purchaser's Design Standards
Listed in Appendix 1. Installation design other than described above shall be in
accordance with this specification and/or as detailed in the Project Documents. Work
not expressly described shall be in accordance with applicable Codes or Standards
detailed in Appendix 1.
2.4 APPROVAL OF DRAWINGS
2.4.1 All design calculations & drawings prepared by the Contractor shall be submitted to the
Engineer / Purchaser / PMC for comments / approval, before they are finalised. The
number of copies to be furnished by the Contractor shall be as indicated in the Contract
Documents.
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2.4.2 The Contractor shall be responsible for obtaining approvals of drawings from Statutory
Authorities or Electrical Power Supply Authority as required, when such drawings are in
his scope of work and required to be prepared by him.
3.0 EQUIPMENT AND MATERIALS

3.1 GENERAL
3.1.1 All equipment and materials supplied by the Contractor shall be suitable in all respects for
the type of environment in which these are to be used. Nature of special conditions of
environment, and the extent of areas affected are specified elsewhere.
3.1.2 All equipment shall be of robust construction. The enclosures of equipment installed
indoors shall be dust & damp proof. Equipments installed outdoors shall have weather
proof enclosures.
However, dust & damp proof equipment with a weather protecting canopy may be
accepted in special cases, subject to the approval of the Purchaser / Consultant's
Engineer.
3.1.3 For equipment installed outdoors, particular attention should be paid to the following:
i) Fixing holes shall not be provided through the enclosure or casing of any
component. External mounting lugs with fixing holes shall be provided.
ii) Removable covers and cable entries at the top of the equipment shall be avoided as
far as possible. Where this is not practicable, suitable means (which
shall be to the approval of the Purchaser / Consultant's Engineer) shall be adopted
to prevent the ingress of water through the covers or cable entries.
iii) Gaskets shall be secured to the main parts of the enclosure, in such a way, that
they need not be detached during normal installation & maintenance. Gasket
material shall be non-deteriorating and shall not deform or set with age. Where
hinged doors are provided, the door fastners shall be designed to ensure uniform
pressure at all points on the gasket. When the door is closed.
3.1.4 Equipment used in hazardous areas shall be certified by a competent authority as suitable
for use in such areas. The enclosures and other requirements shall be in accordance with
the standards & codes listed in Appendix 1.
3.1.5 All equipment & materials supplied by the contractor shall be to the approval of the
Purchaser / Consultant's Engineer regarding its quality, conformity with specifications and
standards and suitability for site conditions.
3.1.6 The Contractor shall furnish required number of copies of test certificates from
manufacturers or statutory authorities for major equipment as well as equipment suitable
for hazardous areas, supplied by him.
3.2 CABLE AND CONDUIT ENTRIES
Tapped entries shall be provided on equipments, for conduits and cables
If tapped entries cannot be provided on the enclosure, conduit or cable glands terminated
at the enclosure shall be effectively bonded to the same by means of an earthing or
bonding washer (e.g. serrated star washer or equal).
3.3 EARTHING TERMINALS / EARTH BUS
All metal work of the enclosures and non-current carrying metallic parts of the equipment
shall be effectively bonded to one another and connected to two external earth terminals
provided on the enclosure. In equipments, such as Motor Control Centres or Switch-
boards on earth bus running along the entire length of the board should be provided in
place of earth terminals, to which the bonding of internal components shall be carried out,
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REVISION NO : 0
the earth bus in turn shall be connected to the main earthing system by 2 separate and
distinct connections.
3.4 EQUIPMENT AND MATERIALS SUPPLIED BY THE CONTRACTOR
The equipment and materials being supplied by the Contractor will be detailed in the
Project Documents. All other equipment and materials required for the complete electrical
installation shall be supplied by the Contractor.
3.5 CABLES
3.5.1 The types of cables used in the installations shall generally be as given below. If any other
special types of cables are required to be used, details of the types will be given
elsewhere.
3.5.1a Paper insulated, lead or lead alloy sheathed armoured or unarmoured, jute served or PVC
sheathed cables of 32, 22 or 11 KV grades, with aluminium conductors.
3.5.1b XLPE insulated screened or unscreened armoured or unarmoured, PVC sheathed cables
of 3.3 KV, 6.6 KV, 11KV, 22KV, 33KV grade with aluminium conductor.
3.5.1c PVC insulated with PVC / rubber inner sheath armoured unarmoured and with overall
PVC sheath with aluminium or copper conductors.
3.5.1d PVC insulated screened or unscreened, armoured or unarmoured PVC outer sheathed
cables of 3.3KV, 6.6KV grade with aluminium conductor.
3.5.1e Muticore flexible cables, with stranded copper conductors, rubber / PVC insulated, with or
without pliable armour and with an overall PVC / Rubber Sheath.
3.5.1f Single core PVC insulated cables with copper / aluminium conductors.
3.5.1g Mineral insulated aluminium conductor cables. Type designation: ALPYRO.
3.5.1h Telephone & communication Cables - Twisted pairs, armoured or unarmoured shielded
cables or coaxial cables.
3.5.1I Special cables - Details of which will be given in specific cases.
3.5.2 Minimum Sizes of Conductors.
No cable having copper conductors of less than 1.5 mm or aluminium conductors of less
than 35 mm shall be used, except special types of cable specifically detailed elsewhere.
3.5.3. CABLE TERMINATIONS AND CABLE JOINTS
3.5.3.1 HV XLPE and PVC armoured cables, shall be terminated or jointed by means of cold
setting epoxy based cast resin jointing system or heat shrinkable or cold setting kit. the
ingredients used shall be of best quality, which will give the joint, excellent mechanical
and electrical properties, resistance to aging & tropical climatic conditions. Plastic moulds
shall be used for casting the joints.
3.5.3.2 Heavy duty PVC cables, up to 1.1 KV grade (armoured & unarmoured) shall be
terminated by means of a compression type cable gland. In hazardous areas or for
outdoor installation, cable glands with two seals, one on outer sheath and one on the
inner sheath, shall be used. In safe and indoor areas, cable glands, with only one seal on
outer sheath may be used. In case of glands for armoured cables, armour earthing cone
or washers shall be incorporated in the gland.
3.5.3.3 Universal type cable glands as per cable manufacturer's design shall be used for Mineral
insulated Cables.
3.5.3.4 Glands used in Division 1 hazardous areas shall be of approved flameproof type.
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3.6 CONDUITS AND CONDUIT ACCESSORIES
Heavy gauge, screwed, rigid steel / PVC conduits shall comply with IS 9537. Steel
conduit may be black enamelled or galvanised as specified elsewhere. PVC conduit
may be black or grey as specified elsewhere.
All conduit fittings and accessories shall be of cast iron / malleable iron / PVC, provided
with screwed entries, and of robust construction. Only large round junction boxes (min.
dia. 80mm) shall be used in the installation. Large round and adaptable rectangular
junction boxes, shall have external fixing lugs. Two external and internal terminals
complete with hardware shall be provided on the steel junction boxes. Terminal blocks
of adequate rating & number shall be provided in the junction boxes for looping.
Inspection type fittings such as bends, elbows and tees shall not be used, unless
specifically called for or approved by the Engineer.
All conduits and accessories shall be black enamelled or galvanised or PVC as
specified elsewhere.
3.7 STRUCTURAL STEEL
All structural steel such as channels, angles, flats, plates, etc. used in the installation
shall be new and of best quality, conforming to relevant Indian Standards.
3.8 CARE OF EQUIPMENT AND MATERIALS
3.8.1 Storage and Care Prior to Erection
The contractor shall be entirely responsible for the safe storage and care of equipment
and materials he supplies for the contract.
Equipment and materials supplied by the Contractor will be held in the Contractors
stores.
During the storage period the Engineer may instruct the Contractor to submit reports
upon the condition of such equipment or materials, to carry out maintenance on
equipment in accordance with manufacturer's instructions or to attend to such points as
giving motors a part turn to alter the position of bearings and insulation resistance tests
on motor winding.
The Contractor shall be responsible for the care and maintenance of all electrical
equipment, whether supplied and/or erected by him, after installation is completed and
until the Certificate of Acceptance of Electrical Installation is signed by the Purchaser.
The Contractor shall ensure that the proper enclosure of equipment is maintained at all
times and that access doors or covers are opened only when necessary to work upon
the equipment. All unused cable or conduit entries shall be effectively sealed.
4.0 CIVIL WORK

4.1 GENERAL
All major Civil work such as foundation for electrical equipment, sub-stations or switch
room buildings shall be carried out by the Contractor. Minor civil works such as
grouting of equipment foundation bolts, breaking and remaking of floor walls, etc. shall
also be carried out by the Contractor.
Excavation & backfilling of trenches for directly buried cables, earth electrodes,
installation of street lighting poles (including concrete foundation for poles) shall be in
Contractor's scope of work. Provisions of Hume pipes for road crossings shall also be
in the scope of Contractor's work.
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5.0 OUTDOOR SWITCHGEAR INSTALLATION

5.1 GENERAL
The installation work for outdoor switchyards shall generally consist of installation of
outdoor equipment, such as air-break switches, lightning arresters, circuit breakers,
current & potential transformers and overhead bus work. Installation of transformers is
covered by Section 6.
5.2 STEEL WORK
All steel work shall be painted in an approved manner as described in Section 13 and
hardware used may be hot dip galvanised.
5.3 INSTALLATION & COMMISSIONING
5.3.1 Requirements of Indian Electricity Rules shall be strictly observed.
5.3.2 Various types of equipment shall be installed in accordance with drawings and / or
manufacturers instructions and good engineering practice. Particular attention shall be
paid to lubrication of moving parts & bearings, alignment tightness of all connections
(mechanical and electrical ) and wiring.
5.3.3 Overhead bus work shall be of copper or aluminium or A.C.S.R. conductors. Suitable
terminal clamps or connectors shall be provided, except where these are provided on
the equipment. Where dissimilar material are joined. The materials of connectors shall
be suitable for preventing bimetallic corrosion. The connectors shall be vibration-proof
and their design shall allow thermal expansion of conductors. Alternatively, expansion
joints shall be used.
5.3.4 Complete installation shall be tested for its intended satisfactory operation.
6.0 INSTALLATION OF TRANSFORMERS

6.1 GENERAL
This section shall apply to the installation of Power and Distribution Transformers. Small
transformers for special purposes, such as instrument supplies, low voltage supply, etc.
are excluded.
6.2 INSTALLATION, TESTING & COMMISSIONING.
6.2.1 The transformer shall be installed in accordance with IS 10028 - 'CODE OF PRACTICE
FOR INSTALLATION & MAINTENANCE OF TRANSFORMERS'.
6.2.2 The transformers shall be moved to its location and shall be correctly positioned on its
base.
All parts of the transformers, which are supplied loose, such as conservator, radiator
banks, buchholz relays, dial thermometers, bushings, etc. shall be fitted onto the
transformer.
Transformer oil supplied in drums shall be filled into the transformer after duly testing /
filtering, up to the correct level required.
6.2.3 In case of large transformers, the tanks may be nitrogen filled. In such cases, the
correct procedure as per manufacturer's instructions should be followed for oil filling.
6.2.4 Wiring of devices such as buchholz relay, dial thermometers, etc. shall be carried out up
to the marshalling box.
6.2.5 The transformer shall be dried out by one of the methods specified in IS 10028. Drying
out with centrifugal or vacuum type filters will, however, be preferred. The Contractor
shall carry out the process of drying out without interruption and shall maintain a sheet
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indicating time, oil temperature and insulation resistance.
6.2.6 After complete drying out of the transformer, oil samples shall be collected by the
Contractor and shall be tested for dielectric strength as specified in IS 335 .
6.2.7 All devices such as buchholz relays, dial type thermometer and their alarm and trip
contacts shall be checked for satisfactory operations.
6.2.8 All tests specified in Appendix 'C' of IS 10028 shall be carried out by the Contractor (as
applicable to the particular installation in consultation with the Engineer).
7.0 INSTALLATION OF EHV, HV & MV SWITCHGEAR & MOTOR CONTROL CENTRES

7.1 GENERAL
This section covers Switchgear & Motor Control Centres of indoor as well as outdoor
type. The term switchgear used throughout shall include Motor Control Centres also.
7.2 PRELIMINARY INSPECTION
The Contractor shall carry out a preliminary inspection of the equipment to ensure that
the switchgear to be installed is in a satisfactory condition.
7.3 INSTALLATION
The Contractor shall place the switchgear correctly on the bases or foundation prepared
for the same. If the switchgear consists of a switchboard with number of panels bolted
together, he will place all sections of the switchboard correctly, align them and bolt the
sections together to form one continuous switchboard. The switchgear shall then be
secured to the foundation by means of nuts and bolts or foundation bolts grouted in the
base. The Contractor shall also make inter-section bus / wiring connections.
The Contractor shall clean all parts of the switchgear, including HV bushings (with
carbon tetrachloride), plug & socket contacts, auxiliary switches, etc. Conducting
petroleum jelly shall be applied to all electrical contact surfaces.
The Contractor shall lubricate all moving parts of the Circuit Breaker mechanism with
recommended lubricants, and ensure satisfactory mechanical operation. Alignment of
draw out type circuit breakers or switches shall be checked, for horizontal and/or
vertical movements and its correctness shall be ensured. Operation of all mechanical
interlocks shall also be checked.
In case of oil circuit breakers, the Contractor shall fill, clean and test transformer oil in
the circuit breakers, collect oil samples and test the same as per IS 335.
The Contractor shall generally check all internal wiring of the switchgear for its accuracy
as per Vendor's wiring diagram. Satisfactory operation of all controls and protection
circuits, relays, meters & electrical interlocks shall also be checked. Relay settings and
adjustments, if any, shall also be carried out by the Contractor.
The Contractor shall test the insulation resistance of main power circuits, bus bars, P.T.
primary windings, etc. of HV & EHV switchgear with a high voltage megger (minimum
2,500 volts). The insulation resistance of MV switchgear and motor control centres as
well as control and auxiliary wiring of HV & EHV switchgear may be tested with a
500 megger.
The Contractor may also have to carry out high voltage tests on the switchgear, if
indicated elsewhere..
The Contractor shall also carry out Primary and Secondary injection test and check the
calibration of relays and meters wherever required.
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8.0 INSTALLATION OF BUSDUCT

The bus duct as per relevant drawings will be supplied in parts and all the parts shall be
assembled and the bus bar connections shall be made at site. The insulators in bus ducts
shall be inspected for any possible damage during transit and the defective ones shall be
replaced. The insulators shall be cleaned. Contact surface of bus bars, bus bar bolts and
nuts shall be thoroughly cleaned. Petroleum jelly shall then be applied and bolted
connection made. The bus duct enclosure shall be checked for earth continuity and then
earthed at two places. The bus duct shall be properly supported between switchgear and
transformer. The opening in the wall where the bus duct enters the switchgear room shall
be completely sealed to avoid rain water entry. Expansion joints, flexible connections etc.
shall be properly connected. The bus duct levelling shall be checked with spirit level and
pendulum weight.
9.0 INSTALLATION OF BATTERIES

Battery shall be erected on stands and insulators supplied by the manufacturer of the
batteries. Electrolyte shall be filled as per manufacturers instructions. Inter row
connections shall be made with the leads supplied by the manufacturer. Charging and
discharging shall be carried out as per manufacturers instructions. Lamp bank load for
discharge test shall be provided by the contractor and battery capacity shall be rechecked.
10.0 INSTALLATION OF NEUTRAL EARTHING RESISTOR

The neutral earthing resistor shall be inspected for any damage to the resistor grid and other
components. The resistor shall be levelled and installed. All covers etc. shall be checked for
tightness to ensure that the enclosure of the resistor is dust, vermin and weatherproof.
Earthing conductors shall be taken from the outer end terminal of the resistor for connection
to earth electrodes and to the main grid.
11.0 INSTALLATION OF POWER & LIGHTING DISTRIBUTION BOARD

11.1 GENERAL
This section shall apply generally to Power & Lighting Distribution Boards, which may
comprise switch-fuse units, isolators, fused distribution boards, distribution boards with
miniature circuit breakers, circuit switchboxes etc.
11.2 PRELIMINARY INSPECTION
The contractor shall carry out a preliminary inspection of the equipment before installation
to ensure that the equipment is in a satisfactory condition.
11.3 INSTALLATION & COMMISSIONING
The installation of factory built distribution boards shall be carried out generally in the same
manner as for M.V. Switchboards of Motor Control Centres.
In case of wall / structure mounted distribution boards, the Contractor shall fabricate and
install the structural steel framework suitable for mounting the various distribution boards.
The Contractor may have to prepare drawing showing the proposed general arrangement,
of the structural frame which shall be to the approval of the Engineer. The fabrication and
installation of the framework shall be recommended only after the approval of drawing.
Various items for the distribution board shall be mounted in accordance with the approved
drawings.
After completion of the installation of distribution boards, internal / interconnecting wiring
shall be checked for correctness. Insulation resistance of wiring and equipment shall be
tested with a 500 Volts megger. Operations of all equipments shall be checked for correct
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functioning.
12.0 MOTORS
12.1 GENERAL
Motor shall be installed along with the driven equipment.
12.2 COMMISSIONING OF MOTORS
The Contractor shall check all the motors installed, carry out the tests required and
commission the motors. The work will include the following:
a. Check rotor for free movement.
b. Check end play in bearings.
c. Check for mechanical defects, if any, by visual inspection.
d. Inspect bearings to ensure they are greased.
e. For D.C. or slip ring induction motors, check commutators, slip rings, brushes,
brush holders and springs, brush lifting gear, etc. for satisfactory condition.
f. Check direction of rotation for correctness and reconnect the leads, if necessary.
g. Check conduit entries on terminal boxes, block unused entries.
h. Carry out insulation test with an appropriate megger.
13.0 CABLE INSTALLATION

13.1 GENERAL
This section covers installation, termination and connection of various types of single-core
or multicore cables (Ref. Sec.3.5).
13.2 INSTALLATION OF CABLES
13.2.1 Cable routes and mode of installation shall generally be as shown in the relevant
construction drawings. When these are not indicated on the drawings, the Contractor shall
determine the same and get them approved from the Engineer before commencing the
work.
For multiple runs of cables, separation between individual cables shall be provided, when
so indicated, to meet the following conditions.
i) Spacing between loaded cables (power) to suit the rating factors applied in the cable
installation design.
ii) Separation between cables for high voltage service and medium or low voltage service.
iii) Separation between certain types of cables for instrument service and other cables.
iv) Separation between duplicate feeders run along the same route, to prevent damage to
one feeder when the other feeder becomes faulty.
13.2.2 Identification tags indicating cable designation, shall be affixed to each cable at ends and at
an interval not exceeding 15 meters or at the location where cables change direction or
elevation. Cable tags shall be made of stainless steel or any other non-corroding material
suitable for site and installation conditions. Cable designation shall be embossed in the
tags.
13.2.3 Mode of Installation
Modes of installation of cables shall generally be as given below:
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i) Directly buried in the ground.
ii) Installed in built-up trenches in ground, floors, etc.
iii) On cable trays run overhead along pipe/cable racks, or supported on structures,
masonry etc.
iv) Cables run along structural steelwork or masonry, supported by suitable saddles, cleats,
hangers, etc.
13.2.4 Directly Buried Cables
Trenches shall be excavated along the routes indicated in the relevant drawings and / or
approved by the Engineer. They shall be straight and excavated uniformly to a depth shown
on the relevant drawings or approved by the Engineer.
After excavation, the floor of the trenches shall be firmed and a bedding of sifted soil or
clean sand with a well distributed grain size shall be prepared. The bedding shall be well
compacted to density of 1,750 kg / cubic meter. The thickness of the compacted bedding
shall not be less than 75mm.
Proper equipment, such as stands for supporting cable drums and rollers for drawing
cables shall be used for laying cables in trenches. Cables shall be laid without kinks and
utmost care shall be taken in handling them.
After laying the cables, they shall be covered with sifted soil or clean sand well compacted,
up to 150 mm above the top of cables. The cables shall be covered by interlocking cable
tiles extending at least 50 mm beyond the cables on both sides. Alternative methods, such
as use of bricks for cable protection or coloured concrete screen, as specified elsewhere.
After placing of cable tiles, the trenches shall be backfilled completely with riddled soil.
Large stones shall not be backfilled. The backfill shall be well rammed and compacted.
At road crossings or at specified locations, cables shall be laid in hume pipes or
prefabricated cable ducts, or any other type of pipes specified elsewhere. After drawing the
cables, the ends of pipes or ducts shall be sealed adequately with wooden plugs or any
other approved means, to prevent ingress of soil or dirt into the pipes and ducts.
When directly buried cables enter the buildings, the openings made in walls shall also be
adequately sealed to prevent ingress of soil or sub--soil water into the building. Bituminous
or suitable type of PVC compound shall be used for this purpose.
Approved type of cable markers shall be fixed along the cable routes at a distance not
exceeding 15 meters along straight routes, and also where cable loops or cable joints are
located. The position of cable markers and cable identification tags shall coincide.
When cables are laid in multiple tiers, space between individual tier shall be filled and
compacted with sifted soil or sand. Spacing between tiers shall be as specified elsewhere.
Protective cable tiles above the topmost tier only.
13.2.5 Cables in Built-up Trenches
Cables run in trenches shall unless otherwise specified, be installed in sand, in layers.
Separators of non-combustible materials shall be provided, where necessary to ensure
adequate segregation between cables.
Each layer of cables shall be laid on a compacted and consolidated bed of clean sand
having well distributed grain sizes (silver sand). Each layer of cables shall be covered by a
well compacted clean sand up to 75 mm above the top of cables. Next layer of cables will
be laid on this sand bed. On completion of laying of cables, the whole trench shall be
completely sand filled and well compacted. The trenches shall then be covered by any one
of the following methods as specified elsewhere.
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Built-up trenches for cables may be provided in outdoor plant areas, buildings, switch
rooms,
a) Fitted with RCC covers (preferably coloured red) and sealed.
b) Screened over with red coloured lean concrete to finished payment level.
c) Fitted with removable steel chequered plate, covers, generally in sub-stations,
switch-rooms, control rooms and similar indoor locations.
d) Fitted with specially designed covers at road crossings or similar locations
subjected to heavy traffic.
Cables emerging from trenches for final runs to items of equipment shall be protected by
steel pipes up to a height of 200 mm above the finished floor/pavement level. Pipes shall
be fixed onto the trench wall and where they pass through the trench cover, shall be
sealed with bitumastic compound.
All openings in trenches for ducts, cable entry into buildings, etc. shall be sealed
adequately with bitumastic compound or lean concrete.
The trenches in non-hazardous indoor areas, such as control rooms, switch rooms, etc.,
need not be sand filled. Cables may be supported in trenches by means of hangers, cleats,
cable trays, etc.
13.2.6 Cables on Walls, Structures or Cable Trays
Cables shall be run on walls, structure or laid on cable trays, as required. Only approved
type of cable supports or fixings such as cleats, saddles, hangers or straps shall be used.
13.2.6.a Cables Fixed to the Walls or Steelwork
Cables shall be secured by means of saddle bars and saddles. Minimum clear spacing
between walls or steelwork and cables shall be 6mm ( "). The type of saddles used shall
be as shown in the relevant drawings or subject to the approval of the Engineer.
13.2.6.b Cables Supported on Cable Trays
Cables shall be secured to the cable trays by means of single fixing type of saddles or
adjustable cable saddles, made of approved material, when run on horizontal or vertical
cable trays.
13.2.6.c Spacing of Cable Supports
Maximum horizontal & vertical spacing of cable supports shall not exceed 750 mm (30") &
500 mm (20") respectively. When cables are run on cable trays, they shall be securely
supported on each rung of the cable tray.
13.2.7 Cable Trays
Cable trays shall be one of the following types or as specified elsewhere:
i) Site fabricated ladder type cable trays from M.S. Channels, angles, flats as per
cable tray details depending on the weight of cables required to be supported on
cable trays and maximum cable tray supporting distance. The construction of
these cable trays shall be all welded type.
ii) Shop fabricated, heavy pattern, perforated, steel cable trays, galvanised or
painted as specified elsewhere. The cable trays shall be in standard length
sections and shop fabricated bends or tees shall be used. Individual sections
shall be securely bolted together.
iii) Shop fabricated PVC / FRP cable trays.
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Cable trays supports and tray design shall be based on the loading of cable trays.
Generally, the design, shall be such that cable trays supports spacing will be 2 meters or
more.
13.2.8 Single Core Cables
Single core Cables comprising one 3 phase circuit shall be run throughout in trefoil
formation. Cables spacers made of hardwood blocks or any other suitable non-magnetic
material shall be used for supporting the cables. Type and material of clamps shall be to
the approval of the Engineer.
Single core cables shall not be run directly buried in ground unless they are installed in a
protected area, not accessible to unauthorised persons and suitable mechanical protection
is provided. When more than one cable is in parallel per phase, care should be taken to
ensure that all such cables have equal lengths. When single core cables are run in trefoil
formation, for long distances, cables shall be transposed at regular intervals.
13.3 TERMINATION & CONNECTION OF CABLES
13.3.1 High Voltage PVC / XLPE Armoured Cables
H.V. XLPE / PVC armoured cables shall be terminated or jointed by means of cold setting
epoxy based cast resin jointing system or heat shrinkable or push on type cold setting kit.
In case of cable terminations at equipment, dust sealing glands may be used where cables
enter the enclosure, even though the termination is made with cast resin. Particular care
shall be taken to ensure proper bond between the cable armour and earthing system. The
earthing clamp and the earth conductor shall be of adequate size to ensure sufficient earth
return current in the event of a fault. for HV cables, a stress cone shall be made for proper
distribution of dielectric stress.
13.3.2 Heavy Duty LT PVC / XLPE Cables
Heavy duty LT PVC / XLPE Cables, armoured or unarmoured shall be terminated with
compression type cable glands.
When armoured cables are used, the armour shall be prepared in a manner suitable for the
type of cable glands. Armour shall be securely clamped & bonded to the body of the gland.
Armour shall be properly cleaned and petroleum conducting jelly applied to the armour as
well as clamping surfaces. When specifically called for and in hazardous areas, cable
glands shall be further sealed with cold setting PVC compound.
When cable glands are fixed onto a sheet metal enclosure, with a slip hole, a bonding /
earthing washer and a heavy check - out shall be used to ensure effective bonding of the
cable gland with the enclosure.
In corrosive areas, glands shall be coated with corrosion inhibiting varnish lacquer after
installation and covered with PVC hoods, if specifically called for.
13.3.3 Mineral Insulated Metal Sheathed Cables
These cables shall be terminated with the appropriate glands and in a manner
recommended by the manufacturers.
13.3.4 Prevention of Strain at Terminations
Special attention shall be given to ensure that the cable is adequately supported so that
there is no strain on the termination or connection of conductors
Particularly when cables are terminated at equipments, which are subject to vibrations,
strain relief clamps shall be provided where the support for the cable is derived from the
equipment so as to prevent relative displacement of the support with respect to the
termination.
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In case of small sized PVC cables or mineral insulated cables a loop may be formed
adjacent to the termination. This will also allow for slight movement of the equipment.
13.3.5 Connection of Cable Cores / Conductors
13.3.5.a All cable cores or conductors shall be connected to the equipment terminals be means of
approved type of connectors. Conductors of small sizes may be directly connected to
equipment terminals, without using special connectors. The sizes of directly connected
conductors will depend on the type of terminals provided. Connections of larger cables or
cables connected to motors shall be made, generally with crimping type cable lugs, unless
best quality, approved type, mechanical connectors are used. Solid conductor of small size
cable shall be connected by forming loop and Ross Cutney.
13.3.5.b Conductors shall be thoroughly cleaned and smeared with conducting petroleum jelly
before they are connected directly or with mechanical connectors, particularly when bi-
metallic connections, such as aluminium and copper or brass are made. Materials used for
mechanical connectors shall also be of suitable type when bi-metallic connections are
involved.
Mechanical connectors or equipment terminals shall be of pressure clamp type (not
pinching type), when aluminium conductors are to be connected. However, if stranded
aluminium conductors have to be made to pinching type terminals, the conductors shall be
soldered solid before connection.
13.3.5.c Core identification ferrules or coloured PVC adhesive tapes shall be provided for all
multicore cables at the point of connection. Generally, red, yellow & blue coloured tapes
may be used for identification of cores in power circuits. Ferrules or numbered tapes shall
be used for identification of control cable cores.
13.3.5.d Jointing & Soldering of Aluminium Conductors
Most of the cables used will be with aluminium conductors, and the contractor shall
exercise care for joining and soldering aluminium cables. The contractor shall ensure that
this work will be carried out by competent persons having a thorough knowledge and
experience of aluminium soldering work in electrical trade and preferably, having a
certificate from cable manufacturers.
The Contractor shall use special soldering materials & accessories such as fluxes, special
wiping cloth, cleaning tongs, special laddies & solder pot with thermometer, which are
essential for joining. The work shall be carried out strictly in accordance with approved
codes of practice for aluminium conductor soldering.
All materials used shall be of approved type. Petroleum conducting jelly or equivalent
corrosion inhibiting compound shall be copiously used after finishing the above work, to
prevent corrosion and its after effects
14.0 LIGHTING INSTALLATION
14.1 GENERAL
The lighting fixtures in the plant shall be fed from lighting panel. All outdoor lighting shall
be group controlled from control stations or through synchronous timer or photocell.
Lighting wiring between panel and lighting fixtures shall be done with PVC insulated
3 core (phase, neutral and earth) copper conductor armoured cable for hazardous areas.
Wiring in the building shall be done by means of 3 core copper conductor, PVC insulated,
armoured cables, or PVC insulated copper conductor wires in conduit / Metsec
channel as specified elsewhere. All joints of conductors in Switchboards / JBs, fittings
shall be made only by means of approved mechanical connectors (nylon / PVC
connectors), Bare twist joints shall be permitted any where in the wiring system.
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14.1.1 The electrical contractor shall determine, with approval of Engineer-in-charge or his
authorised representative, the exact locations of each fixture in order to avoid interference
with piping or other mechanical equipment and also with a view to obtain as much uniform
illumination as practicable and to avoid objectionable shadow. Conduits shall be laid out
by the contractor to suit field conditions as per directions of the Engineer-in-Charge.
14.1.2 On walkway, platforms and other outdoor area, lighting fixtures shall be located nearer to
landing of stairs or ladders, gauges, flow meters, panel boards and other equipment to
provide proper illumination.
14.1.3 The minimum height of any lighting fixture shall be preferably not less than 2.5 meters
above the floor level.
14.1.4 All outdoor cable terminations to junction boxes, panels etc. shall be preferably through
bottom or side entry. Top entries for cables shall be avoided to avoid water entry. All
cable glands for outdoor terminations shall be double compression type and the gland
shall be covered with PVC or rubber boot shroud. All unused cable entries shall be
plugged with suitable blanking plugs.
14.1.5 Mounting height of equipment shall be as under :-
Top of Witch Box : 1200 mm from FFL (Finished floor level)
Top of Lighting / Power Panel : 1800 mm from FFL
5/15 Amp. Receptacle : 300 mm from FFL unless otherwise specified
(1200 mm for process areas).
Lighting fixture : As indicated in layout drawing.
Exhaust fan : In the cut out provided / As indicated in Layout
Drawing.
14.1.6 Fixtures shall be firmly supported from the structures. Support clamps etc. may be bolted
or welded to the existing steel work or metal inserts. In case of concrete structures, where
metal inserts are not available, fixtures shall be suspended from Concrete surfaces with
the help of anchor fasteners. In such cases special care shall be taken to see that
anchoring is firm. In places where ceiling fans are provided, lighting fixtures shall be
suspended below the level of fan to avoid shadow of fan falling on ground.
14.1.7 Circuit cables shall be cleared in a group to structure by using galvanised strip clamps or
run in cable trays wherever trays are available. Spacers and cleats shall be of required
size to accommodate the cables. All hardware shall be galvanised or zinc passivated.
Underground lighting cables (in paved areas) shall be taken in suitable G.I. sleeves buried
at a minimum depth of 300 mm from FFL. GI pipe sleeves shall be extended to 300 mm
above FFL. Exact termination / layout of G.I. pipes ( for protection of cables ) shall be
decided at site as per site convenience.)
14.1.8 Wiring for all socket outlet shall be done with 3 cores of equal sizes of wire for phase,
neutral and earth. The terminals of switch sockets shall be suitable to receive the size of
wire specified elsewhere.
14.1.9 All lighting fixtures shall be provided with terminal block with required terminals suitable for
connection of 2.5 sq. mm conductor size or higher as specified elsewhere.
14.1.10 The cable shall be straightened after unwinding it from the drum. All cables be clamped /
laid in straight run without any sag and kink.
14.1.11 For location where fan points are shown, fan hooks with junction box shall be provided
during concreting. Where fan hooks and J.Bs. are provided separately JB shall be located
within a distance of 300 mm from hook for mounting of ceiling rose.
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14.1.12 Industrial type plug sockets with appropriate rating of MCB or rating as per job
specification shall be provided at a height of 500 mm from FFL for window AC units.
Socket outlets plugs in Sub-station, DG shed, workshop maintenance shop etc. shall be of
industrial metal clad type.
14.1.13 Wiring for exhaust fans shall be terminated in receptacles as specified elsewhere and
the connection from receptacle to the exhaust fan shall be by means of a flexible cord
equivalent in size to the main run of wires. Switch for exhaust fan shall be located in
a separate switch board along with other switches.
14.2 CONDUIT INSTALLATION
14.2.1 Surface Conduit Installation
When conduits for exposed or concealed wiring are installed on surface, the complete
routing shall be marked on the surfaces. The installation shall be carried out only after
approval of the routing by the Engineer. Conduit installation shall be carried out accurately
and neatly, with conduit runs truly vertical or horizontal. Conduits shall be threaded to close
tolerances and burr removed from the ends after threading. All screwed connections shall
ensure that at least five threads are engaged and electrical continuity maintained.
Conduits shall be supported with saddles at a spacing of 1200mm max. for conduits up to
1" size and 180mm maximum for larger sizes. Saddles shall also be provided at both ends
of fittings, equipment, devices, junction boxes, bends or offsets, within 200mm max.
Minimum clearance between conduit and surface shall be 6mm. Saddles shall be of cast /
malleable iron, cast aluminium or any other approved material, and galvanised painted or
cadmium plated.
14.2.2 Embedded Conduit Installation
Conduit installation may be embedded in RCC structures or brick work.
The installation in RCC structures shall be carried out after the form work and
reinforcement work is complete, but before concreting . Concreting, which will be done only
after completion of the conduit installation and its approval by the Engineer. Conduits laid
in concrete all have minimum 50mm cover up to the finished surface and shall preferably
be laid behind the reinforcement. Conduits shall be securely led to prevent their movement
during concreting.
Installation in brickwork will require chases to be made in brickwork, sufficiently deep to
provide adequate cover for the conduits. Conduits shall be securely fixed to the brickwork
and chases made good.
In this type of conduit installation, a galvanised fish wire shall be drawn in conduits.
All embedded accessories such as junction boxes, switchboxes, etc. shall be mounted
such that they will flush with the finished surfaces including plaster. All joints in the
installation shall be tight and covers properly gasketted and fixed to prevent ingress of
concrete slurry, water or dust.
14.3 Conduit Wiring
Conduit wiring shall generally be carried out with single core PVC insulated cables / wires.
If any other type of cables is to be used, the same will be indicated in the Contract
Documents.
The Conduit installation shall be complete in all respects before the cables are drawn in
conduits. All conduit runs shall be thoroughly cleaned of dust, moisture, etc. by blowing
compressed air or by any other suitable means. An approved lubricating compound (such
as soap stone powder, lux flakes or talc) shall be applied to the insulated cables before
they are drawn in conduits. The cables shall be neatly bunched together to prevent kinks or
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twisting.
14.4 POINT WIRING
Each point wiring shall comprise the following:
Supply and installation of " /1" / 1" heavy duty M.S. / PVC conduits with MS / PVC
accessories such as 90 bends, inspection Tees etc. as required - supply and pulling of 2
nos. 3/22 PVC insulated stranded copper single core wires of 440V grade and one number
14 SWG copper wire outside conduit for earthing. It shall also include supply and
installation of multi-way large round junction boxes with Dome / Flat covers and four way,
15A terminal block. For suspending of fluorescent lighting fitting, dome cover junction box
shall be used.
Supply, Fabrication and Fixing of hardware such as clamp, Saddles Bolts, Nuts,
Framework, etc. as required. 14 gauge bare copper earthing wire shall be run within
conduits for earthing of fittings, junction boxes, switch / single phase socket outlet
enclosures.
Earthing shall be done at single point.
Wiring from LDB to lighting fittings exhaust fans single phase outlets, shall be carried out
with 3/22, YY cables through " /1" / 1" heavy duty M.S / PVC conduits.
Junction boxes shall be fixed on brackets, fabricated from 25 x 3 mm MS flat. Such
brackets shall be fixed to the ceiling / wall by means of anchor bolts / nylon raw plugs and
screws. Each equipment such as lighting fittings, switches, junction boxes, socket outlets,
exhaust fans etc. shall be earthed internally by the third core of the 3 x 2.5 mm YWY cable
used.
14.5 MEASUREMENT OF POINT WIRING
Wiring from D.B's / switchboard to the first lighting fitting through the circuit switch shall be
considered as one point. Wiring from the first fitting to the next fitting in the same circuit
shall be considered as half point. Wiring to the exhaust fan shall be considered as one
point. For measurement of switch socket point wiring, wiring from D.B. / switchboard upto
first socket outlet through ckt. switch shall be considered as one point. Subsequent wiring
to next socket outlet shall be considered as half point, supply and installation of light fitting,
fans, exhaust fans, socket outlets shall be covered under separate item rate.
If a separate circuit is tapped from the same lighting circuit, it shall be treated as half point.
If a socket is located very near to a Distribution Board, it will be considered as half point.
Otherwise this shall be considered as an independent point.
Quoted rate of point wiring is applicable for any length of conduit emanating from LDB to
first fitting and for subsequent points also.
14.6 HAZARDOUS AREA INSTALLATION

14.6.1 Wiring in hazardous area shall be done by using minimum 2.5 mm2 copper conductor
armoured cable. Circuit wiring feeding hazardous areas shall be controlled by two pole
switches / MCBs ( for phase as well as neutral isolation).
14.6.2 Correct type of lighting equipment (fixtures and JBs) with regard to enclosure protection
as specified elsewhere, shall be installed for the areas classified as Zone 1, Zone 2 etc.
14.6.3 The terminations in the junction boxes and the lighting fittings shall be done avoiding
possibility of loose connections due to vibrations. After the terminations are made the
cover of the junction boxes and the lighting fittings shall be closed properly with all bolts
and hardware in correct position, retaining its explosion and weather protections. In
fixtures having double cable entries, both the entries shall be used for looping in and
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looping out connection, thus minimising the use of a separate junction box. Wherever
separate control gear boxes (C.G. box) are provided looping in and looping out
connections shall be through CG box, thus avoiding the use of an additional junction box.
All unused cable entries shall be sealed with suitable plugs.
14.6.4 Cable glands for terminating cable on flameproof equipment shall be of double
compression FLP type. Any material / equipment specified to be supplied by contractor for
installation in hazardous areas, shall be tested by CMRI and duly approved by C.C.E
Nagpur.
14.7 BUILDING LIGHTING
14.7.1 The type of wiring system shall comprise surface / concealed conduit system or cable
wiring as specified elsewhere.
14.7.2 Mounting details of fixtures shall be indicated on the drawings.
14.7.3 Wiring in areas above false ceiling shall be done in Surface Conduit (25 mm dia GI
conduit) suitably clamped to the true ceiling. Vertical drops from true ceiling for panels,
switches, receptacles etc. shall be taken in 25 mm dia PVC conduit concealed in walls up
to switch boards / panels. Lighting fixtures shall be supported from true ceiling. Exact
location of fixtures shall be finalised in co-ordination with air-conditioning duct diffuser
layout, panels layout and false ceiling grid layout. To facilitate easy maintenance Looping
back system of wiring shall be followed throughout. Accordingly supply tappings and other
interconnections including those for earthing are made only at fixture connector blocks or
at switch boards. Required number of junction boxes shall be used at intervals for wire
pulling and inspection.
14.8 STREET LIGHTING
14.8.1 Street lighting poles to be located on road side shall be installed at a minimum distance of
300 mm from the edge of the walkway of the road. Size of wires from marshalling box up
to fixture shall be 1.5 mm2 / 2.5 mm2, copper conductor PVC insulated.
14.8.2 Each pole shall be earthed at two points by connecting to the plant earth grid as shown on
Installation standards.
14.8.3 Street lighting fixture shall be mounted on steel tubular poles as per standard drawings.
The foundation for the street lighting poles will be made by electrical contractor. Street
lighting poles shall be supplied with a base plate.
14.9 MAST LIGHTING
14.9.1 The lattice structure masts shall be installed on concrete foundations with the base plate
bolted on to the anchor bolts. The lattice structure shall be painted with a coat of primer
and two coats of aluminium paint, the second coat to be given just before handing over to
the owner. The masts shall be numbered as per drawings. The masts shall be connected
to the plant earth grid at two points.
14.9.2 The main feeder up to the distribution board of lighting mast shall be through PVC
insulated armoured cable of size as specified elsewhere. Wiring from Distribution Board to
each flood light fixture shall be by means of a 3-core 2.5 sq mm, copper conductor PVC
insulated armoured cable. All the cables shall be neatly clamped to the structure at
intervals not exceeding 25 cms.
15.0 EARTHING AND LIGHTNING PROTECTION

15.1 GENERAL
This Section covers installation of earthing system for electrical equipment, static earthing
and for lightning protection. Installation of earthing system for electrical equipment and
static earthing shall be carried out in accordance with IS 3043 - 'CODE OF PRACTICE
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FOR EARTHING' and IS 7689 - GUIDE FOR CONTROL OF UNDESIRABLE STATIC
ELECTRICITY respectively. Earthing system for lightning protection shall be in
accordance with IS 2309 - 'CODE OF PRACTICE FOR THE PROTECTION OF
BUILDINGS AND ALLIED STRUCTURES AGAINST LIGHTNING'.
Generally, a common earthing system shall be provided for equipment earthing and static
earthing. The earthing system for lightning protection shall be separate and may be
interconnected with the former, unless otherwise specified elsewhere.
15.2 EARTH ELECTRODES
Earth electrodes shall generally consist of copper or G.I. plates buried in ground or copper
coated steel rods or cast-iron pipes driven in ground. The type of electrodes shall be as
specified elsewhere. The method of installation of earth electrode shall be in accordance
with the drawings or in accordance with IS 3043, when the drawings are not furnished.
15.3 MAIN EARTH CONDUCTORS
Main earth conductors shall be copper or G.I flats or stranded copper / aluminium
conductors with or without PVC sheath as specified elsewhere. They shall be connected,
at one end, to the earth electrode and to the earth bus or test - link at the other end. All
connections below ground shall be made by bolting or riveting and brazing or welding.
Sizes of main earth conductors shall be as specified elsewhere. All connections to the test
- link or earth bus shall be securely bolted. Contact surfaces shall be tinned and suitably
protected with Petroleum Conducting Jelly to prevent corrosion. All connections below
ground shall be protected as per IS 3043.
15.4 EARTH SYSTEM AND EQUIPMENT BONDING

Main Earth Loops or Earthing Ring Mains shall originate from the earth bus or test links.
Equipments shall be connected to the main earth loops by means of earth conductors.
All electrical equipment viz. transformers, switchgear, motor control centres, motors,
control stations, switches lighting fittings and other electrical apparatus shall be connected
to the main earth loop by means of two separate and distinct, external earth conductors.
The material, type and size of the earth conductors will be as shown in the drawings or as
specified elsewhere.
Two earth terminals will, generally, be provided on most of the electrical equipment.
However, if these are not provided, the Contractor shall provide the same, by drilling and
tapping the equipment suitably and supply necessary hardware.
The entire conduit installation, cable sheaths and cable armour shall also be bonded to
earth at both ends. It must be ensured that the conduit installations maintain electrical
continuity throughout its entire length. Conduits shall be effectively bonded together at
each joint, such as couplings, junction boxes, draw boxes or any other accessories and
equipments. Where conduits and screwed cable glands are terminated at equipment
enclosures with slip-holes, earthing / bonding washer (e.g. star - washer) shall be used to
maintain electrical continuity.
All earth connections with solid or stranded conductors shall be made by means of
soldered / crimping cable lugs. Connections with copper or G.I. flats shall be directly
bolted type. All hardware used shall be galvanised steel, brass or passivated to prevent
corrosion. Spring washer or lock washers shall be used to make all connections secure
and vibration
Earth connections from transformer neutrals and lightning arresters shall be taken as
directly as possible to the earth buses or test links. Main earth conductors from earth bus
or test - link to the Earth Electrode shall be coated with bitumastic.
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15.5 LIGHTNING PROTECTION
Lightning protection system shall generally comprise lightning finals (air terminals), roof
conductors, down conductors, test links and earth electrodes. The number, types,
materials and sizes shall be in accordance with the drawings or as specified elsewhere.
Air terminals shall be mounted on top of buildings or structures as shown in the drawings.
All air terminals shall be inter-connected with roof conductors, chimneys, vent, pipes, hand
rails or any other metallic projection above the roofs shall also be bonded to the roof
conductors. Down conductors from air terminals or from roof conductors shall be routed as
directly as possible to the test links on earth buses, with minimum bends.
All provisions regarding connections of conductors for equipment earthing system shall
also apply to lightning protection system. In corrosive atmospheres, lightning finials or air
terminals shall be covered by plumbing metal for corrosion protection.
16.0 ELECTRICAL INSTALLATION IN HAZARDOUS AREAS

16.1 GENERAL
Electrical installation in hazardous areas as defined in I.S. 5571 shall be carried out with
utmost care and special precautions shall be taken to ensure operational safety.
All personnel, especially supervisory staff, working on such installations shall be fully
conversant with the applicable National Standards and Codes of Practice and shall have
previous experience of such work.
16.2 EQUIPMENT & MATERIALS
Electrical equipment and materials used in the installation shall conform to the relevant
Standards and shall be certified (by a competent authority) suitable for use in Division 1 or
Division 2 hazardous areas, as the case may be.
No modifications shall be made in any certified equipment or material used in the
installation which will impair its effectiveness and invalidate the certificate.
All certified equipments shall be inspected before their use for any damaged or
deteriorated condition which will render the equipment unsafe. Such equipments shall not
be used in the installation.
When any equipment is dismantled for the purpose of installation, care shall be taken to
prevent damage to vulnerable parts such as screw threads, conduit threads, machined
surfaces, etc. If the equipment is to remain dismantled for a prolonged period, machined
surfaces, screw threads, etc. shall be protected against corrosion by means of grease, oil,
petroleum jelly or any suitable corrosion inhibiter. These shall, however, be cleaned
thoroughly before re-assembly.
All hardware used for mounting shall be hot dip galvanised or plated to prevent corrosion.
All bolted connections shall be made secure and vibration proof by means of locknuts,
lock washers, etc.
16.3 WIRING
All wiring in Division 1 hazardous areas shall be carried out with armoured cables or with
PVC insulated wires laid in solid drawn seamless conduits. In Division 2 areas, ERW
conduit may be used.
Termination of cables shall be made with certified or approved cable glands or cable end
boxes. Cable glands and boxes shall be effectively sealed. All conductors connections
shall be made with soldered / crimping cable lugs, or approved mechanical connectors. It
must be ensured that all connections shall be made secure and vibration-proof, by means
of locknuts, lock-washers, etc. Prevention of strain at terminations is of utmost
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importance.
16.4 EARTHING
All provisions of Section 12 for earthing apply with much greater force regarding effective
bonding of electrical equipment, cable armour, conduit installation, process equipments
and process piping (requiring static earthing) to the earthing system.
Special attention shall be paid to the following:
a) Adequate support for earth conductors throughout for protection against breakage.
b) Secure and vibration proof earth connections, protected suitably against corrosion.
c) Continuity of conduit installation or process piping when static earthing is required, by
means of conduit bonds.
16.5 MISCELLANEOUS
All opening between hazardous and non-hazardous areas for cable and conduits shall be
properly sealed by approved means. In case of conduit wiring, conduit stopper boxes shall
be used in conduit runs at the junction of hazardous and non-hazardous areas or at
terminations of conduit runs at any equipment such as motors, starters, push buttons, etc.
Stopper boxes at the junction of hazardous and non-hazardous areas, shall be located at
the boundary between the 2 areas.
17.0 STEEL WORK

17.1 All steel work carried out by the Contractor for equipment and cable supports such as
cable trays, brackets, hangers, saddles, etc. shall be of the best workmanship. Only
certified welders shall be employed for welding. All bolted connections shall be made
secure and vibration proof by means of spring washers or lock washers or lock nuts.
Fixing or grouting of steel-work in floor, ceilings or walls shall be carried out with
approved foundation bolts or fasteners.
17.2 Finished steel work shall be thoroughly cleaned by wire-brushing or sand blasting etc.
All scales and rust shall be removed. The steelwork shall be then painted with 2 coats of
approved primer such as red oxide or red lead and shall be finished with 2 further coats
of approved paint.
17.3 When atmospheric conditions are highly corrosive, chemical works type paints may be
specified. In such cases, special primers and paints shall be used for adequate
protection from corrosion.
18.0 INSPECTION, TESTS & COMMISSIONING OF ELECTRICAL EQUIPMENT

AND INSTALLATION
18.1 GENERAL
This Section covers the requirements of inspection & tests to be carried out on
equipment and installation as well as commissioning of electrical installation. Inspection
and tests shall be carried out jointly by the Contractor in presence of Engineer and / or
Owner.
18.2 INSPECTION
Inspection shall be carried out to ensure that the complete installation is carried out in
accordance with drawings and complies with the requirements laid down by Indian
Electricity Rules, Regulations for the Electrical Equipment of Building by Insurance
Association of India (Fire Section), Indian Standard Specifications & Codes of Practice,
Electrical Inspector, Explosive inspector and any other statutory regulations and
competent authorities. The complete installation shall be subject to the approval of any
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or all of the competent authorities and the Owner / Engineer.
18.3 DETAILS OF TESTS
The tests specified below shall be carried out on the electrical equipment and
installation before commissioning the same. The tests shall be performed by or under
the direct supervision of a competent person, qualified to carry out the tests. All tests
shall be carried out in the presence of the Authorised Representative of the Owner
and/or the Engineer, unless this stipulation is waived in writing.
The installation shall not be accepted by the Owner unless it has been approved by the
competent authorities, and the authorised representative of the Owner and/or the
Engineer.
All test results shall be recorded on prescribed 'ELECTRICAL TEST REPORTS' duly
signed by the person conducting the test and by the authorised representative of the
Owner and/or the Engineer, if tests are witnessed.
In case the installation is found to be not in conformity with the requirements or the test
results indicate defective materials or workmanship, the same will have to be rectified to
the complete satisfaction of the Owner / Engineer and tested again.
18.3.1 POWER & DISTRIBUTION TRANSFORMERS
a) Check HV & LV cable terminations, ground connections, fittings and accessories,
oil level and oil leaks at various joints. Check breather, thermometers & buchholz
relay for proper functioning and operation. Check junction boxes, marshalling
box, etc. for correct wiring.
b) Oil Test
c) Dielectric test as per Clause 7.11 of IS 10028. The oil shall withstand at least 40
KV with a gap of 4mm.
d) Insulation Resistance Test
e) This may be carried out on new transformer without drying out the transformer,
provided the transformer has not been idle or stored for a long period.
Otherwise, this test shall be carried out during drying out of transformers.
Insulation resistance test shall be carried out between primary & secondary to
ground as well as between primary and secondary. Windings not under test shall
be grounded during the test.
f) A megger rated 1000 volts or higher shall be used for the test.
g) Check operation of automatic tap changer and its control panels (local and
remote), for correct functioning, if provided.
h) Check operation of forced cooling system complete with its control panel for
correct functioning, if provided.
i) Polarity & Phasing Out Test
j) Check external connection of the transformer in accordance with diagram of
connections and phase sequence (anti - clockwise).
k) Polarity & Connections of Instrument Transformers
l) Check for correctness of CT & PT connections provided with transformer. Check
electrical continuity of secondary circuits with ELV tester.
m) Adjust spacing of arcing horns / rod gaps, if provided.
18.3.2 EHV, HV & MV SWITCHGEAR
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a) Check proper mechanical operation of circuit breakers including alignment of
trolleys in case of draw - out type circuits breakers, smooth operation of all
mechanical parts, lubrication, mechanical interlocks etc.
b) Check contact alignment and wipe, proper sequence of closing and opening of
main and arcing contacts.
c) Oil test for transformers, in case of oil circuit breakers.
d) Check electrical relays, instruments & controls for correct wiring
e) Insulation test on busbars - phase to phase and phase to ground. This test will be
carried out with circuit breakers in service position, but contacts remaining open.
f) Insulation test on relays & control wiring including current and potential
transformers and wiring of CT & PT secondaries.
g) Insulation test on circuit breakers in withdrawn position - phase to phase and
phase to ground with contacts closed.
h) Adjust correct settings of relays and/or direct acting trips - as specified
elsewhere.
i) Operation Test
Energise only control circuits and carry out closing and tripping operations (where AC
supply derived from main supply is used for operation, the switch-gear bus may be
energised). Check operations of electrical interlocks. Check tripping of circuit breakers
by manual operations of protective relay contacts. Check operations of mechanical
closing and tripping devices. Check lockout conditions for closing of circuit breakers by
simulating the required conditions. Check control, indications, sequence interlocks and
alarms.
a) Polarity and connections of instrument transformers - Check for correctness of
CT & PT connections provided. Check electrical continuity of secondary with ELV
tester.
b) Adjust spacing of arcing horns / rod gaps, if provided.
c) Check operation of instruments, meters, relays and tripping of circuit breakers by
primary / secondary injections as specified elsewhere.
d) Check continuity of power circuits and earth continuity of all non current metallic
parts with a low voltage (6 volts or less) continuity tester.
e) Carry out HV test on power and control circuits, if specifically called for.
18.3.3 MOTOR CONTROL CENTRES, SWITCHGEARS, POWER CONTROL CENTRES
(POWER DISTRIBUTION BOARDS ), UPS, V / F PANEL, ETC.
a) Check equipment, internal wiring, smooth mechanical operation, interlocks, etc.
b) Check continuity of power circuits and earth continuity of all non-current carrying
metallic parts with a low voltage continuity tester.
c) Insulation test for power & control circuits between phases, between phases and
neutral and between phase / neutral and ground.
d) Check operation by energising control circuits (without energising power circuits)
for correct functioning. Simulate external controls and interlocks for the same.
Note chatter or humming of Contactor and rectify, if necessary.
e) Check fuse ratings and adjust relay settings (overload, single phasing preventers
etc.) in accordance with load ratings.
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f) Carry out HV test on power & control circuits, if specifically called for in Contract
Documents.
g) Polarity and connections of instrument transformers - check for correctness of CT
& PT connections provided. Check electrical continuity of secondary circuits with
ELV tester.
18.3.4 MOTORS & ROTATING EQUIPMENT
a) Check equipment for free movement of rotor, and play, lubrication, and for any
other mechanical defects.
b) Check commutators, slip rings, brushes, brush-holders etc. for satisfactory
conditions.
c) Insulation test of motors - between winding and ground. Use 500 volts megger
for M.V. motors and 1000 volts megger for HV motors.
d) Check electrical continuity with ELV tester.
e) No load running of motor noting down no load current and voltages in all three
phases.
18.3.5 CABLES
a) Insulation Test - between each phase and neutral and between each phase /
neutral and ground (Ref. APPENDIX - II).
b) D.C. High Voltage Test on HV cables in accordance with the relevant Indian
Standards and Code of Practice. This test shall be carried out on cables installed
in final positions, and all joints and terminations have been made. The cables,
however, may not be connected to the equipment, so that the equipment may not
be subjected to the test voltage (Ref. Appendix-II)
c) In case of lighting wiring, insulation test shall be carried out on lighting feeders
with branch circuits open. Branch circuits shall be tested separately with lamp
holders, plug receptacles and lighting fittings in position, but without lamps. In
case of lighting circuits with lamp ballasts and glow starters insulation resistance
may be measured between phase and ground only.
d) In case of directly buried cables, insulation resistance of cables shall be
measured before and after the back-filling.
e) Test all receptacles for correct phase sequence.
18.3.6 EARTHING SYSTEM
a) Measure earth resistance of each electrode separately. If a number of earth
electrodes are interconnected with one another, combined earth resistance shall
also be measured. The earth resistance of each electrode and/or a group of
electrodes shall not exceed the values specified elsewhere.
b) Carry out line earth loop impedance test. The loop comprises the line conductor
from the point of fault, back to the supply transformer, the path through
transformer winding, the earthed neutral point of the transformer and path from
that point to the point of fault through the earthing system.
c) Continuity test for earth continuity conductors with ELV tester.
18.3.7 RELAY & CONTROL PANELS, ALARMS PANELS & MISCELLANEOUS EQUIPMENT
a) Carry out insulation test on all power and control circuits.
b) Check all equipment for satisfactory operation and correct wiring.
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18.3.8 BATTERY
a) Visual inspection of all components.
b) Capacity test as per I.S.
18.3.9 BATTERY CHARGER
a) Connection checking
b) Measurement of voltage regulation
c) Insulation test
d) Functional check of auxiliary devices
e) Alternating current measurement at no load and rated load
19.0 INSTRUMENT AND TOOLS

19.1 GENERAL
This section covers the instruments, tools & plant which will normally be required to
carry out the electrical installation including testing & commissioning and which shall be
made available as and when required by the contractor. Meters used for tests shall be
of proven accuracy and to the satisfaction of the engineer.
19.2 TOOLS & PLANT
Hand Tools
Screw drivers, pliers, cutters, spanners, hacksaw, hammers, rawl punches, etc.
Power driven Tools & Equipment
Drilling, grinding, cutting machines, hammers, arc welding set, oxy-acetylene welding
and cutting set and welding accessories.
19.3 INSTRUMENTS
a) Instruments to be always available at Site.
i) Insulation resistance tester (Megger) rated 500 volts
ii) Multi-meter of a reputed make
iii) Clip-on ammeter / voltmeter (tong tester)
iv) Phase sequence indicator
v) Extra low voltage continuity tester (6 volts or less)
b) Instruments to be made available as and when required.
i) Insulation resistance tester, (Megger) rated 500V / 1000V / 2500V, 5000V.
ii) Earth resistance tester with all accessories
iii) Transformer oil testing set
iv) High Voltage testing set
v) Relay testing equipment
vi) Centrifugal or vacuum type oil filtering unit.
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20.0 LABOUR, SUPERVISION, COORDINATION & PROGRESS, LICENCE,
STATUTORY APPROVAL
20.1 SUPERVISORY LICENCE
The contractor shall possess a valid contractor's licence for the state in which site is
located and shall ensure its validity during the duration of the contract. The contractor
shall furnish authenticated copies of certificates to the purchaser for himself and his
workmen before commencement of work.
20.2 LABOUR
The Contractor shall employ adequate skilled and unskilled labour to complete all work
according to programme of work. Skilled workers shall possess the minimum
qualifications stipulated by statutory or competent authorities.
20.3 SUPERVISION
The Contractor shall employ adequate number of supervisors to control the labour force
and to carry out the work as per schedule. Supervisory staff shall also possess the
minimum qualifications stipulated by statutory and competent authorities.
20.4 CO-ORDINATION
The Contractor shall coordinate his work with that of other agencies, so that the work
can proceed smoothly and without hindrance to all concerned.
20.5 PROGRESS
The Contractor shall submit periodic Progress Reports to the engineer. The period of
report shall be determined by the Engineer. The Progress Report shall indicate planned
progress as per programme and physical progress. the format in which the reports are
to be submitted shall be decided by the Engineer.
20.6 STATUTORY APPROVAL
The Contractor shall be totally responsible for obtaining statutory approval from the
electrical inspector or any other statutory authority for the entire installation carried out
by him unless otherwise specified and agreed. Necessary test reports shall be
submitted by him to electrical inspector. This will be an integral part of the contract and
shall not be paid for separately.
21.0 QUALITY ASSURANCE - QUALITY CONTROL

21.1 Quality Assurance (Q.A.) shall follow the requirements of the Purchaser's Q.A.
documentation applicable to the equipment and/or systems being installed.
21.2 Q.A. involvement will commence at the instigation of the project and follow through to
final acceptance of each and every system and item of equipment, thus ensuring total
conformity to the Purchaser's requirements.
21.3 The Contractor shall provide the necessary 'Test Sheets' for recording the results of his
electrical acceptance tests.
The full set of forms shall be submitted to the Engineer for his approval prior to the
implementation of the acceptance testing programme.
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21.4 The tests which the Contractor must perform, as a minimum requirement, shall be those
described in clause 15.0 of this specification in the order indicated and shall be made in
accordance with the equipment and / or systems Standards and Regulations quoted by
the Engineer in the Contract Documents and any tests required by the particular
equipment / system manufacturer.
21.5 Test values acceptable to the Engineer shall be those laid down in the indicated
standards and specifications by the Engineer, together with any values quoted in the
Contract Documents. Any discrepancy in the acceptable test values discovered by the
Contractor shall be resolved by the Engineer, whose interpretation shall be final. No
equipment shall be set to work unless tests on its associated circuits have been found
satisfactory.
22.0 ACCEPTANCE OF INSTALLATION

On completion of the work the Engineer, together with a representative of the Purchaser
and the Contractor, will carry out an Inspection of the Installation. The Engineer will
issue a completed copy of the Purchaser's Acceptance of Electrical Installation to the
contractor as confirmation that the work has been accepted, subject to any matters
noted on the form being attended to.
23.0 ATTACHMENTS / APPENDICES:
23.1 APPENDIX I -LIST OF CODES, STANDARDS & STATUTORY
REGULATIONS
23.2 APPENDIX II
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23.1 APPENDIX I - LIST OF CODES, STANDARDS & STATUTORY

REGULATIONS (Refer Section 1.2)
IS 732 : Code of Practice for Electrical Wiring Installations.
IS 1646 : Code of Practice for Fire Safety of Buildings (General)
Electrical Installation.
IS 3043 : Code of Practice for Earthing.
IS 2309 : Code of Practice for the Protection of Buildings & Allied
Structures against Lightning.
IS 7689 : Guide for control of undesirable static electricity.
IS 10028 Part 1 to 3 : Code of Practice for Selection, Installation & Maintenance
of Transformers.
IS 900 : Code of Practice for Installation & Maintenance of
Induction Motors.
IS 1255 : Code of Practice for Installation and Maintenance of
Power cables upto and including 33 KV rating.
IS 10118 Parts 1 to 4 : Code of Practice for Selection, Installation and
Maintenance of Switch gear and Control gear.
IS 5571 : Guide for Selection of Electrical Equipment for Hazardous
Areas.
IS 5572 : Classification of Hazardous Areas(other than mines)
having flammable gases and vapours for Electrical
Installation.
IS 5216 Parts 1 & 2 : Guide for Safety Procedure & Practice in Electrical work.
IS 5479 : Solders for Jointing Aluminium and Aluminium Alloys.
IS 335 : New Insulating oils
IS 9537 Parts 1 to 4 : Conduits for electrical Installation
- Regulations for the Electrical Equipment of Buildings -
The Institution of Electrical Engineers.
- Indian Electricity Rules
- Fire Insurance Regulations
- Factory Act & Regulations
- National Building Code ( ISI Publication)
- National Electrical Code ( ISI Publication)
- Tariff Advisory Committee regulation
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23.2 APPENDIX II
1.0 TESTING AND ELECTRICAL MEASUREMENTS OF CABLE INSTALLATIONS
1.1 INSULATION RESISTANCE TEST ON NEWLY INSTALLED CABLES BEFORE
JOINTING
All new cables should be tested for insulation resistance before jointing. After satisfactory
results are obtained cable jointing and termination work should commence. It should be
noted here that insulation resistance test gives only approximate insulation resistance and
the test is meant to reveal gross insulation fault(s). A fairly low insulation resistance
reading compared to the values obtained at factory testing should not be a cause of worry
since the insulation resistance varies greatly with parameters such as length and
temperature. This is particularly more pronounced in the case of PVC cables. The voltage
rating of the insulation resistance tester for cables of different voltage grades should be
chosen from the following table:
Voltage Grade of Cable Voltage Rating of IR Tester
1.1 kV 500 V
3.3 kV 1000 V
6.6 kV 1000 V
11 kV 1000 V
22 kV 2.5 kV ( see Note)

33 kV 2.5 kV ( see Note)
NOTE - For long feeders, motorized insulation resistance tester should be used.
1.1.1 More accurate insulation resistance values can be measured only by a portable resistance
measuring bridge.
1.2 TEST RESULT OF COMPLETED CABLE INSTALLATION
The test of completed installation may be carried out and entered into record book for
comparison purposes during service life of cable installation and during fault location.
1.2.1 Insulation Resistance
Insulation resistance is measured by a suitable bridge. In non-screened cables, the
insulation resistance of each core is measured against all the other cores and armour /
metal sheath connected to earth. With screened construction the insulation of each core is
measured against all the other cores and the metal screen connected to earth.
1.2.2 Conductor Resistance (dc)
1.2.2a The resistance of conductor is measured by a suitable bridge. For this purpose conductors
at other end are looped together with connecting bond of at least same effective electrical
cross - section as conductor. The contact resistance is kept to a minimum by proper
clamped or bolted connections. With properly installed and jointed cables, values thus
measured and corrected to 20C, are in general agreement with values given in test
certificates.
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REVISION NO : 0
1.2.2b The measured loop resistance is converted to ohms per km per conductor as :
R
Rt = ------
2L
Where
R = measured loop resistance in ohms at temperature, tC;
Rt = measured resistance per conductor at tC in ohms; and
L = length of cable (not the loop) in km.
The ambient temperature at the time of measurement to be recorded and the

conductor resistance to be corrected to 20C by the following formula:
Rt
R20 = ----------------- ohm/km at 20C.
(1+a) (t-20)
Where
R20 = conductor resistance at 20C in ohm / km,
t = ambient temperature during measurement (in
C)
and
a = temperature coefficient of resistance
(3.93 x 10.3 ohms / C for aluminium).
1.2.3 Capacitance
1.2.3.1 For unscreened cables, capacitance is measured for one conductor against others and
metal sheath / armour connected to earth. In case of screened cable it is measured
between conductor and screen. Capacitance bridge is used for this purpose. The
measurement may be carried in case of cables above 11 KV; alternatively values given
in test certificate are considered sufficient.
1.2.4 High Voltage Test
1.2.4a Cables after jointing and terminating are subjected to dc high voltage test. The
recommended values of test voltages are given in Table 6. The leakage current shall
also be measured and recorded for future reference.
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TABLE 6 DC TEST VOLTAGES AFTER INSTALLATION ( BEFORE

COMMISSIONING)
RATED TEST VOLTAGE BETWEEN DURATION
VOLTAGE
OF CABLE
U./ U Any Conductor and Conductor to Conductor
Metallic Sheath / (For Unscreened
Screen / Armour Cables)
KV KV KV Minutes
(1) (2) (3) (4)
0.65/1.1 3 3 5
1.9 / 3.3 5 9 5
3.3 / 3.3 9 9 5
3.8 / 6.6 10.5 18 5
6.6 / 6.6 18 18 5
6.35 / 11 18 30 5
11/11 30 30 5
12.7 / 22 37.5 - 5
19 / 33 60 - 5
1.2.4b Generally dc test should be preferred as test equipment required is compact, easily
portable and power requirements are low.
1.2.4c The cable cores must be discharged on completion of dc high voltage test and cable
should be kept earthed until it is put into service.
1.2.4d DC test voltage for old cables is 1.5 times voltage or less depending on the age of
cables, repair work or nature of jointing work carried out, etc. In any case, the test
voltage should not be less than the rated voltage. Test voltage in these cases should be
determined by the Engineer - in - charge of the work.
1.2.4e It may be noted that frequent high voltage tests on cable installations should not be
carried out. This test should be carried only when essential. During the high voltage
test, all other electrical equipment related to the cable installation, such as switches,
instrument transformers, bus bars, etc., must be earthed and adequate clearance
should be maintained from the other equipment and framework to prevent flashovers.
1.2.4f In each test, the metallic sheath / screen / armour should be connected, to earth.
2.0 CABLE INSTALLATION PLAN
2.1 On completion of laying, terminating and jointing of the cables, a plan should be
prepared, which should contain the following details of the installation:
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a) Types of cables, cross - section area, rated voltage. Details of construction,
cable number and drum number;
b) Year and month of laying;
c) Actual length between joint - to - joint or ends;
d) Location of cables and joints in relation to certain fixed reference points, for
example, buildings, hydrant, boundary stones, etc;
e) Name of the jointer who carried the jointing work;
f) Date of making joint; and
g) Results of original electrical measurements and testing on cable installation
2.2 All subsequent changes in the cable plan should also be entered.
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Page 1 of 8
MEDIUM AND HIGH VOLTAGE HEAVY DUTY CABLES
By By By
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MEDIUM AND HIGH VOLTAGE HEAVY DUTY CABLES PAGE : 2 OF 8
REVISION NO : 0
TABLE OF CONTENTS
1.0 SCOPE
2.0 STANDARDS
4.0 GENERAL CONSTRUCTION
5.0 TYPE DESIGNATION (FOR PVC INSULATED CABLES)
6.0 GENERAL
8.0 INFORMATION AND TEST CERTIFICATES
10.0 DEVIATIONS
11.0 ATTACHMENTS / APPENDICES : NONE
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1.0 SCOPE
1.1 This specification covers design, manufacture, testing and supply of Medium Voltage PVC
Cables and High Voltage XLPE Cables.
1.2 This specification shall accompany data Sheets, technical specification which will stipulate
specific requirements of Medium and High Voltage Heavy Duty Cables. In case of any
contradiction between various referred standards/specifications/data sheets and statutory
regulations, the following order of precedence shall govern:
- Statutory regulations
- Technical Specifications
- This Specification
- Codes & Standards
2.0 STANDARDS
2.1 The cables shall conform to latest edition of the relevant Indian Standard Specifications with
amendment upto the date of issue of Enquiry, particularly the following Standards :-
IS 613 : Copper rods and bars for electrical purposes
IS 1554 : PVC insulated (heavy duty) electric cables for working voltages
(Part 1) upto and including 1100 Volts
IS 1554 : PVC insulated (heavy duty) electric cables for working voltages
(Part 2) from 3.3kV upto & including 11kV
IS 1885 : Electro Technical Vocabulary Electrical cables

(Part 32)
IS 2633 : Methods for testing uniformity of coating of zinc coated articles
IS 3961 : Recommended current ratings for cables : Part 2 PVC insulated

(Part 2) and PVC sheathed heavy duty cables
IS 3975 : Mild Steel wire, formed wires and tapes for armouring of cables
IS 5831 : Specification for PVC insulation and sheath of electric cables
IS 7098 : Cross - linked polyethylene insulated PVC sheathed cables for

(Part 1) working voltages upto and including 1100 V.
IS 7098 : Cross - linked polyethylene insulated PVC sheathed cables for

(Part 2) working voltages from 3.3 kV upto and including 33 kV
IS 7098 : Cross - linked polyethylene insulated thermoplastic sheathed

(Part 3) cables for working voltages from 66 kV upto and including 220 kV
IS 8130 : Conductors for insulated electric cables and flexible cords
IS 10418 : Drums for Electrical Cables
IS 10462 : Fictitious calculation method for determination of dimensions of

(Part 1) protective coverings of cables
IS 10810 : Methods of test for cables : Mass of zinc coating on steel armour
(Part 41)
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REVISION NO : 0
IS 10810 : Methods of test for cables : Oxygen Index test

(Part 58)
IS 10810 : Methods of test for cables : Flame Retardant test

(Part 61)
IS 10810 : Methods of test for cables : Flame Retardant test for bunched
(Part 62) cables
IEC 230 : Impulse tests on cables and their accessories
IEC 811 : Test methods for insulating and sheathing materials of electric
cables
IEC 840 : Tests for power cables with extruded insulation for rated voltages
above 30KV upto 150KV
IEC 60332 : Test on electric cables under fire conditions
IEC 60540 & : Test methods for insulation and sheaths of electric cables
IEC 60540 A
ASTM D2863 : Standard method for test for flammability of plastics using oxygen
index method
IECAS-61-402 : Thermoplastic insulated wire & cable for transmission & distribution
NEMA-WC5 of electrical energy
IECAS-66-524 : Cross linked thermosetting poly ethylene insulated wire & cable for
NEMA-WC7 transmission & distribution of electrical energy
2.2 In case of medium and high voltage heavy duty cables manufactured in accordance with
other standards, manufacturer or vendor shall state the reference number and title of the
standards adopted. Generally IEC/ BS/ VDE/ IEEE/ NEMA or equivalent standards shall be
acceptable.
2.3 In case of imported medium and high voltage heavy duty cables, standards of the country of
the origin shall be followed if these are equivalent / stringent than the applicable Indian
Standards.
2.4 Medium and high voltage medium voltage heavy duty cables details shall be as specified in
the Technical Specification enclosed with this specification. Manufacturer shall furnish all the
information asked in the enquiry along with the quotation.

Cables shall be suitable for installation as follows:
Above ground in open air locations (trays ducts) in tropical, humid and corrosive atmosphere
prevalent in refineries/petrochemical plants with severe weathering and exposure to solar
radiation.
Directly buried in underground trenches, conduits with uncontrolled back-fill and possibility of
flooding by water and chemicals.
Laid underground in RCC lined cable trenches with possibility of flooding by water.
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3.0 GENERAL CONSTRUCTION
All power and control cables for use on medium/high voltage shall be heavy duty type,
aluminium / copper conductor, PVC / XLPE insulated, inner sheathed, armoured and overall
PVC sheathed as described below.
4.1 PVC INSULATED CABLES (MEDIUM VOLTAGE)
4.1.1 Conductor
The conductor shall be made from high purity aluminium of grade H4 or shall be of annealed
high conductivity copper of sizes as indicated in the enclosed "Specific Requirements" and
conforming to IS 8130. The conductors of nominal area 10 sq.mm and less shall be circular.
Conductors above 10 sq.mm may be circular or sector shaped.
4.1.2 Insulation
The core insulation shall be of PVC and applied over conductor by extrusion. The PVC
compound shall conform to type A of IS 5831. The core identification shall be as per IS 1554
Part 1. The insulation shall have uniform thickness throughout its length. The average
thickness of insulation and tolerance on the same shall be as per IS 1554 Part 1.
4.1.3 Inner Sheath
For all cables having two or more cores, inner sheath shall be applied over laid cores either
by extrusion or by wrapping, as indicated in enclosed "Specific Requirements". The inner
sheath shall be applied as circular as possible and to fit closely on the laid up cores so that it
can be removed without damage to the insulation.
The inner sheath shall be of PVC compound and shall not be harder than PVC used for
insulation. This shall conform to requirement of type ST-I of IS 5831.
4.1.4 Armouring
Armouring shall be applied over inner sheath, where specified and shall be of galvanised
steel as per IS 3975. The armour shall be applied as closely as possible with left hand
direction of lay. For cables having diameter over the inner sheath less than 13 mm, the
armour shall be of galvanised round steel wires. Where the calculated diameter over the inner
sheath is greater than 13 mm, the armour shall consists of either galvanised round steel wires
or galvanised steel strips. The dimension and resistance of armour shall be as per IS 1554
Part 1.
4.1.5 Outer Sheath
The outer sheath of the cable shall be applied by extrusion and shall be of black colour PVC
compound conforming to requirements of type ST-1 compound of IS 5831. The thickness of
outer PVC sheath and its tolerance shall be as per IS 1554 (Part 1). To protect the cable
against rodent and termite attack, suitable chemicals shall be added into the PVC compound
of the outer sheath.
4.2 XLPE INSULATED CABLES (HIGH VOLTAGE) :
4.2.1 Conductors
Page 490 of 564

REVISION NO : 0
The conductors shall be made from H4 grade aluminium wires. These shall be stranded and
compacted circular in shape up to 35 sq.mm size cables. The conductors of three core cables
having their nominal cross section 50 sq.mm and above shall be either circular or sector
shaped. The conductor and its construction shall conform to IS 8130 and IS 7098 (Part 2).
4.2.2 Insulation
The insulation shall be chemically cross-linked polythylene conforming to the physical,

electrical and ageing properties as required by IS 7098 (Part 2). Only natural colour
compounds shall be used for insulation of cables. It shall be free from voids and shall
withstand all mechanical as well as thermal stresses under steady state and transient
operating conditions.
4.2.3 All cables rated above 4.3/4.3 KV shall be provided with screening. This shall consist of
conductor screening as well as insulation screening.
1 Conductor Screening
Conductor screening shall be non-metallic and shall consist of either semi-conducting
tape or extruded semi-conducting compound.
2 Insulating screening shall be in two parts, first non-metallic semi-conducting part and
second metallic part. Non-metallic part shall be applied directly over insulation of
each core and shall consist of tapped or extruded semi-conducting compound. On
top of this, metallic screening of non-magnetic tap or braid or concentric serving of
wire shall be applied.
4.2.4 Inner Sheath
In cables having three cores, the individual core shall be laid up with suitable non-
hygroscopic fillers and then applied with common covering of PVC or thermoplastic material
by extrusion or tapping such that circulating of cable is maintained. The sheath shall conform
to requirements of type ST-2 compound of IS 5831. The thickness of sheath shall be as per
IS 7098 (Part 21).
4.2.5 Armouring and Outer Sheath
The Armouring and outer sheath of XLPE cables shall be generally in line with Clause 4.1.4
and 4.1.5 , respectively, as described above. However, size and tolerance for XLPE cable
shall be as per IS 7098 (Part 21), except for outer sheath to be of type ST-2 as per IS 5831.
5.0 TYPE DESIGNATION (For PVC insulated cables)
1 AYWY : Aluminium conductor, PVC insulated, PVC sheathed round steel

wire armoured with overall PVC sheathed.
2 AYFY : Same as in '1' above, except that flat steel strip armoured in place of
round steel wire
3 YWY : Same as in '1' above, except that copper conductor in place of

aluminium conductor
4 YFY : Same as in '2' above, except that copper conductor in place of

aluminium conductor
5 AYY : Same as in '1' above but without armour
Page 491 of 564

REVISION NO : 0
6 YY : Same as in '3' above but without armour
6.0 GENERAL
6.1 Cables shall be supplied in accordance with the enclosed "Specific Requirements". Cable
lengths indicated therein are tentative and actual requirements will be indicated to the
Supplier at the time of order placement. Quoted unit rate shall be applied for actual length
required without any price variation for change in length.
6.2 Cables less than standard drum length shall be supplied in one length.
6.3 Each type and size of cables ordered shall be supplied in separate non-returnable wooden
drum of robust construction covered with wooden planks all round as per IS 10418. Each
cable drum shall be clearly marked with cable size, type, length of cable, total weight,
direction of drum rotation etc. as per IS 1554.
6.4 Both ends of every cable piece shall be adequately sealed and protected against damage
and ingress of moisture.
6.5 A tolerance of plus or minus 5% maximum shall be permissible for each drum unless
specifically agreed. Short/non-standard length of cable shall not be accepted.
6.6 Following information shall be embossed at every one (1) meter for full length of cable.
- Manufacturer's identification mark
- Standard mark of Bureau of Indian Standard with applicable specification
number
- Sequential marking of cable length in meter
- Cable size
7.1 After completion of manufacturing of cables and prior to despatch, cable shall be subjected to
routine tests, acceptance test and type test (if indicated in "Specific Requirements") in
accordance with latest edition of relevant Indian Standard Specification at manufacturer's
works.
7.2 Purchaser/Consultants reserve the right to inspect cables during process of manufacture in
all its stages as well as after manufacture to witness tests. Final acceptance of materials shall
be subject to satisfactory inspection and testing at manufacturer's works.
8.0 INFORMATION AND TEST CERTIFICATES
Information and test certificates shall be furnished by the Vendor as per the Vendor
Document Requirement enclosed and given below.
8.1 Copy of certification mark license obtained from Bureau of Indian Standards.
8.2 Full constructional data giving details of conductor, insulation, sheath, armour etc.
8.3 Current ratings in air as well as ground under normal condition of installation at an ambient
temperature of 40C. (Also indicate - (a) Normal conditions, (b) Maximum conductor
temperature when it is carrying its rated current, and (c) Maximum conductor temperature
during short circuit );
Page 492 of 564

REVISION NO : 0
8.4 Rating factors for different methods of installation with reference to ambient/ground
temperature, grouping, variation in depth of laying in ground, thermal resistivity of soil etc.;
8.5 Colour scheme for core identification;
8.6 Insulation resistance at 20C per K.M.;
8.7 Conductor resistance at 20C;
8.8 Values of inductance and capacitance per km.;
8.9 Overload capacity giving values of current and duration;
8.9 Short circuit capacity giving values of current and duration;
8.10 Weight in kg. per km.;
8.11 Standard drum lengths for each size of cable;
8.1 Quality Assurance shall follow the requirements of Jacobs. Q.A. Documents, as applicable.
8.2 Q.A. involvement will commence at Enquiry and follow through to completion and accep-
tance, thus ensuring total conformity to Purchaser's requirements.
10.0 DEVIATIONS
9.1 Deviation from Specifications must be stated in writing at the quotation stage. In the absence
of such a statement, it will be assumed that the requirements of the Specifications are met
without exception.
Page 493 of 564

TYP. INSTALLATION DETAILS STANDARD No.
OIRtaei ENGINEERS
Iguria154eg
,
I eirelArA0512,151.3 AISAA (A
INDIA LIMITED
Govt. of 2nclto Undertok,ng)
OF ELECTRICAL PANELS 7-51-0335 Rev. 2
ON FALSE FLOORING Page 1 of 1
DEPTH
(SEE NOTE-1)
INTEGRAL BASE FRAME/

KICK PLATE
PANEL FRONT
ELECTRICAL PANEL TOP OF FALSE FLOORING
MC-100 (SEE NOTE-3)
BASE FRAME
MC-100 0
o
(TYP.)
RCC FLOOR
200x200x10 MM THICK M.S. I

BASE PLATE FIXED TO FLOOR
WITH 4 NOS. 1/2" DIA. ANCHOR
FASTENERS (TYP.)
ELEVATION
(VIEW-A)
MalaMabOulaliVaul.M.M.M.S.OulSflE
Ea MI II
MC-100 BOX (TYP.)
,Th
MC-100 BASE FRAME
T
w
1 1
EACH PANEL JOINT
(TYPICAL)
Ls,
a
z
0
Ls,
cn
A
112 An12 02
SISIPPralrtIlISISIMINIMMNRIMIMIME
MC-100 BASE FRAME

(TYPICAL)
PLAN
NOTES:
FOR PANELS DEPTH UPTO 800 MM SUPPORTING ARRANGEMENT AS SHOWN SHALL BE FOLLWED.
FOR PANELS DEPTH MORE THAN 800 MM ADDITIONAL SUPPORTS AS PER VENDOR'S FDN. PLAN
SHALL BE PROVIDED.
ALL PANELS SHALL BE TACK WELDED WITH BASE FRAME OF SWITCHBOARD.
3. SUPPORTING ARRANGEMENT FOR FALSE FLOORING SHALL BE AS PER ARCHITECTURAL DRAWINGS.
.-1/
2 02.03.12 REAFFIRMED & ISSUED S SC
`4144 UAP/JMS DM
1 26.09.06 REVISED AND REISSUED BP RKS/UAP JMS VC
Rev Prepared Checked Stds. Committee Stds. Bureau
No. by by
Page 494 of 564
Approved by
Formal No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved
Page 1 of 2
CHENNAI PETROLEUM CORPORATION LIMITED

(A group company of Indian Oil)

AT
MANALI REFINERY
VENDORS LIST
$9/
DOCUMENT NO : 44NC-4600:00:R:01:0005:A4
Prepared and Issued by:
Jacobs Engineering India Private Ltd.

Navi Mumbai
Rev. Issue Date Pages Rev. Description Prepared Checked Approved
No. By By By
0 16.06.2010 Issued for Clients review / comments NRK AMN SBN
1 20.07.2010 Revised as per client comments NRK AMN SBN
2 23.08.2010 Revised as per client comments NRK AMN SBN
3 14.09.2010 Revision as per client comments NRK AMN SBN

(only for Instrumentation)
4 22.09.10 Revision as per client comments NRK AMN SBN

(only for Electrical)
Page 495 of 564

44NC-4600 VENDOR LIST CPCL. Manali Refinery
Resid Upgradation Project
Revision : 4 Doc. No. A133-000-16-50-VL-1500 5HY$ Page 2 of 2
INDEX
No. of
Sheets
NOTES ON VENDOR LIST 2
i. STATIC EQUIPMENT (Fabrication Equipment) 14
ii. HEAT TRANSFER EQUIPMENT 12
iii. MECHANICAL EQUIPMENT 13
iv. ROTARY EQUIPMENT 14
v. PIPING 29
vi. ELECTRICAL 22 4
vii. INSTRUMENTATION 26
viii. ARCHITECTURAL ITEMS 9
ix. MISCELLANEOUS 4
x. REFRACTORIES AND INSULATING FIBER BLANKET 2
Page 496 of 564

44NC-4600:CPCL
NOTES ON VENDORS LIST
A) Part of the unit / plant from OWNER / CONSULTANT approved vendors only. This shall
include sub-ordered items / components also. The Approved Vendors shall be items
specific.
B) OWNER / CONSULTANT approved vendors list for the following items is enclosed in this
section.
i. Pressure Vessels (Fabrication equipment)

ii. Rotating Equipment.
iii. Piping
iv. Electrical
v. Instrumentation
vi. Mechanical Equipment
vii. Heat & Mass Transfer Equipment
viii. Architectural Items
ix. Miscellaneous
C) CONTRACTOR may procure material from any of OWNER / CONSULTANT approved

vendors. However, workload, stability and solvency need to be verified by the
CONTRACTOR before placement of order. In case where such vendors are not
available prior approval to be taken from OWNER / CONSULTANT before issue of
enquiry.
Vendors on OWNER / CONSULTANT holiday list shall not be considered for ordering.
Names of such vendors who are put on OWNER / CONSULTANTHoliday List
subsequent to vendor approval at bidding stage shall be informed to the CONTRACTOR
at any stage of the Project. CONTRACTOR shall comply with this requirement without
any time or cost implication to the OWNER.
D) Compliance to procurement of material from approved vendors is mandatory and shall be

fully complied with. No deviation to approved vendor list shall generally be acceptable.
E) For items not covered in the above list, the vendors list shall be approved by OWNER /
CONSULTANT prior to placement of order by CONTRACTOR. CONTRACTOR shall list
down the proposed suppliers / vendors for such items and submit the same for OWNER /
CONSULTANTs review / approval along with necessary documents / credentials. Non-
acceptance of a particular proposed vendor due to any reasons whatsoever shall not be
a cause of schedule and cost implication.
F) CONTRACTOR shall make an independent assessment of capability of all the vendors

for timely deliveries of material / equipment. Any delays in deliveries by vendor(s) shall
not be a cause of schedule and cost implication.
G) For vendors included in each category, it will be Contractors responsibility to ensure that
item being ordered on approved vendor has been manufactured and supplied by them
(range, thickness, size, capacity, MOC etc.) on past projects of CPCL / CONSULTANT or
any reputed Refinery / Hydrocarbon Sector under TPI.
Doc. No. 44NC-4600:00:R:01:0005:A4 Page 1 of 2
Page 497 of 564

44NC-4600:CPCL
NOTES ON VENDORS LIST
H) At any stage of the project, if it comes to the notice of OWNER / CONSULTANT that
CONTRACTOR have procured material / equipment, intentionally or unintentionally
whatsoever, from an unapproved vendor and/or items not falling in approved range of
vendor(s), the same shall be rejected forthwith and CONTRACTOR shall be liable to
replace such material / plant / machinery without any schedule and cost implication to the
OWNER.
I) List of vendors appearing anywhere else in the contract document, except for the
vendors list provided by PROCESS LICENSOR, shall not be considered by
CONTRACTOR and shall be superseded by the vendor list enclosed herewith.
Wherever, vendors list is given by Process Licensor, for specific items, it shall be
mandatory. If contractor intends to procure from any other vendors, clearance has to be
obtained from Licensor. Also other aspects like capability, timely delivery, solvency etc.
has to be ascertained by Contractor before placement of Orders.
J) It is understood that, should the name of vendors be changed due to change in their
Company or Corporate share holding, OWNER will accept such Vendors under its new
name with prior approval.
Any such approval shall, however, not release the CONTRACTOR from any of his
obligations under the contract; neither shall any such approval signify nominations or
instruction to use such a vendor. All approved vendors are deemed to have been freely
chosen by the CONTRACTOR at his own risk.
K) The approved vendors list for fabricated equipment (Vessels, Columns, Heat
Exchangers, Ejectors etc.) is for fabrication alone. Where mechanical design of the
equipment is included in CONTRACTORs scope, CONTRACTOR shall either himself or
through his Detailed Engineering sub-contractor be responsible for designing and
obtaining approval / review of Mechanical design calculations as per codes /
specifications specified elsewhere in the Bid / Contract document, from OWNER /
CONSULTANT.
Doc. No. 44NC-4600:00:R:01:0005:A4 Page 2 of 2
Page 498 of 564

(vi)
ELECTRICAL
C:\Documents and Settings\Mfernandes\Desktop\Vendor List for Tender Rev 4_23.09.10\08_Electrical Vendor list.doc
Page 499 of 564

Revision : 4 ELECTRICAL Page 3 of 22
VENDOR NAME COUNTRY
6. DRY TYPE TRANSFORMERS (LIGHTING) UPTO 1000 KVA

1 Crompton Greaves Ltd India
2 Kirloskar Electric Co. india
3 Vijay Electricals India - Hyderabad
4 Voltamp Transformers Pvt. Ltd. India
7. INSTRUMENT TRANSFORMERS CT & PT (HV)

1 ABB Ltd India Vadodara
2 Areva T&D Ltd. India
3 Electrical Controls & Systems India
4 Jyoti India
5 Kalpa Electricals India
6 Kappa Electricals India
7 Pragati Electricals Pvt. Ltd. India
8. INSTRUMENT TRANSFORMERS CT & PT (MV)

1. AE
2. Gilbert & Maxwell Electricals Pvt. Ltd India
3. Jyoti India
4. Kalpa Electricals India
5. Kappa Electricals India
6. Narayan Powertech Pvt. Ltd India
7. Pragati Electricals Pvt. Ltd. India
8. Precise Electricals India
9. Silkaans Electricals Pvt. Ltd. India
9. CABLES COMMUNICATION (JELLY FILLED)

1 CMI Ltd.
2 Cord Cable
3 Delton Cables Ltd India
4 Elkay
5 Finolex Cables Ltd India
6 KEI
7 Reliance
8 Rpg Cables Ltd India
9 Usha Beltron Ltd India
10 Vindhya Telelinks Ltd India
10. HIGH VOLTAGE XLPE CABLES

1 Cable Corporation Of India India
2 Industrial Cable
3 KEI Industries Ltd India
4 Nicco Corporation Ltd India
5 Polycab Wires Pvt. Ltd India
Page 500 of 564

VENDOR NAME COUNTRY
6 RPG Cables Ltd India

7 Torrent Cable Ltd Upto 33kv India
8 Uniflex Cables Ltd India
9 Universal Cables Ltd India
11. MEDIUM VOLTAGE POWER CABLES XLPE & PVC

1 Associate India
2 Cable Corporation of India India
4 Gemscab Industries Ltd
5 Havells
6 Industrial Cable India
9 Polycab Wires Pvt Ltd India
11 Ravin Cables Pvt. Ltd India
12 RPG
13 Torrent Cables Ltd India
12. CABLES CONTROL

1 Associated Cable Pvt Ltd India
2 Associated Flexibles and Wires (P) Ltd. India
3 Brooks Cables Pvt. Ltd. India Mumbai
4 CMI Limited India
5 Cords Cable Ind Ltd India
7 Ecko Cables INDIA
8 Elkay Telelinks (P) Ltd India
9 Evershine Electricals India
11 Gemscab Industries Ltd India
12 Goyolene Fibres (I) Pvt. Ltd. India
13 Havells India Pvt. Ltd. India
14 Hindustan Vidyut Product India
15 Industrial cables (I) Ltd. India
18 North Eastern cables Pvt. Ltd. India
19 Paramount Communications Ltd. India
(Manufacturing Unit Paramount Cable Corporation)
20 Polycab Wires (P) Ltd India
22 Ravin Cables Pvt. Ltd. India
Page 501 of 564

VENDOR NAME COUNTRY
23 Reliance Engineers Ltd India

24 RPG Cables India
25 Suyog Electricals India
26 Thermocables Ltd. India
27 Torrent Cables Ltd India
13. CABLES FIRE ALARM & COMMUNICATION

1 CMI Ltd India
2 Cords Cable Industries Ltd India
4 Elkay Telelinks Ltd India
6 Reliance Engineers Ltd India
14. NEUTRAL GROUNDING RESISTORS - HV

1 AMP Control Equipment Pvt. Ltd. India Pune
2 RSI Switchgear Pvt. Ltd India Haryana
3 S R Narkhede Engineering Pvt. Ltd India
15. CAPACITOR HIGH VOLTAGE

1 ABB Ltd India Bangalore
2 BHEL India Bhopal
3 CG Power Systems India
16. PLANT COMMUNICATION SYSTEM

1 Industrionic GmbH & Co KG GERMANY
2 Neuman Elektronik GmbH &Co GERMANY
3 Siemens Enterprise Communications INDIA
17. MOTOR INDUCTION HV (INDL. TYPE SAFE AREA)

1 ABB LTD India - Faridabad
2 Alstom Moteurs SA (C/o Alstom Limited) India / France
3 Bharat Bijlee Limited India
5 Jyoti India
6 Kirloskar Electric Co Ltd India
7 Laxmi Hydrolics India
8 Siemens Limited India
9 BHEL (Bhopal) India
Page 502 of 564

VENDOR NAME COUNTRY
22. ACTUATORS - MOV

1 Auma India Ltd India
2 Limitorque Ind Ltd India
3 Rotork Controls Ind Ltd India
4 Marsh Engineers ( only for Safe Area) India
23. BATTERY CHARGERS

1 Amara Raja Power System Ltd India
2 Caldyne Automatic (P) Ltd India
3 Chhabi Electricals (P) Ltd India
4 Dubas Engineering Pvt. Ltd. India
5 HBL Power Systems Ltd India
6 Kerala State Elect Dev Corp Ltd. India
7 Mass Tech Control Pvt. Ltd. India
8 Universal Ind. Products India
9 Universal Instrument Mfg Co (P) Ltd India
24. UPS SYSTEM

UPS SYSTEM INDIGENOUS
1 DB Power Electronics Pvt Ltd India
2 Emerson Network Power Pvt Ltd India
3 Hi-Rel Electronics India
4 Kerala State ELECT Dev Corp Ltd India KRKULM
UPS SYSTEM FOREIGN

1 Chloride Industrial Systems UK
2 Fuji Electric Co Ltd Japan
3 Gutor Electronics Ltd Switzerland
4 MGE Asia Pte Ltd Singapore
Saftnife AB
5 Toshiba Corporation Sweden
6 India/Japan
25. FIRE ALARM SYSTEM

1 Honeywell Inc India
2 Kidde India Ltd. India
3 Mather & Platt India Ltd India
4 New Fire Engineers (P) Ltd India
26. RELAY & CONTROL PANEL

1 ABB Ltd. India Mumbai
2 Areva T&D Ltd India Chennai
3 Bharat Heavy Electricals India
4 Controls & Switchgear India
Page 503 of 564

VENDOR NAME COUNTRY
30. CONTROL STATIONS (FLAME PROOF)

1 Baliga Lighting Eqpts Ltd India
2 FCG Flameproof Control Gear Pvt. Ltd India
3 FCG Power Industries Pvt. Ltd. India
4 Flame Proof Eqpts Pvt Ltd India
5 Flexpro Electricals Pvt Ltd India
6 Govan Industries (India) Pvt Ltd. India
7 Prompt Engineering Works India
8 Sudhir Switch Gears Pvt Ltd India
31. LIGHTNING ARRESTORS

1 Areva
3 Elpro International Ltd India
4 Oblum Electrical Ind Pvt Ltd India
5 W. Insulation Of India India
32. BATTERIES LEAD ACID (VRLA)

1 Exide Ind Ltd India
2 Amara Raja Batteries Ltd India
3 HBL Power System Ltd India
33. BATTERY (NI-CAD)

1 Amaraja
2 Amco Saft
3 HBL Nife
34. AIR CIRCUIT BREAKER

1 Controls & Switchgear Co Ltd India
2 GE Power Control Ind Ltd India
3 Larsen & Toubro Ltd. (Mumbai) India
4 Schneider Electric India Pvt Ltd India
5 Siemens Ltd India
35. BUS DUCT (HV)

1 Controls & Switchgears Co Ltd India
2 Enpro Engg. India
3 Powergear India
4 Reep Industries India
5 Stardrive Busducts Pvt Ltd India
Page 504 of 564

VENDOR NAME COUNTRY
75. EARTH LEAKAGE CIRCUIT BREAKER

1 Datar Switchgear Pvt. Limited India
2 Havells India
3 Indo Asian Fusegear Limited India
4 Legrand (India) Pvt. Limited India
5 Schneider Electric India (P) Limited India
76. FUSES
1 Cooper Bussman India
2 GE India (P) Limited India
4 Larsen & Toubro Limited India
77. FUSE SWITCH COMBINATION

1 ABB Limited (Bangalore) India
2 Controls & Switchgears Co. Limited India
3 GE India India
4 Havells India Pvt. Limited India
9 Standard Electricals Limited India
78. MCCB
1 AEG India
2 GE India (P) Limited India
5 Siemens India
79. HEAVY DUTY SWITCHES (POWER SWITCHES)

1 ABB India
3 EE India
Page 505 of 564

VENDOR NAME COUNTRY
80. MCB
1 Datar Switchgear Pvt. Limited India
2 Havells India Pvt. Limited India
3 Indiana Current Control Limited India
5 Legrand (India) Pvt. Limited (Mds) India
7 Siemens India
8 Standard Electricals Limited India
81. METERS
1 Areva T&D India
2 Automatic Electric Limited India
3 Imp India
4 Meco Instruments Pvt. Limited India
5 Nippen Electrical Instruments
6 Rishabh Instruments Pvt. Limited India
82. TIMERS
1 ABB India
2 Bhartia Industries Limited India
3 Electronic Autiomation Pvt. Limited India
4 GEC India
5 Larsen & Toubro Limited
6 Schneider India
7 Siemens Limited
83. PUSH BUTTON AND INDICATING LAMPS

1 Bhartia Industries Limited India
2 Cands
4 Essen Deinki
5 Hotline Switchgear & Controls
6 Larsen & Toubro Limited
7 Precifine Products Pvt. Limited (Led Type Indicating Lamps Only) India
8 Schneider Electric India (P) Limited
9 Shri Tulsi Switchgears Limited India
11 Technic
12 Teknic Controls
Page 506 of 564

VENDOR NAME COUNTRY
84. INSTRUMENT TRANSFORMERS (CT/PT)-LV

1 AE
2 Gilbert & Maxwell Elect. Pvt. Limited India
3 Jyoti India
4 Kalpa Electricals
5 Kappa
6 Narayan Powertech Pvt. Limited India
7 Pragati Electricals Pvt. Limited India
8 Precise Electricals India
9 Silkaans Electrical Mfg. Co. Limited
85. VACUUM BOTTLES

1 Areva T&D India
2 Crompton Greaves India
86. CABLE GLANDS FOR HAZARDOUS AREA

1 Baliga India
2 Comet Brass Products India
3 Comet Industries India
4 FCG Flameproof Control Gears India
5 FCG Power Industries India
6 Flameproof Equipment Pvt. Limited India
7 Flexpro India
8 Prompt Engineers India
9 Standard Metal India
10 Sudhir Switchgear India
87. LT ISOLATOR
1 GE Power India
2 L&T India
3 Siemens India
88. TRANSDUCER
1 ABB India
2 ELSTER India
3 MECO India
4 Pyrotech Electronics India
5 Vitronics India India
Page 507 of 564

Document No.
VENDOR DATA REQUIREMENTS A133-000-16-50-VDR-1500
FOR Rev. A
AC UPS FOR DCS PACKAGE Page 1 of 3
VENDOR DATA REQUIREMENTS

FOR
AC UPS FOR DCS PACKAGE
A 21-JAN-2014 ISSUED FOR BIDS VB ANPS SA

Rev. Date Purpose Prepared by Checked by Approved by
No.
Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved
Page 508 of 564

Document No.
FOR Rev. A
VENDOR DATA REQUIREMENTS
The following drawings/documents marked " " shall be furnished by the bidder.
UPS SYSTEM
POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
1. Schedule of Vendor Documents
2. Confirmation of Technical Compliance
3. Data Sheets (Duly filled-in)
4. Dimensional/Assembly Drawings : GA
Drawings UPS Panels ,Cell booster and Aux.
Board
5. Dimensional/Assembly Drawings : Installation
Plan/ Mounting Details/ Cable Cutout Details
6. Dimensional/Assembly Drawings : Sectional
View Drawing
7. Dimensional/Assembly Drawings : Cubical
Arrangement Drawing
8. Dimensional/Assembly Drawings : Battery Rack
Arrangement Drawing
9. Dimensional/Assembly Drawings : Bill of
Material
10. Electrical Wiring Drawings : Single Line
Diagram
11. Electrical Wiring Drawings : Block and Logic
Diagrams
12. Electrical Wiring Drawings : Control Schematics
13. Electrical Wiring Drawings : Wiring Diagram
and Terminal Details
14. Electrical Wiring Drawings : Interconnection
Diagrams
15. Performance Curves of battery
16. Inspection & Test Plan (ITP) -For review by
Inspection Dept.
17. Test Records
18. Calculations for : Battery Sizing
19. Calculations for : Charger Sizing
20. Calculations for : Component Sizing(power
&electronic devices)
21. Calculations for : System Cables
22. Type Test Certificates for similar equipment
23. List of Mandatory Spares
24. List of Commissioning Spares
Page 509 of 564

Document No.
FOR Rev. A
POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
25. List of Maintenance Spares
26. List of Special Tools & Tackles
27. Sizing calculation for UPS system(when
supplied with DCS package)
28. Data Books/ Manuals : Installation Manual
29. Data Books/ Manuals : Operating/ Maintenance
Manual
30. Data Books/ Manuals : Catalogues/ Brochures
31. Heat loss calculation
32. Layout for UPS Room and Battery Room
Notes :
1. "TICK" denotes applicability.
2. Post order, drawing / document review shall commence only after approval of Document Control Index (DCI).
3. All post order documents shall be submitted / approved through EIL eDMS portal.
4. Final documentation shall be submitted in hard copy (Six prints) and soft ( two CDs/DVDs ) in addition to
submission through EIL eDMS.
5. Refer - 6-78-0001: Specification for quality management system from Bidders.
6. Refer - 6-78-0003: Specification for documentation requirement from Suppliers.
7. All drawings & documents shall be submitted in A4 or A3 paper sizes. Documents in higher paper size shall
be submitted in exceptional circumstances or as indicated in the MR/Tender.
8. Post order- The schedule of drawing / data submission shall be mutually agreed between EIL & the bidder /
contractor / supplier during finalization of Document Control Index (DCI).
9. "@" indicates submission of documents to Inspection Agency.
10. Bill of Material shall form part of the respective drawing.
11. Also refer other department's VDR :-
12. Instrumentation
13. UPS and battery room layouts shall indicate battery isolator switches, battery management equipments, etc.
14. All technical details, documents and drawings furnished with bids shall be treated as data for engineering.
These shall, however, be subject to Purchaser's review after order placement and bidder shall comply with MR
requirements without any time and cost implication to the Purchaser.
Page 510 of 564

Page 511 of 564
APPENDIX - A
INDICATIVE INSPECTION & TEST PLAN**

PROJECT : 44NC-4600 : CPCL MANALI REFINERY, CHENNAI : RESID UPGRADATION SHEET 1 OF 2
PROJECT
EQUIPMENT / ITEM DESCRIPTION : UPS SYSTEM VENDOR :
P.O. NO. :
EQUIPMENT / ITEM TAG NO. :
TEST & INSPECTION AS PER : PR/PS NO.
(CODES & SPECIFICATIONS) : DRG. NO.
EQUIPMENT INSPECTION CODE : A
A 1 WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY OWNER / PMC
C
T 2 WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY THIRD PARTY
I INSPECTION AGENCY (TPIA) / STATUTORY AUTHORITY
V 3 WITNESS INSPECTION BY SUB VENDOR,VENDOR & LSTK CONTRACTOR
I
T 4 CERTIFICATES / DATA TO BE SUBMITTED BY LSTK CONTRACTOR /
Y VENDOR FOR APPROVAL / REVIEW BY TPI A / OWNER / PMC
1 H H X PRE-INSPECTION MEETING TO BE CONDUCTED AFTER ISSUE OF

PO/PR/PS. AGENDA TO BE PREPARED BY LSTK CONTRACTOR.
2 A A R X DETAILED INSPECTION & TEST PLAN AFTER ISSUE OF PO/PR/PS
3 A R X INSPECTION & TEST PROCEDURES
4 R R X SUMMARY OF ALL SUPPLIMENTARY REQUIREMENTS AS SPECIFIED

IN THE ORDER /PS/PR
5 A X PACKING PROCEDURE / SHIPPING DRAWING OF COMPLETED
EQUIPMENT
6 H H W X ROUTINE TEST CONSISTING OF:
VISUAL CHECK FOR BUS BAR, CREEPAGE, PAINT SHADE ETC.
BILL OF MATERIALS INCLUDING BATTERIES.
NAME PLATE CHECK FOR EACH INSTRUMENT/ITEM.
LAYOUT CHECK
DIMENSIONAL CHECK
TERMINAL BLOCK WIRING, TERMINATION FACILITY
7 R R X REVIEW OF DOCUMENTS AS BELOW:
INTERNAL QA TEST REPORTS.
TEST CERTIFICATES FOR ALL COMPONENTS.
TEST CERTIFICATES FOR BATTERY
DESIGN CALCULATION
8 H W X PERFORMANCE AND ACCEPTANCE TEST CONSISTING OF:
OPERATION OF SWITCHES, ANNUCIATION & DIAGNOSTICS,

START UP, AUTO/MANUAL OPERATION ON CHARGER &
INVERTOR, RIPPLE ON CHARGER & BOOST CHARGING.
EFFECT OF INPUT VOLTAGE / FREQUENCY VARIATION ON
CHARGER & INVERTOR.
LOAD REGULATION & EFFICIENCY OF SYSTEM (UP TO 100% IN
STEPS OF 25%)AT +OR- 10% OF SUPPLY VOLTAGE
INVERTOR OUTPUT & HARMONICS UNDER VARIOUS LOAD &
VOLTAGE CONDITIONS.
CHECKING OF CURRENT LIMITING FEATURE OF THE INVERTER
BY APPLYING SHORT CIRCUIT, ON INVERTER O/P.
Page 512 of 564

APPENDIX - A
INDICATIVE INSPECTION & TEST PLAN**

PROJECT : 44NC-4600 : CPCL MANALI REFINERY, CHENNAI : RESID UPGRADATION SHEET 2 OF 2
PROJECT
EQUIPMENT / ITEM DESCRIPTION : UPS SYSTEM VENDOR :
P.O. NO. :
EQUIPMENT / ITEM TAG NO. :
TEST & INSPECTION AS PER : PR/PS NO.
(CODES & SPECIFICATIONS) : DRG. NO.
EQUIPMENT INSPECTION CODE : A
A 1 WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY OWNER / PMC
C
T 2 WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY THIRD PARTY
I INSPECTION AGENCY (TPIA) / STATUTORY AUTHORITY
V 3 WITNESS INSPECTION BY SUB VENDOR,VENDOR & LSTK CONTRACTOR
I
T 4 CERTIFICATES / DATA TO BE SUBMITTED BY LSTK CONTRACTOR /
Y VENDOR FOR APPROVAL / REVIEW BY TPI A / OWNER / PMC
9 H H W X OVERLOAD CAPACITY TEST.

DYNAMIC RESPONSE (UPTO 100% FOR BOTH LOAD THROW-IN
AND THROW OUT).
TRANSFER TIME & EFFECTS OF OUTPUT VOLTAGE FOR
TRANSFER BETWEEN INVERTORS, INVERTER TO BY-PASS ETC.
UPS SHORT CIRCUIT TEST
NOISE LEVEL TEST.
EFFECT OF INPUT VOLTAGE UNBALANCE.
HARMONICS UNDER FULL LOAD
E/F RELAY OPERATION
HEAT RUN TEST (16 HOURS FOR)
HV TEST
IR TEST, BEFORE AND AFTER HV TEST.
VERIFICATION OF HEAT LOSS, VALUES AT 50%, 75% & 100%
RATED O/P AT 0.8 LAG PF.
10 H W X CAPACITY TEST FOR BATTERY ON SAMPLE
11 H W X EFFECT OF OUTPUT LOAD UNBALANCE

12 H X SPARES & PACKING LIST CHECK. PACKING & LOADING OF
EQUIPMENT AS PER SHIPPING DRAWING
13 H H INSPECTION RELEASE CERTIFICATE
LEGENDS : H - HOLD, W - WITNESS, R - REVIEW, A APPROVAL, I - INFORMATION, X SUBMIT

PO PURCHASE ORDER, PR PURCHASE REQUISITION, PS PURCHASE SPECIFICATION
** NOTE : THIS IS AN INDICATIVE INSPECTION AND TEST PLAN IDENTIFYING SCOPE OF INSPECTION
/REVIEW OF DOCUMENTS AS A MINIMUM REQUIREMENT, DETAILED INSPECTION AND TEST PLAN
INDICATING ALL SPECIFIED REQUIREMENTS AFTER ISSUE OF PO / PR TO BE GENERATED BY
VENDOR AND SAME DULY APPROVED BY TPI A TO BE SUBMITTED TO OWNERPPMC FOR APPROVAL.
* TPI A TO CARRY OUT INSPECTION AT SUB-VENDORS WORKS.
OWNER/PMC RESERVES RIGHT TO WITNESS INSPECTION OF ANY ITEM AT ANY STAGE WHICH SHALL BE INDICATED ON QAP /
INSPECTION & TEST PLAN AT THE TIME OF APPROVAL AND SAME TO BE COVERED AS PART OF PURCHASE ORDER
CONDITION ISSUED BY CONTRACTOR.
Page 513 of 564

CCTV SYSTEM Part C
RESID UPGRADATION PROJECT A133-000-16-51-SOW-1501 Rev. B
SCOPE OF WORK
CCTV SYSTEM
B 11-03-2014 ISSUED with MR SP NZ AR
A 17-01-2014 ISSUED with MR SP NZ AR

No by by

Page 514 of 564
CCTV SYSTEM Part C
1.0 SCOPE OF WORK
1.1 The scope of work for CCTV shall comprise of the following:
SR. NO DESCRIPTION VENDOR PURCHASER
Design, Engineering, procurement of bought out items,
manufacture, integration, inspection, factory testing and
1 supply of complete CCTV System for the entire plant as
per MR consisting of following including necessary

hardware, software and accessories as applicable:
CCD day and night coloured cameras suitable for

mounting in field and remote operation with all necessary
accessories and installation hardware consisting of but not
limited to the following:
1.1 -
-
High speed zoom lens
Automatic Iris

- Pan and tilt unit
- wiper and washer unit
- Receiver unit
- Flameproof junction box
- Flameproof housing for camera unit
System cabinet consisting of:
- Central Control Unit with all control functions like pan,

1.2
-
tilt, focus and switching unit
DVR to record video images

- Network switches
- Interface to Giant Screen and DCS
3 Nos. 32, LCD Screen (free hanging from ceiling) Video

Monitor including mounting accessories for all monitors
1.3
1 No. 32 LCD screen with key board & furniture located in

shift in-charge room
Programming PC consisting of LCD monitor, key board

independent of monitoring unit with all required hard ware
1.4 and software and license including any interface
software/licence required for its interface with Giant Screen

and DCS.
1.5
All furniture required in the DCU MCR to mount the CCTV
equipment like PC, keyboards, etc.
1.6
Supply of complete installation material for CCTV System
including:
All types cables consists of single and multi pair ( video,
control/data, fiber optic cables with HDPE conduits, TCP/
1.8.1
IP (Ethernet), Power Supply etc.), cable glands, plugs,
connectors and accessories for interconnection of various
Equipment supplied by vendor including interface cables
for interfacing with Giant Screen.

Page 515 of 564
CCTV SYSTEM Part C
1.8.2
Junction boxes, Power distribution boxes, repeaters, cable
glands etc. as necessary.
Structural mounting poles of 10 meter long ( designed for
1.8.3 maximum wind velocity (185 km/Hr) for mounting the
cameras along with climbing ladder.

1/2" SS pipe with necessary pipe fittings along with SOV
1.8.4 for water connection to washer and wiper system for each
camera in field.

Provision of permanent service water head connection with
1.8.5 isolation valve and suitable pressure reduction device for
each camera in field.

HDPE pipe with required pipe fittings for laying optical fibre
1.8.6 cables wherever required between CCTV cameras and
DCU Main Control Rooms.

1.8.7
Cable trays with required accessories for laying CCTV
cables within DCU Control Rooms.
1.8.8
All necessary supports for installation of all items supplied
by vendor.
1.8.9
All mounting accessories required to mount various items
supplied by vendor.
1.8.10
Earthing material required for earthing of CCTV equipment
installed by Vendor.
1.8.11
Necessary channel base frames for mounting CCTV
cabinets in DCU Main Control Room.
1.8.12
Any other item necessary but not specifically listed for
successful operation of CCTV system.
Packing, forwarding, transportation, custom clearance,
insurance, storage at site including unloading of all
2.0 equipments, keeping under safe custody of complete
CCTV system and accessories and shifting of all cabinets/

consoles to DCU Main Control Rooms.
Installation, integration of complete CCTV system and

2.1 associated accessories including calibration, cabling,
junction boxes, power supply, distribution boxes etc.

2.2
Installation of CCTV Cameras along with its accessories
and mounting poles
Installation of CCTV monitors ( Work stations and ceiling
2.3 hanging type 32LCD monitors), 1 No. 32 LCD monitor in
shift in-charge room ,CCTV cabinet in rack room , joy

stick/pan/tilt /zoom control unit in hardware console and all

Page 516 of 564
CCTV SYSTEM Part C
other control room mounted equipments
2.4
Installation of structural mounting poles for the cameras
including its anchor bolts and minor civil works as required.
2.8
Installation of all types of bidder supplied junction boxes
(signal, power, control) in field/control room.
Installation of all types of bidder supplied cables ( signal,
power, co-axial, fiber optic with HDPE conduits , earthing )
in field for various cameras and all interconnection cables
2.9 within control room between all the bidder supplied
equipments (CCTV system cabinets/monitors/joystick)

including glanding, termination at both ends of all the
cables for the complete CCTV system
2.14
Installation of SS Pipe and SOV for wiper and washer
assembly for each CCTV camera in field.
2.19
Interfacing of CCTV systems with the Giant screens /DCS
and fire alarm panel in the Control Rooms.
2.20
Painting of Non SS installation materials in the field.

Field-testing, pre-commissioning, commissioning & final
3.0
acceptance of complete CCTV system at site. This
includes coordination with purchaser their erection
contractor, during above-mentioned activities.
4.0
Site acceptance test of complete CCTV system including
generation of all reports.
5.0
Documentation including
complete CCTV system.
as-built documentation of

6.0
Warranty of complete CCTV system.

7.0
Supply of special instrument or tools needed for testing,
calibration and maintenance of offered CCTV system.
8.0
Supply of consumables and commissioning
mandatory spares as per MR for CCTV system.
and

9.0
Supply of two year operation and maintenance spares for
CCTV system in case ordered by Owner. (Note-2)
10.0
Training as per MR for CCTV system.


Page 517 of 564
CCTV SYSTEM Part C
11.0
5 years of Post-warranty maintenance contract for CCTV
system as specified in MR.
Any other item or/and activity not listed/indicated
12.0 specifically but necessary for successful operation of
CCTV system.

Note-1: Part nos. of the 2 years O&M spares shall be furnished by the vendor if these
optional spares are ordered later by Owner.
1.2 The detailed scope of work shall be as per this MR.

1.3 Attachments to this scope of work are as follows:
a) Annexure-A (Responsibility Definition)
b) Annexure-B : (Distance Table)
c) Annexure-C (Proven Track Record)
d) Annexure-D (Logistic Support)
e) Annexure-E (Compliance statement)

Page 518 of 564
Part C
CCTV SYSTEM
RESID UPGRADATION PROJECT Annexure A to
A133-000-16-51-SOW-1501 Rev. A
CPCL,CHENNAI
Page 1 of 4
ANNEXURE-A
(RESPONSIBILITY CHART)

Rev.
No

Page 519 of 564
Part C
CCTV SYSTEM
A133-000-16-51-SOW-1501 Rev. A
CPCL,CHENNAI
Page 2 of 4
RESPONSIBILITY
S. VENDOR MANUFACTURER OTHERS (AGENCY

DESCRIPTION LOCATION
NO. OTHER THAN MANU./
VENDOR)
1 SOURCE OF SUPPLY
a) CAMERA
b) ENCLOSURE
c) VIDEO ENCODER
d) MONITOR
e) NVR
f) CABLES
g) MONITORING UNIT
KEYBOARDS
h) PROGRAMMING UNIT
i) LCD MONITORS
j) CENTRAL CONTROL
UNIT
k) ANY OTHER(PLEASE
SPECIFY)
2 SYSTEM ENGINEERING

Page 520 of 564
Part C
CCTV SYSTEM
A133-000-16-51-SOW-1501 Rev. A
CPCL,CHENNAI
Page 3 of 4
a) BASIC & DETAILED

SYSTEM DESIGN
b) CONFIGURATION
c) SOFTWARE
d) ANY OTHER
( PLEASE SPECIFY)
INTEGRATION AND
INSTALLATION OF
VARIOUS COMPONENTS
LIKE VIDEO ENCODER,
3
NETWORK SWITCHER
AND CENTROL
CONTROL UNIT IN DCU
CONTROL ROOM.
FACTORY ACCEPTANCE
4
TEST
INSTALLATION,
ERECTION,
INTERGRATION OF
COMPLETE CCTV
SYSTEM AT SITE
5
INCLUDING LAYING OF
VARIOUS
INTERCONNECTING
CABLES AS
APPLICABLE.

Page 521 of 564
Part C
CCTV SYSTEM
A133-000-16-51-SOW-1501 Rev. A
CPCL,CHENNAI
Page 4 of 4
FIELD CALIBRATION,
TESTING, PRE-
6 COMMISSIONING AND
COMMISSIONING OF
CCTV SYSTEM AT SITE.
SITE ACCEPTANCE
7 TEST OF COMPLETE
CCTV SYSTEM
8 SITE TRAINING

Page 522 of 564
Part C
CCTV SYSTEM
RESID UPGRADATION PROJECT Annexure B to
A133-000-16-51-SOW-1501 Rev. A
ANNEXURE-B
(DISTANCE TABLE)

Rev.
No
Page 523 of 564
Part C
CCTV SYSTEM
RESID UPGRADATION PROJECT Annexure B to
A133-000-YE-SP-1510 Rev. 1
CPCL,CHENNAI
Page 2 of 2
1. Process Area CCTV SYSTEM#1 (Refer CCTV configuration diagram A133-000-16-51-MD08 ( Sheet 4 of 4)
2. ) Qty. of Cameras (PTZ Location of Distance

Distance
Cameras) (Field video encoder between Location
between
Sl. explosion-proof & Power Camera unit Qty. of Qty of of CCU
Unit Tag No. Encoder Remarks
No. Suitable for gas group Distribu- and video Monitors CCU and
and CCU
IIA/ IIB) tion encoder ( in Monitors
(in Metres)
Board DCU MCR)
1 1 86-CCTV-1001
2 1 86-CCTV-1002
3 1 86-CCTV-1003 DCU MCR
DCU Unit 700 mtrs each
4 1 86-CCTV-1004
5 1 86-CCTV-1005
6 1 86-CCTV-1006 Within
By DCU
7 Heater 1 86-CCTV-1007 DCU
DCU MCR 700 mtrs each 3 Nos Vendor MCR
8 Package 1 86-CCTV-1008 MCR
9 1 87-CCTV-1001
LPG Unit DCU MCR 350 mtrs each
10 1 87-CCTV-1002
11 Cooling Water 1 00-CCTV-1001
DCU MCR 1250 mtrs each
12 System 1 00-CCTV-1002
13 Instrument Air 1 00-CCTV-1003
DCU MCR 1250 mtrs each
14 Compressor 1 00-CCTV-1004

Page 524 of 564
Part C
CCTV SYSTEM
RESID UPGRADATION PROJECT Annexure C to
A133-000-16-51-SOW-1501 Rev.A
CPCL,CHENNAI
Page 1 of 3
ANNEXURE-C
(PROVEN TRACK RECORD)

Rev.
No

Page 525 of 564
Part C
CCTV SYSTEM
A133-000-16-51-SOW-1501 Rev.A
CPCL,CHENNAI
Page 2 of 3
Sl. Description As offered System as System as System as System as

No for this installed @ site installed @ site installed @ site 3 installed @ site 4
project 1 2
NAME OF PLANT
1
2 NAME, ADDRESS, FAX NO.,
TELEPHONE NO. & E-MAIL OF
CONTACT PERSON IN THE
PLANT.
3 NAME, ADDRESS, FAX NO. OF

CONSULTANT
4 MONTH & YEAR OF SYSTEM

SUPPLY
5 MONTH & YEAR OF SYSTEM

COMMISSIONING
6 ANY MAJOR BREAKDOWNS TILL

DATE
7 IF YES, CAUSE OF BREAK-DOWN
8 SCOPE OF VENDORS
RESPONSIBILITY
DESIGN & SUPPLY

a) SYSTEM ENGINEERING
b) FACTORY TESTING
c) COMMISSIONING AT SITE
d) INTEGRATION

Page 526 of 564
Part C
CCTV SYSTEM
A133-000-16-51-SOW-1501 Rev.A
CPCL,CHENNAI
Page 3 of 3
9 SYSTEM DETAILS AND MODEL

NOS. FOR :
a) CAMERA
b) CAMERA ENCLOSURE
c) MONITOR
d) ENCODER
e) NETWORK COMPONENTS
f) NETWORK VIDEO
RECORDER.
g) CONTROL UNIT
10 SALIENT FEATURES OF
OFFERED SYSTEM OVER
EARLIER INSTALLED

Page 527 of 564
Part C
CCTV SYSTEM
RESID UPGRADATION PROJECT Annexure D to
A133-000-16-51-SOW-1501Rev.A
CPCL,CHENNAI
Page 1 of 2
ANNEXURE-D
(LOGISTIC SUPPORT FORMAT)

No by by

Page 528 of 564
Part C
CCTV SYSTEM
RESID UPGRADATION PROJECT Annexure D to
A133-000-16-51-SOW-1501Rev.A
CPCL,CHENNAI
Page 2 of 2
CERTIFICATE FOR LOGISTICS SUPPORT
(To be signed by Manufacturer's corporate level signatory on company's letter head)
I, ON BEHALF OF M/S______________________________ CONFIRM THAT THE CCTV
SYSTEM __________________ QUOTED BY M/S ____________________________ FOR
RESID UPGRADATION PROJECT, CPCL, CHENNAI, INDIA AGAINST MATERIAL
REQUISITION A133-000-YE-MR-1500, REV.A, SHALL CONTINUE TO BE SUPPORTED BY US
AND QUOTED SYSTEM SHALL NOT BE WITHDRAWN FROM INDIAN MARKET IN NEXT
THREE (3) YEARS FROM THE DATE OF PLACEMENT OF ORDER AS A MATTER OF
CORPORATE POLICY.
I FURTHER CONFIRM THAT IN CASE OF PLACEMENT OF ORDER BY CPCL ON M/s -----------
-------------------------------, WE SHALL CONTINUE TO SUPPORT CPCL IN PROVIDING BACK-UP
ENGINEERING, MAINTENANCE SUPPORT AND SPARE PART SUPPORT FOR A PERIOD OF
NOT LESS THAN TEN (10) YEARS FROM THE DATE OF EXPIRY OF WARRANTY.
SIGNATURE WITH SEAL
AUTHOURIZED, SENIOR MANAGEMENT

LEVEL SIGNATORY

Page 529 of 564
Part C
CCTV SYSTEM
RESID UPGRADATION PROJECT Annexure E to
A133-000-16-51-SOW-1501 Rev. A
CPCL,CHENNAI
Page 1 of 2
ANNEXURE-E
(COMPLIANCE STATEMENT)

No by by

Page 530 of 564
Part C
CCTV SYSTEM
RESID UPGRADATION PROJECT Annexure E to
A133-000-16-51-SOW-1501 Rev. A
CPCL,CHENNAI
Page 2 of 2
COMPLIANCE STATEMENT
(TO BE SIGNED BY VENDOR'S PRINCIPAL CORPORATE LEVEL SIGNATORY ON

COMPANY LETTERHEAD)
I, ON BEHALF OF M/s CONFIRM THAT THE PROPOSAL OF THE
CCTV SYSTEM QUOTED BY M/s FOR RESID UPGRADATION
PROJECT, CPCL, CHENNAI, INDIA OF M/s CPCL AGAINST MATERIAL REQUISITION
A133-000-YE-MR-1500, REV.A MEETS ALL THE TECHNICAL SPECIFICATIONS LISTED
IN THE STANDARD AND PROJECT SPECIFICATIONS ENCLOSED WITH THIS MR AND
NO DEVIATION HAS BEEN TAKEN BY US TO THE REQUIREMENTS OF THE MR.
(SIGNATURE WITH SEAL)

Page 531 of 564
This document, drawing, and the design/ details given in this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrowers express agreement that they will not be reproduced, copied,
Close Circuit Television System
Amarel8 1 Tag Number Refer Note-1
2 Service CCTVs for DCU unit
General 3 Area Classification Note-2
Colour, Electronics, Day & Night Vision | Refer Annexure-

4 Type | Quantity
B/System configuration drawing
5 Lens assembly *
6 Focal Length Range mm *
7 Relative Aperture Range *
8 Filter | Type Required | IR
9 IRIS Control Focus Control Auto Auto
10 Zoom Control Auto
11 Sensitivity | Resolution 2.5 lux for good picture | Minimum 540 TV lines.
12 Signal to noise ration 50 dB
13 Auto Gain Control | Maximum Gain Yes | 18 dBA
14 Pan & Tilt arrangement Required
Camera
15 Pan range 0 360 (Horizontally)
16 Tilt range 90 (Vertically)
17 Wiper | Washer Required | Required
exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.EIL-1641-507. A4-210 x 297.
18 Type of washing (Water / Air) Water

19 Washing inlet Connection inch Flanged
20 Pressure | Flow *
21 Power Supply 110VAC 10% UPS, 50Hz. Also refer Note-4
22 Enclosure Type IP 65, Flameproof Exd
23 Cable Entry- Signal / Control | Power * | *
24 Camera Location Refer Annexure-B
25 Mounting Arrangement Structure Mounting
26 Type | Quantity 1. Colour TFT LCD | Refer Annexure-B
27 System | Size 2. PAL | 32
28 Input Signal 3. Signal from Camera
29 Input impedance 4. *
Monitor
30 Resolution 5. *
Unit
31 Viewing Angle (H/V) 6. *
32 Contrast Ratio 7. *
33 Monitor Control: Local / Remote 8. Remote
34 Remote Control Device 9. Monitoring Unit Control Key Board
35 Remote Control Device Location 10. DCU MCR Console Room
36 Power Supply 11. 110VAC 10% UPS, 50Hz.
37 Enclosure 12. General Purpose
38 Mounting Location | Style 13. Refer Annexure-B | Free Hanging from Ceiling
39 Keyboard | Type 14. Required | *
40 Keyboard operation Requirements 15.
41 Network Video Recorder | Quantity 16. Required | 1 Lot for complete CCTV system
42 Type 17. *
46 Mounting Location 19. Central control unit in DCU MCR
47 CCU Capability
Central 48 No. of camera | No. of monitors Refer Note-5 | Refer Note-5
Control 49 Video Selection Unit Required
unit 50 Camera Selection :- Single / Multiple Multiple
51 Quad Splitter Required
52 Video Signal Amplifier Required
(CCU)
53 Signal to Noise Ratio 50 dB
54 Camera Switching Control Required
55 Switching Frequency *
56 Mounting type Free standing ( Rittal Make)
57 Channel Base Required
58 Enclosure General Purpose
59 Power supply to instruments 110VAC 10% UPS, 50Hz. (Note 4)
B 11/03/14 SP NZ AR
A 17/01/14 SP NZ AR REQ. NO. : A133-000-YE-MR-1500 LEGEND :
REV DATE BY CHKD APPD VENDOR : * - By Vendor

^ - data Revised
PLANT : RESID UPGRADATION PROJECT

SPECIFICATION REV
ENGINEERS INDIA LIMITED UNIT : 000
NEW DELHI
CLIENT : M/s CPCL A133-000-YE-DS-5001 B
Page 1 of 2
Page 532 of 564
This document, drawing, and the design/ details given in this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrowers express agreement that they will not be reproduced, copied,
Close Circuit Television System
CCU 60 Cable Entry Bottom
Cabinet 61 Colour : Internal | External Manuf. Std | RAL 7035
Program 62 Programming Unit | Quantity Required Refer Note-5

ming 63 Monitor Type 21 inch TFT LCD (Colour)
64 Printer | Type
Unit 65 Location Refer Note-5
67 Mounting 21. Table Top
Cable 68
Requirem Signal and Control Cable
ent
(i) Between Camera and Video Encoder /
Network Switcher cabinet in DCU C/R
Type | Required Fibre Optic / Coaxial/patch-cord with connectors | Yes
(ii)
(iii) Between CCU and monitor in DCU MCR
Type | Required * | Yes
exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.EIL-1641-507. A4-210 x 297.
(iv) Between CCU and monitoring unit keyboard

(v) Between CCU and Programming unit
(vi) Between Programming unit & Printer
(vii) Between CCU & Giant screen
69 Power Cable Refer Note-4
(i) Between each Camera & PDB in DCU MCR Yes
(ii)
Between Monitor in DCU MCR & PDB in
Yes
DCU MCR.
(iii) Between Programming Unit in DCU MCR &

Yes
PDB in DCU MCR respectively.
Certificati 70
Statutory Certificates Required ( PESO/CCE)
on
Others 71 Model No.
Lens | Camera *
Encoder
Monitor *
Central Control Unit *
Video Signal Amplifier *
Network Video Recorder *
72 Manufacturer *
Notes :-
Note-1: This is a typical datasheet for all CCTV tags. Refer Annexure-B for CCTV camera tags.
Note-2: (i) For all units, all field mounted items such as camera, amplifier, junction box, cable glands, SOVs etc. shall be
weatherproof to IP-65 and certified flameproof suitable for mounting in Zone-1 Gr. IIA/IIB/IIC, Temp Class T3.
(ii) All items mounted in DCU Main Control Room (MCR) shall be suitable for mounting in safe area.
Note-3: Refer System Configuration Diagram
Note-4: Power supply to the camera units in the field shall be from the CCTV system cabinet located in control room..
Note-5: Quantity shall be as per CCTV system configuration diagram attached with MR..
Note-6: Each individual camera video and control signals shall be connected to CCTV system cabinet located at control room .
Note-7: All license required for the CCTV recording and viewing shall be supplied. Future expansion of DVR and cameras (
minimum 2 nos) shall be possible without any additional hardware and software including any additional license.
B 11/03/14 SP NZ AR
A 17/01/14 SP NZ AR REQ. NO. : A133-000-YE-MR-1500 LEGEND :
REV DATE BY CHKD APPD VENDOR : * - By Vendor

^ - data Revised
PLANT : RESID UPGRADATION PROJECT

SPECIFICATION REV
ENGINEERS INDIA LIMITED UNIT : 000
NEW DELHI
CLIENT : M/s CPCL A133-000-YE-DS-5001 B
Page 2 of 2
Page 533 of 564
CCTV SYSTEM Part C
RESID UPGRADATION PROJECT A133-000-16-51-SIV-1501 Rev. B
(SPECIAL INSTRUCTIONS TO VENDOR)
CCTV SYSTEM
B 11-03-2014 ISSUED with MR RK NZ AR

No by by

Page 534 of 564
CCTV SYSTEM Part C
PART-A (BIDDING INSTRUCTIONS)
A1. The vendor must follow the following guidelines while submitting their offer for CCTV
system. Offers not complying with these guidelines may be rejected without any intimation
to the vendor:
a) The CCTV system specifications (i.e. data sheets, scope of work, specifications and
other attachments to this M.R.) shall be fully complied with. No deviations of any type are
acceptable in general.
A2. The vendor is responsible for the selection of the equipments including accessories and
it's suitability to meet the specifications in totality. . If at any stage, till the completion of the
order, the offered equipments & accessories are found unsuitable for the specified
operating and design conditions, the vendor shall replace the same with a suitable model
no. meeting the specifications without any schedule/cost implication.
A3. Vendor shall submit the following documents with the offer. Deviation indicated anywhere in
the offer shall not be considered.
1) Compliance Statement (Annexure-E)
2) Deviation List (if any)
Offers will be evaluated as received on the basis of criteria set forth in clause A3 above
and based on the documents specified above. Vendor shall note that there may / may not
be any subsequent technical correspondence.
A4. Provenness requirements
A4.1 Vendor must offer all the equipment / items and the services from the agencies and
their locations which meet the provenness requirements specified below. The items
not meeting these requirements shall be rejected hence shall not be offered.
All offered items including camera ( Ex"d") and its accessories, control unit, monitor
and recorder shall meet individually and also as an integrated system should have
been supplied and working satisfactorily for a period of minimum 4000 hrs in an
Hydrocarbon industry like Refinery, Petrochemicals etc on bid due date.
A4.2 In addition to above the system engineering shall also be carried out by an agency
which has carried out system engineering of a similar system which is working
satisfactorily for a period of minimum 4000hrs.
The information shall be furnished in the "Proven Track Record Format' attached
along-with MR.
A5. The vendor shall submit the required drawings/documents as per the Vendor Data
Requirements (A133-000-YE-VD-1501) enclosed with the MR.
A6. The vendor must clearly indicate the responsibilities of each of the agencies in the
'Responsibility Chart' format attached with MR.
A7. Vendor shall furnish a certificate for providing necessary support services. The certificate
shall be as per the format enclosed (Annexure-D) in PART-C and shall be duly signed by
CCTV system vendor.

Page 535 of 564
CCTV SYSTEM Part C
PART - B (SPECIFIC TECHNICAL REQUIREMENTS)
B1. This specification shall be read in conjunction with PMC job specifications(44NC-4600-
0000/J.02/0101/A4) Standard specification for Instrumentation work(44NC-4600-
0000/J.SS/0101/A4, scope of work, configuration drawings and the data sheets enclosed
in this Material Requisition. Vendor must furnish all the information asked specifically in
the data sheets along with offer. Wherever any discrepancy exists between the above
documents, Special Instructions to Vendor and the data sheets shall override. however it
shall be obligatory on the vendor's part to bring to the notice of the purchaser all such
conflicts, wherein the purchaser's decision shall be final.
B2. CCTV system is required for surveillance of DCU unit of Resid Upgradation Project CPCL,
Chennai, India. This MR specifies the requirements of complete CCTV system which
includes cameras, mounting accessories, all types of cables including video, control,
TCP/IP and power cables, encoder, network switcher, control units, monitors, keyboards,
network video recorders, Programming Units, etc. for following area of Resid Upgradation
Project, CPCL :
1. Process Area CCTV SYSTEM#1
a) DCU
b) HEATER PACKAGE
c) LPG UNIT
d) COOLING WATER SYSTEM
e) INSTRUMENT AIR COMPRESSOR
Vendor shall specifically note that all the items of CCTV system shall be sourced from
single approved vendor only.
B3 System configuration shall be as per enclosed drawings A133-086-16-51-MD08 ( Sheet4

of 4) attached with MR.. Number of cameras, monitors and other accessories for each unit
shall be as per above system configuration diagram. Distance table is attached as
Annexure-B for various cameras and its estimated distance. It is vendor responsibility to
supply all the required cables in line with the distance specified for various cameras.
Bidder shall note that actual location and elevation of cameras shall be finalized during
detail engineering. Bidder shall consider the elevation range for the location of cameras as
below:
For 2 cameras in DCU Block: Between 30 Meters to 60 Meters
For Balance Cameras in unit areas: Between 15 Meters to 25 Meters.
Accordingly, bidder shall ensure the proper operation of cameras at different elevation
including its washer unit meeting the functional and technical requirements specified in the
MR specification.
B4 All the cameras shall be located in field flame proof and IP-65 weather proof protection
and shall be suitable for hazardous areas Zone-I, Gas Groups IIA/IIB Temperature T3. All
the interconnecting cables between cameras ( co-axial, fiber optic cables with HDPE
conduit and power supply cables etc) specified in the system configuration diagram shall
be supplied and installed by bidder. All the CCTV system hardware shall be housed in
CCTV system cabinet located in rack room of control room. The system cabinet make
shall be Rittal Make and shall have IP-42 weather proof protection..
B5 Bidder shall note that only feeder of 110VAC UPS identified from UPS ACDB located in
UPS room of Main Control room. Further distribution from UPS ACDB to CCTV system
cabinet and distribution to cameras in field and all other equipments within control room
shall be provided by bidder. Bidder shall note that any other voltage level required shall be
Page 536 of 564
CCTV SYSTEM Part C
provided by bidder. Bidder shall note that UPS feeder load indicated is indicative. Any
additional load required for CCTV system shall be considered and provided by DCS
vendor without any implications. The UPS power supply consumption shall be furnished
by bidder along with offer.
Further conversion to any other voltage level (if any) required shall be considered by
vendor.
1) Each camera in field.

2) Video encoder unit, at DCU MCR.
3) CCTV cabinet for Centre control unit, CCTV Monitors and CCTV Engineering PC at
DCU MCR.
B7. Vendor's scope of supply shall include field cameras along with zoom lens / pan and tilt units
/ washer & wiper assemblies / video amplifiers / surge protectors for video, optical fibre
converters, control, signal & power junction boxes ,camera housing, keyboards, monitors,
programming unit PCs , Control cabinets for housing switchers/matrixes, quads/splitters,
receivers, surge protectors for video, control & power, DVR ( including spare DVR),
programming PC, joy sticks, 32 LCD monitors(3 nos) , 1 number 32 LCD monitor in shift
in-charge room, mounting poles and other installation material etc. as required for
satisfactory operation of CCTV system .Bidder shall also refer to the attached document No.
A133-000-YE-SP-1510 for detailed Scope of Work & Supply.
B8. All the furniture required in the control rooms to mount the CCTV equipments like PC shall
be provided by Vendor.
B9. Vendor shall also note that all cable shall be armoured type only.
B10. The control units, monitors, Network Video Recorders, Keyboards, Programming unit PC
shall be located in control rooms. The installation of cameras, supply & installation of
mounting poles and cable laying between the cameras and control room equipment for all
units shall be carried out by vendor.
B11. CCTV system shall be interfaced with giant screen as shown in configuration diagrams for
displaying the CCTV images on the giant screen provided as part of DCS at MCR
B12. Structural mounting poles of 10 Meters height shall be provided for each cameras. The
fabrication of mounting along with suitable ladder including painting and installation at site
shall be in the scope of bidder. The foundation details for the mounting poles shall be
furnished by bidder during detail engineering. The mounting pole shall be supported on a
concrete foundation. For other cameras pedestal mounted poles on structure shall be
provided by vendor. The structural steel shall be painted to meet the environment. Pole
material shall be GI.
B13. The CCTV system shall be provided with PC as programming unit along with all
necessary hardware and software at Control Room. The CCTV system shall be integrated
with the large screens and necessary hardware, software, convertor required to integrate
with giant screen shall be provided by vendor.
B16. Cameras in field shall be suitable for 1/2" water line connection and shall be provided with
Exd SOV suitable for the hazardous area classification for water connection to washer
and wiper system.
B17. Junction Boxes, Cable Glands:

i). All junction boxes & cable glands required for power supply, power distribution,
signals etc shall be weather proof to IP-65 & flameproof Ex' d' type as per specified
hazardous area classification. The cable glands shall be double compression type
Page 537 of 564
CCTV SYSTEM Part C
with SS-304 material and certified flame proof type. All cable glands in field shall be
provided with PVC slipper..
ii). Vendor to note that separate cable entries for power supply & signal cables shall be
provided. Cable entries and cable gland sizes shall be in NPT standards (1/2" NPT
for signal and " NPT for power supply in general).
iii) All cables shall be properly terminated in junction boxes. Flying leads are not
acceptable. Separate junction boxes wherever required shall be provided for power,
video and control cables.
B20. Vendor shall supply following mandatory spares for CCTV as per mandatory list ( Annexure-
XII) attached with Part-A of MR. consumables and commissioning spares :
B21. Vendor to quote separately for spare parts for 2 years recommended operational and
maintenance spares for the CCTV system. The price for the 2 years operational
maintenance spares shall be valid for 2 years from the date of placement of order.
B22. Vendor shall supply any special instrument or tools required for testing, calibration &
maintenance of offered CCTV system and accessories. List of same shall be furnished by
Vendor in his offer and price shall be included in base price of offered CCTV system.
B23. FAT for complete CCTV system shall be carried out at CCTV vendors works. The Inspection
shall be carried out as defined in commercial section of MR. Bidder shall develop detail
inspection and test plan for CCTV system and submit to purchaser for review .
B24. Installation, testing & Commissioning:
(i) Vendor shall be responsible for system installation, testing and commissioning at site
including the Site Acceptance Testing of the CCTV system including its interface with
DCS and Giant Screen..
B25. Process conditions for service water is as follows:
Pressure:- 4.0 kg /cm2g (Min) / 4.5 kg /cm2g (Norm) / 5.0 kg /cm2g (Max) / 15.6 kg /cm2g
(Design)
Temperature:- Ambient / 65 deg C (Design)
External Water tank ( with adequate storage capacity) and Pump required for the
connection of service water to washer unit mounted in camera, shall be supplied by
Vendor.
B26. Vendor shall supply solenoid valve from the approved vendor indicated in Part-A of MR.
B27 Unit Rates: Vendor shall furnish unit price for all items and accessories including different
types of cables (video, data, control, power) to be supplied by Vendor as part of the
offered CCTV system for future addition/deletion purpose by Purchaser. This shall include
but limited to the following as a minimum:
I. Complete Camera Unit along with zoom lens / pan and tilt units / washer & wiper
assembly, junction box, field amplifier, surge protectors etc.
II. Monitors as offered for mounting in control room with required mounting accessories.
III. Network Video Recorder/DVR
IV. Programming Unit PC
V. Cables of each type and size
VI. HDPE conduit
VII. Camera Mounting Pole with climbing ladder
VIII. Each type of Camera with zoom lens as offered.
IX. Pan & tilt units as offered.

Page 538 of 564
CCTV SYSTEM Part C
X. Wiper & washer assembly as offered.

XI. Control Console Cabinet duly wired including Power distribution box, video encoder,
receiver unit, Switcher/Matrix , Quad/Splitter, Network Video Recorder.
XII. All accessories such as power surge protectors, video surge protectors, optical fibre
converters, SOV etc.
XIII. Any other item not mentioned above but quoted by Vendor as part of complete CCTV
system to meet MR requirements.
Unit rates furnished shall include engineering for the items wherever applicable.
B28. Vendor quote for training of Owner personnel for CCTV system as per Part-A of MR.
B29. COMPREHENSIVE POST WARRANTY MAINTENANCE (ANNUAL MAINTENANCE

CONTRACT)
Bidder shall quote for PWMC for CCTV as per Part-A of MR.

Page 539 of 564
Page 1 of 2222
TITLE: STANDARD SPECIFICATION FOR INSTRUMENTATION

WORK
PROJECT REFERENCE:
APPROVALS
No. Date

Issued this Revision o In-house Review o Purchase
o Revised Pages Only o Client Approval o Construction
Issued this Revision Enquiry o Engineering
Page 540 of 564

TITLE: STANDARD SPECIFICATION FOR REV. NO / ISSUE DATE - 0 / 12-Mar-10

INSTRUMENTATION WORK Page 2 of 22
1.0 PURPOSE
The purpose of this specification is to define the minimum requirements of design,

engineering, supply, inspection, testing, installation and commissioning of instrumentation
and control systems.
2.0 GENERAL
2.1 SCOPE
2.1.1 This specification together with the attachments covers the design, engineering, supply,
factory inspection and testing, field testing and calibration, installation and commissioning of
instrumentation and control systems on a turnkey basis for its successful operation.
2.1.2 The detailed scope of work shall be as indicated in job specification. The contractor shall
refer to standard instrument specifications that define the minimum requirements for design
of instrumentation systems. The design basis shall cover the design philosophy for this
project.
2.1.3 This specification along with standard specifications, provides only the qualitative
specifications of commonly used instruments and system, but by no means covers the
specification of each and every item covered in the bid document. Instrument specification
for those items not covered in this specification shall be submitted by the contractor for
approval.
2.1.4 Contractor shall be fully responsible for design, material selection, sizing and proper
selection of all the instruments and systems being supplied by them. Any approval or
comment on any document or guideline issued to contractor before or after placement of
contract or during execution of the contract shall not absolve the contractor of their
contractual obligations and responsibility with regard to completeness, proper selection,
satisfactory operation and easy maintenance of the unit.
2.1.5 All equipment supplied shall be of field proven quality both with respect to design and
materials. Prototype instruments or instruments of an experimental nature shall not be
offered or supplied.
In general, all instruments and instrument control systems, like Programmable Logic
Controller (PLC), Distributed Control System (DCS), Analyser Systems, Gas Detection
Systems, etc. offered by contractor shall have a well proven performance record of operating
satisfactorily in an hydro carbon industry like refinery, petrochemical or fertiliser etc. for a
minimum of 10000 running hours in India
No instrument requiring special maintenance or operating facilities shall be offered or

supplied as far as possible.
2.1.6 In the event of any conflict between this specification, related standards, codes etc. the
contractor shall refer the matter to the owner / PMC for clarification and only after obtaining
the same should proceed with the manufacture / engineering of the item in question.
2.2 BIDS
2.2.1 Bidder shall clearly define the operational philosophy suggested by them, in line with
requirements specified in the bid specifications. Bidder shall also clearly indicate the
provision of control panels, and control systems required for their sub packages offered by
them.
Page 541 of 564

2.2.2 Bidder shall provide the following information along with their offer as a minimum:-
- Compliance statement as given in bid document

- Configuration diagram and details of the offered control systems like Distributed Control
System, Programmable Logic Controller, CCTV system etc.
- Details of special instruments and control systems, if any.
- List of deviations, if any, from bid package clause number wise with reasons thereof,
wherever applicable.
2.2.3 DELETED.
2.2.4 In addition to mandatory spares and consumable spares indicated elsewhere in the bid
document, bidder shall also quote for two years operational spares for all the instruments
and control systems including those required for sub packages being offered by them.
2.3 DRAWING AND DATA
2.3.1 Detailed drawings, documents, data, catalogues etc. as required from the Contractor have
been indicated separately. The required number of reproducible and print should be
despatched to the address mentioned, adhering to the time limits indicated.
2.3.2 Bidder shall furnish all documents in A4 Size (210 mm x 297 mm) paper or folded in A4 size
unless otherwise specified. All drawings and sketches shall be in multiples of A4 size like
A3 (297 mm x 420 mm) or A2 (420 mm x 594 mm) etc., but folded to 'A4' size. Final
documentation shall be submitted in bound volumes. In addition to the above all the
documents/drawings shall be submitted in electronic form on CDs with index.
2.3.3 Definitions of deliverable documents
2.3.3.1 Drawing and document schedule
This document lists out drawings and documents to be prepared and submitted by
contractor to Owner / PMC either during engineering or as a part of final documentation.
Following information shall be available in this document:-
- Name and number of each drawing and document listed.

- The schedule for the document submission, contractor shall follow as per the overall
schedule.
2.3.3.2 Sub vendor list (for instruments and accessories)
Separate sub-vendor list is included elsewhere for instrumentation item. The list provided is
for make only and not for model number. It is contractor's responsibility to select correct
model number to suit the requirements and it shall have requisite proven track record. It
may be possible that make and / or model number of some instruments are identified in
licensor's process package or in P&IDs, in such cases licensor process package or P&ID
shall be guiding. In case for certain instruments vendor list is not included, suggested
vendor list will have to be got approved from owner / PMC.
2.3.3.3 Instrument sizing calculations
Instrument sizing calculations provide information regarding sizing (as per standards
specified elsewhere in this document), type, selection and other related information.
Following sizing calculation shall be applicable, in general, duly approved by the authority
indicated in Vendor's Standard Quality Plan:-
Page 542 of 564


- Utility consumption calculation including power supply UPS (Uninterrupted Power
Supply) / Non UPS etc.
- Cable size calculations for power cables.
- Calculation for intrinsically safe loop for proper selection considering various entity
parameters.
- Control system calculations like scan time, communication bus loading, response time,
system heat load for air-conditioning etc.
2.3.3.4 Utility requirements
This document lists out the following information regarding utilities required by the
contractor:
- List of utilities required i.e. Power (UPS, Non UPS), Instrument air, Cooling water, Steam
for tracing, Nitrogen etc.
- Location and estimated/actual requirement at each location. The requirement shall be
listed as minimum/normal/maximum.
- In case of AC power, the In-rush current with duration and power factor shall also be
indicated for each location.
2.3.3.5 DELETED.
2.3.3.6 Purchase requisition (PR)
Purchase Requisition contains all information which form part of material requisition but
updated in line with the finally accepted offer of the successful bidder. Typically purchase
requisition shall contain:
- Instrumentation specification, detailed instrument data sheets

- Standard specification, quality assurance requirements
- Testing (shop and field), inspection and shipping
- Drawing / document requirement
- Training requirements, if applicable.
- Make and Model number of selected vendor.
2.3.3.7 Functional loop schematics
These shall include all the information required by the DCS/PLC/Panel vendor for
preparation of detail Loop wiring diagrams required for manufacturing and for loop checking
purpose. The minimum information contents of the Functional Loop Schematics shall be as
listed below.
- All the loop components as per the P&I diagrams shall be shown so that functionality
is fully depicted. Any additional blocks as required shall be shown. Functional and
logic blocks shall be complete with the algorithm, logic description or any other
description/expression required to define the functionality.
- Controller action, valve fail safe position, alarm level, logging points shall be
identified.
- Loop components shall be depicted physical location wise (e.g. field / marshalling
cabinet / operator console etc.).
- Safety barriers, signal isolators, interposing relays and similar components as

defined in the standard specifications and job specifications shall be shown.
Page 543 of 564 - Power distribution shall be shown with reference to the source.

- Items like remote set point, slave/master status, set point / function generators shall
be identified and clearly depicted.
- Symbols used in the drawing should be as per ISA standards.
- Connection between software blocks shall be in correct logical way.
- Details of function generators, curves, linearisation, compensation, logics which

cannot be properly depicted, shall be described / drawn in supplement pages.
2.3.3.8 Logic diagrams
Logic diagrams for the process plants, utilities including boilers, turbines etc. shall be drawn
by the use of logic blocks like AND / OR gates, flip-flops, timers, counters, function
generators etc. by using symbols in accordance with ISA S5.2. The diagrams shall contain
the list of symbols with a brief description of the function of the corresponding logic block.
The status of the contacts, as shown on the logic diagram shall be clearly defined i.e. one
should be able to identify the correct contact status with the process condition or with the
operator action.
The sequential processes like those of material handling plants shall be described by
Sequence Flow Diagrams.
Logic diagrams shall be supported by write-up and / or cause and effect diagrams.
- Logic diagram shall indicate the tag no. / location / contact configuration of the logic
initiator.
- The logic output shall be described with the type of signal, tag no, action to be taken
and destination of the output.
- The logic output linked with further logics shall be clearly identified by the destination
reference.
2.3.3.9 Instrument loop drawings
Each loop shall have a separate instrument loop drawing which shall show each component
from field device to final receiver including physical location, initiating device, its terminal
number, junction box with its terminal number. cable number with pair number / polarity,
receiver instrument terminals / cabinet terminals, system functional blocks of loop in
simplified manner (without configuration details)
These drawings shall be developed from the functional loop schematics. These drawings
shall incorporate all other details not shown in the functional loop schematics. These
drawings shall be separate for each loop.
2.3.3.10 DELETED.
2.3.3.11 DELETED.
2.3.3.12 Panel front arrangement / Panel wiring drawings
These drawings shall show the arrangement of Panel mounted instruments like indicating
instruments, alarm annunciator, indicating lamps, push buttons, switches etc. including their
approximate sizes and their mounting locations. This drawing shall show the followings as a
minimum.
Page 544 of 564

- All items on the front of panel with bezel dimensions.
- Relative distance among the items and the distances from the panel sides.
- Layout of components inside the panel.
- Layout of wiring with the ducts, spacing between the ducts.
- Layout of tubing, tubing supports arrangements with dimensions.
- Arrangement of terminal blocks, gland plates and bulk heads.
- Arrangement of power distribution boxes / bus-bars, transformers, bulk power
supply units, relays etc.
- Arrangement of components required for panel pressurising / purging.
- Arrangement of Instrument Air distribution in the panel.
- Earthing arrangements and busbars details.
- Details of panel doors, canopy, lifting hooks, stiffeners, coupling between adjacent
sections, sheet thickness, and other relevant mechanical details.
- Arrangement of illumination, fans, louvers etc.
- Base frame and panel fixing details.
- Weight of the panel.
Panel wiring drawings shall include following information as a minimum
- Wiring connection details showing the components at both the ends, terminal nos.,
component nos., tag nos.
- Specifications of the wire (for the conductor and insulation) and the standard
followed for colour to be stated.
- Seperate drawings to be furnished for Power Distribution, Logics, Analogue signals,
Annunciation, Panel Purge interlocks, Power distribution to panel utilities like
illumination etc.
- Detail of wire loopings.
- All fused terminals, isolating links, safety barriers , fuses,MCBs to be clearly shown
with identification numbers.
- Terminal plans.
2.3.3.13 Configuration diagram
This drawing is a graphical representation of all major hardware required in a configurable

control system which are necessary to meet all the expected function requirements.
2.3.3.14 Dynamic graphic display drawings
These drawings provide a graphic representation of P&ID's arranged in a sequence which

when displayed on the CRT, shall provide easy and logical operational views.
The graphics shall be decided based on the operation and safety requirement of the plants.
The type of graphics, the number of graphic pages, the specification of the various displays,
targets, buttons, trends, panels, annunciation, messages, windowing, calling more than one
page at a time, linking, scaling, zooming etc. shall be decided in cosultation with the Owner /
PMC.
To implement the above EPCC contractor shall prepare graphic sheets and specifications
and submit to Owner PMC for approval.
2.3.3.15 Input / output assignment
This document indicates the physical assignment of various I/O modules and their
respective channels to various physical inputs and outputs. This document shall contain
cabinet number, rack number, slot number, type of module, channel number and process
Page 545 ofnumber
564 as a minimum.

2.3.3.16 Instrument duct/tray/trench layout
Instrument duct / tray layout drawing show the routing of main instrument duct/tray layout in
the unit / plant. The drawing shall be prepared on plot-plan or equipment layout as
applicable and shall show the size, cross-section at various locations, general notes,
symbols, reference drawings, and the control room entry.
The minmum information content shall be as below.
- Dimensions of the trays.

- Cable tag nos. on a running section.
- Sectional details.
- All joints, bends, change of elevations to be identified.
- Support details.
- Relative distance with respect to the adjacent members.
- Loading on the supports.
- Eatrhing details.
2.3.3.17 DELETED.
2.3.3.18 Instrument cable schedule
The instrument cable schedule shall show all instrument and power cables and cable glands
required for complete instrumentation. The document shall show, tag number, cable number,
type, length and size of cables, type of junction box, identity of local panel, control room panel/
cabinet location etc.
2.3.3.19 Cable block diagram
The cable block diagram shall be prepared to indicate all the multicore cables running between
junction box and rack room, JB and local panel, local panel and rack room, MCC and rack
room, Analyser shed/room and rack room and direct run cables from field to rack room. Cable
no, cable type and length shall be indicated for each multicore/direct run cable.
2.3.3.20 MCT layout drawings
Two types of drawings shall be prepared.
- First type shall indicate following details for each MCT frame
- MCT overall dimensions.
- Gable transit block configuration used including dummy blocks.
- Gable entry size and outside dimensions for each block within a frame
- Details of mounting accessories
- Overall MTO to cover hardware requirement inclusive of 20% spare.
- Second type shall be prepared to indicate planned physical location of each multicore
and direct run cable passing through MCT and shall be identified by the cable number
2.3.3.21 DELETED.
2.3.3.22 DELETED.
2.3.3.23 Junction Box Wiring And Other Interconnection Drawings.
The minimum content of this drawing shall be as follows:

Page 546 of 564

- Tag no. of the source and destination of the signals.

- Junnction box identification number and type (analogue/digital/intrinsic safe etc.)
- Cable tag number, type, number of cores/pairs/triads.
- Junction box terminal numbers and identification numbers of the conductors, terminal
numbers of the signal source / destination (field instrument terminal numbers,
marshalling rack terminal numbers etc.).
- Description/Number/Location of Panels,Racks ,Cabinets etc. for complete identification.
For cabinets with mounting on both the sides 'Front' or 'Rear' should be written.
- Termination details of the drain wires(cable shields).
- The drawings will group the items as per physical location with clear identification.
The above drawings shall be used for the termination of the conductors. Other than junction
box related terminations these drawings shall also cover the terminations of instrument
signals to MCCs, H.T.(High Tension) Boards, Local Panels and all
other items connected to instrument signals.
2.3.3.24 Instrument Power supply distribution drawings.
These drawings shall include the following information as a minimum.
- The incoming power from the UPS with all the components.
- The further distribution of Power with the complete description of the consumers,
connected load, power factor values.
- All voltage levels and frequecy values shall be clearly specified.
- Output voltage and frequency of all sources shall be specified with the maximum
fluctuation ranges.
- Sizes, ratings, types of the circuit breakers, fuses, terminals, transformers, links,
isolators, bus bars power sources, ammeters, voltmeters etc. shall be specified with
make and model numbers.
- Physical location of the components shall be clearly identified.
- Incoming and outgoing cable specifications shall be indicated.
- Allowable voltage drop at the consumer end.
- Similar drawings shall be provided for non UPS power.
2.3.3.25 Instrument earthing layout.
These drawings shall include the layout of earthing cables / conductors from instrument
items to the main earthing grid. The details of main earth grid may not be shown in the
instrument drawings if such details are covered in the electrical drawings. Typical drawings
of earthing arrangement along with the bill of materials shall also be given.
Details of Instrument earth pits with their locations to be given. Earth resistance values to be
specified.
3.0 DESIGN PHILOSOPHY
3.1 GENERAL REQUIREMENTS OF INSTRUMENTS
3.1.1 Instrumentation shall be complete in every respect and liberal to the extent of providing data
on all operations and variables sufficient for the safe, efficient and easy operation, start up
and shut down of the plant.
3.1.2 The design and installation of instruments shall be generally in accordance with ISA/API
recommended practices and other applicable standards like BIS, IBR etc. Material
specifications and practices shall, in general, conform to appropriate ASTM or equivalent
standards. All standards and code of practices referred to herein shall be of the latest
edition prior to the date of purchaser's enquiry.
Page 547 of 564

3.1.3 All instruments and equipments shall be suitable for use in a hot, humid and tropical
industrial climate in which corrosive gases and/or chemicals may be present. As a
minimum, all instruments and enclosures in field shall be dust proof and weatherproof to IP-
65 as per IEC-529 / IS-2147 and secure against the ingress of fumes, dampness, insects
and vermin. Temperature and pressure ratings for instruments and end connections shall
be inline with Piping Specifications. All external surfaces shall be suitably treated to provide
protection against corrosive plant atmosphere. All electrically powered instruments shall be
flame proof or intrinsic safe for use in applicable hazardous area.
3.1.4 DELETED.
3.1.5 All controllers shall have facility for bumpless manual-auto and auto-manual transfer and set
point adjustment. Flow, pressure and level controller shall be provided with proportional plus
integral action, while temperature controller with proportional plus integral plus derivative
action.
3.1.6 DELETED.
3.1.7 DELETED.
3.1.8 DELETED.
3.1.9 DELETED.
3.1.10 DELETED.
3.1.11 DELETED.
3.1.12 DELETED.
3.1.13 DELETED.
3.2 DELETED.
3.3 DELETED.
3.4 DELETED.
3.5 STATUTORY APPROVALS
3.5.1 Contractor shall be responsible for obtaining all statutory approvals, as applicable for all
instruments and control systems.
3.5.2 In addition, equipments / instruments / systems located in the hazardous area shall be
certified by the local statutory authorities for their use in the area of their installation. In
general following certification shall be given:-
- For all intrinsically safe/explosion proof/ flameproof equipments /instruments/systems or

equipments with any other type of protection allowable as per this package which are
manufactured abroad and certified by any statutory authority like BASEEFA, FM, UL,
PTB, LCIE, CENELEC etc. should also have the approval of Chief Controller of
Explosives (CCE), Nagpur.
- For all flame proof equipments manufactured locally (indegenously), the testing shall be
carried out by any of the approved test house like CMRI/ERTL etc. The equipment shall
Page 548 of 564

in addition bear the valid approval from Chief Controller of Explosives, Nagpur and a valid
BIS license.
- For all intrinsically safe equipment manufactured locally (indegeneously), the testing shall
be carried out by any of the approved test house like CMRI/ERTL etc. The equipment
shall in addition bear the valid approval from Chief Controller of Explosives, Nagpur.
- Approvals other than above shall neither be offered nor these will be acceptable.
3.5.3 DELETED.
3.6 INTRINSICALLY SAFE SYSTEM REQUIREMENTS
Following points must be considered while designing an intrinsically safe system:-
3.6.1 All intrinsic safety barriers shall be active isolating type only and shall have isolation between
input, output and power supply.
3.6.2 Barriers must be selected based on entity concept. Cable parameters shall also be
considered while matching entity parameters.
3.6.3 The signal transfer accuracy of barrier shall be at least equal to or better than the transmitter
selected.
3.6.4 Each instrument in the hazardous areas and the intrinsic barrier shall be certified for intrinsic
safety by a statutory authority.
3.6.5 Configuration tools whenever required for any intrinsically safe item which forms part of the
intrinsically safe item shall also be certified intrinsically safe.
3.6.6 Universal barrier with programmable capability shall be used for temperature inputs i.e. for
thermocouple / RTD inputs.
3.6.7 It is desirable to use one make of barrier for entire plant. The series shall be of reputed
makes such as MTL / P&F.
3.6.8 Intrinsically Safe barriers wherever required shall be provided by contractor as part of the
control system to which these input / outputs are connected. Generally locating barriers in
the local panels shall be avoided.
3.7 POW ER SUPPLIES AND THEIR DISTRIBUTION
3.7.1 Power supply voltage levels shall be as per engineering design basis or as indicated in job
specification.
For bulk power supplies, whenever supplied by contractor, dual redundant power packs shall
be provided.
3.7.2 Power feeder if specifically indicated, shall be supplied to the bidder at only one location. All
further distribution within the package shall be taken care of by the bidder.
3.7.3 Instrument power circuits shall be individually protected from fault with the help of fuses.
Power supply to the individual instrument shall be connected through Double Pole Single
Throw (DPST) switch and protected with the help of fuses. Miniature circuit breakers
(MCB's) may be selected in place of switch fuse unit in case protection is provided for
overload protection.
Page 549 of 110

3.7.4 564 V AC UPS power distribution

3.7.4.1 Power from UPS shall be distributed to individual consumer with the Miniature Circuit
Breaker (MCB) of appropriate ratings. Completely isolated feeders with isolating transformer
shall be provided for DCS free issue control room mounted panels / equipment, package
items in the field etc.
3.7.4.2 20% feeder or minimum of one number of each feeder shall be provided as spare and UPS
shall be sized accordingly.
3.7.4.3 The main isolator shall be DPST type to isolate AC line and neutral. Likewise individual
distribution feeders to have isolators of DPST type to isolate line and neutral.
3.7.4.4 In order to obtain proper fuse co-ordination following point must be taken into consideration.
- All the feeders for DCS shall feed to separate sets of bus bars (line and neutral)
- All the sets of feeders shall be fully independent and shall not be jointed together at any
point.
3.7.4.5 Voltmeter and ammeter in each main power feeder entry point inside the power supply
distribution board shall be provided.
3.7.4.6 Automatic sequential start-up facility for power supply in the AC distribution board shall be
provided.
3.7.5 DC Power Distribution
3.7.5.1 Main isolators shall be DPST (double pole single throw) type to isolate both lines with HRC
fuse on both lines. Like wise individual distribution feeder shall have isolation of DPST type
and fuse on both DC lines.
3.7.5.2 Contractor shall provide 20% or minimum one spare power distribution outlet with isolators
and fuses. The charger / rectifier shall be sized to cater for 30% spare feeder as specified
above.
3.7.5.3 Dc power distribution shall be designed to avoid any common mode failure.
3.7.6 230 V AC Non UPS Power Distribution
3.7.6.1 Main and individual distribution feeder shall be provided with switch fuse assembly or MCB.
3.7.6.2 The contractor to note that 230V AC non UPS shall be used for panel lighting, Analyzer
shelter and cabinet lighting etc. as indicated in design basis. Necessary distribution for the
same, supply and laying of the power supply cables from the switchgear to the field shall be
by the contractor.
3.8 ALARM PHILOSOPHY
3.8.1 Alarms shall be provided to give audible and visual warning of any process and machine
malfunction.
3.8.2 All trips shall have a pre-trip warning alarm in addition to alarm at the trip condition.
Page 550 of 564


3.8.3 All package alarms including pre-trip warning alarms and trip alarms (Shutdown alarms) shall
be annunciated in control room as well as on the local panel. First out alarm sequence as
per ISA, whenever required.
3.8.4 All rotating equipments shall have the status indication provided on the local panel wherever
applicable.
3.8.5 Common pre-warning alarm and common trip alarm contacts from the sub packages shall be
provided for remote annunciation. Additional alarm contacts shall be provided when
specified.
3.8.6 Fail-safe type with normally closed alarm contacts shall be used.
3.9 SIGNAL INTERFACE PHILOSOPHY
3.9.1 Interface with Main Control Room

3.9.1.1 DELETED.
3.9.1.2 DELETED.
3.9.1.3 Whenever multidrop serial communications is adopted, intermediate junction boxes may be
used for multidropping purpose only.
3.9.1.4 For all cables only single run shall be considered and cable joints shall not be acceptable.
3.9.2 Signals from contractor's scope to purchaser
Whenever signals are required to be routed for purchaser's use, contractor shall use
separate dedicated junction box or terminal strip (in case of control panel/system cabinet) for
each type of signal i.e. for 4-20 mA / alarm / contacts / temperature element etc.
In case of serial signals, contractor shall provide a separate dedicated port for purchaser's
use.
3.9.3 DELETED.
3.10 DELETED.
4.0 SPARE PHILOSOPHY
4.1 MANDATORY SPARES
Mandatory spares for instrumentation and control system shall be provided specified in the
mandatory spares list. This spares list defines the minimum requirement. For items not
covered in the list, the contractor to prepare the mandatory spares list and submit to
PMC/owner for approval.
4.2 2-YEARS OPERATIONAL SPARES
Contractor shall provide all spares required for 2 years trouble free operation.
4.3 COMMISSIONING SPARES
Any kind of spares required for start-up & commissioning shall be provided.
Page 551 of 564

4.4 CONSUMABLE SPARES.
Consumable spares such as chart paper, printer papers, ink cartridges, floppies, for a
minimum of one year duration after acceptance shall be provided by the contractor.
5.0 GENERAL REQUIREMENTS OF INSTRUMENTATION SYSTEMS
5.1 INSTRUMENT CONCEPT
5.1.1 DELETED.
5.1.2 Electronic transmitters shall generally be two wire type. These shall have output signal of 4-
20 mA DC and shall be capable of delivering rated current into external load of at least 600
ohms when powered with 24 VDC nominal voltage.
5.1.3 DELETED.
5.1.4 The design of electronic instruments shall be in compliance with the electromagnetic
compatibility requirements as per IEC-801.
5.1.5 DELETED.
5.1.6 DELETED.
5.1.7 DELETED.
5.2 DELETED.
5.3 INTERLOCK AND SHUTDOWN SYSTYEM
5.3.1 The inter lock and shutdown system shall be designed fail safe and shall meet the following
requirements as a minimum:-
5.3.1.1 All initiating contacts shall be close under normal conditions and shall open under abnormal
conditions.
5.3.1.2 All relays and solenoid valves shall be energised under normal conditions and shall de-
energise under abnormal conditions.
5.3.1.3 If desired, because of operational requirements trip by-pass facilities are to be provided with
warning lights to indicate that the trip has been bypassed. Trip bypass alarms shall be
provided on local panel as well as in remote location. All such by-pass switches shall be
key-operated type.
5.3.2 Programmable Logic Controller (PLC) used for interlock and shutdown., shall be located in
environmentally controlled remote control room. This shall meet the following minimum
requirements:-
5.3.2.1 PLC shall have dual redundant processor configuration for non-critical systems as a
minimum unless otherwise specified. Critical system PLC shall have Tripple Modular
Redundant configuration. Additional redundancy for I/O's /Power Supply / Communication
network shall be provided whenever specified.
Page 552 of 564


5.4 DELETED.
5.5 CLOSED CIRCUIT TELEVISION (CCTV) SYSTEM
5.5.1 Functionally CCTV system is required for the surveillance of the plant and equipment as
detailed out in job specification.
5.5.2 All the cameras shall have Pan and Tilt control. The camera viewing angle can be varied
between 7 deg. To 40 deg. And shall have zooming facility.
5.5.3 The CCTV central unit shall be located in the main control room or satellite rack room as
required. Separate monitors shall be suitably located in console area and keyboard, joystick
etc. shall be located on the hardwired console unless otherwise specified in job
specification.
5.5.4 The minimum enclosure protection degree of the system components shall be in accordance
with IEC 529 as follows:-
- Outdoor IP 65
- Indoor IP 42
- Panels with open doors IP 20 (live parts shielded)
5.5.5 Control unit and all peripherals shall be installed in air conditioned main control room.
Cameras shall be installed outdoor in the field. Cameras with its accessories shall be
housed in explosion proof certified Ex-'d' housing suitable for gas grouping of the plant.
5.5.6 The system shall include all hardware, wiring, cabinets, materials and application software
for a fully function system. Components shall be for industrial grade.
5.5.7 Cameras shall be as a minimum, comply with the following specification:

Pick up element : %" / 1/3 " interlined CCD colour
Picture point : 512 x 582
Sampling system : PAL standard CCIR 625/50 lines per frame
Video band width : 5 MHz = -3 dB
Horizontal resolution : Minimum 450 lines
Sensitivity : 3 lux for a good picture ( @ F = 0.95 and 3200 K)
Zoom lens : 11-66 mm
Controls : Zoom, Focus. Iris and external synchronization
Signal noise ratio : Approx. 50 dB
Gamma : 0.5
Automatic light level control : 1:10
Temp. range : 5-80 deg. C
Video output : 75 ohm unbalanced 1 V peak to peak
Camera identification : Yes
Automatic gain control facility : Yes
The zoom objective shall be equipped with an automatic diaphragm control., auto focus and
spot filter.
5.5.8 The time lapse Video recorder shall be as below unless mentioned otherwise:
Cassette tape : Standard 2 hour %" S-VHS E-120 or E-180
Record /play back speed : 2, 12, 24 and at least up to 72 hours
Video input / output : 1 V peak to peak 75 ohms unbalanced.
5.5.9 Movable cameras shall have an electric control mechanism (pan and tilt) which shall be
controllable through a joy stick and the same shall be located on the hardwired console. The
Page 553 ofpan
564 and tilt shall comply with the following:

Angular travel : Pan 0-360 degrees, Tilt +/- 90 degrees
Stops : Externally adjustable
Speed (no load) : Pan 6 degrees/second. Tilt 3 degrees/ second
Loading : Suitable for camera and camera housing
5.5.10 Outdoor cameras and accessories shall be housed in an Ex 'd' and ingress protected (IP 65)
housing Sand protector, wash and spray installation on the lens cover shall be provided.
5.5.11 A sun cap shall prevent direct sun radiation into the lens and camera housing. The
enclosure shall be epoxy painted.
5.5.12 Cameras with its accessories shall be installed on steel structure (mounting poles), Mounting
pole/structure shall be 10 meter high (minimum and shall be designed for maximum wind
velocity of the plant location. The allowable deflection at the top shall be +/- 5 mm. The
mounting pole / structure shall be supported on concrete foundation. A ladder shall be
provided to access the camera at top for the purpose of installation and maintenance of
camera and its accessories. The design, supply fabrication and erection of poles including
its support arrangement shall be in contractor's scope. The structural steel shall be epoxy
painted to meet the environment.
5.5.13 From a master control panel (keyboard) it shall be possible to select any camera and display
the picture at the monitor.
5.5.14 Remote control panels/keyboard shall be programmed for the control of selected cameras
with the possibility to call up any camera connected to the system.
5.5.15 Commands from the control units are sent via a data transceiver to the control receiver at the
camera side. The control receiver will control the camera lens and pan/till functions.
5.5.16 Operator shall be able to control all camera and pan tilt and zoom functions manually.
5.5.17 The video recorder shall record the activities at all entrances and at locations where alarms
have been alerted. The time laps video recorder(s) shall be able to record up to 72 hours
without reloading.
5.5.18 It shall be possible to view pictures of four cameras or three cameras and VCR
simultaneously on the screen. Suitable quad unit shall be provided.
5.5.19 Wiring and connection shall be as below unless specified otherwise:-
- All the cables (indoor/outdoor), connectors and plugs shall be supplied. The connectors
shall be BNC type.
- Flexible cables shall only be used for flexible connections.
- Video signals from cameras to the control unit shall be transmitted via coaxial cables.
- Camera control signals may be transmitted either via twisted pair or via multicore cables.
- All interconnection cabling between field mounted cameras to control equipment shall be
shielded and armoured. Indoor cabling between control equipment / monitor / key board
and optical fibre cable shall also be shielded and armoured.
- Materials shall be of proven design for similar application.
5.5.20 All the outdoor items shall be tropicalized and epoxy painted. All carbon steel bolting shall
be hot dip galvanized or Cadmium plated and bi-chromated. Screw, rivers, brackets and
stiffeners shall be stainless steel. Colour of the top coat of panels shall be manufacturer
standard.
Page 554 of 564


6.0 CONTROL ROOM / RACK ROOM REQUIREMENTS
The control and rack rooms required for housing control system and other instrument items
shall be designed, constructed totally by contractor. The following shall be considered as
minimum:
6.1 CONTROL ROOM
6.1.1 DELETED.
6.1.2 DELETED.
6.1.3 DELETED.
6.1.4 DELETED.
6.1.5 The control room shall be illuminated adequately with lighting arrangement which shall not
cause any glare at viewing area. The lighting arrangement shall be approved by purchaser /
purchaser's representative.
6.1.6 Painting and finish of floor and colour of consoles / racks shall be aesthetically matched.
6.1.7 DELETED.
6.1.8 The UPS and other electrical equipments shall be housed in UPS room with separate cable
entry. In general no high voltage electrical equipment shall be placed at rack area.
6.1.9 In the console area consoles shall be arranged in a arch form or straight. Ergonomic
techniques shall be used in design and layout of the consoles based on the assumption that
operators are seated while using the CRT displays, keyboards HW switches other console
equipments. A minimum clearance of 2 meters at the back side wall to console and 3 meters
at the front shall be kept.
For arch type console minimum of 2 metres from the tip to the front wall shall be considered
on either side.
6.1.10 The console area shall be sized to accommodate consoles for future units to be installed by
owner at a later date if specified in job specification. The channel base shall be provided
based on base frame details to be provided during detailed engineering.
6.1.11 The printers shall be arranged in console area.
6.1.12 All cabling inside the control room shall be done through trays below false flooring. No cable
shall be laid on the floor.
6.1.13 All consoles, racks, in control room and EC/PLC room be bolted on into the channel bases.
6.1.14 DELETED.
6.2 RACK ROOM
For rack room, the layout shall be made considering the following:-
6.2.1 Clearance between back and front rows from wall shall be 1.5 m (minimum)
6.2.2 Clearance between 2 rows shall be equal to 1.4 m or DCS vendor's recommendation
whichever is higher.
Page 555 of 564

6.2.3 Clearance between all rows from side wall shall be equal to 1.5 m (minimum)
6.2.4 The sizing for rack room shall be made in such a way that 20% spare cabinet space
available for future use.
7.0 DELETED.
8.0 INSPECTION AND TESTING REQUIREMENT
8.1 DELETED.
8.2 DELETED.
8.3 DELETED.
8.4 DELETED.
8.5 DELETED.
8.6 DELETED.
8.7 CCTV SYSTEM
8.7.1 All material / equipment / integrated system shall be tested at the manufacturers workshop
and witnessed by PMC and / or owner's representative prior to shipment of materials.
Internal test shall be carried out prior to the system is available for testing in presence of
PMC and / or owner's representative.
8.7.2 After installation completion, field test shall be performed and control function shall be
programmed in accordance with the functional requirements. Tests shall include functional
test of all inputs, output and alarm functions.
8.8 DELETED.
8.9 DELETED.
9.0 INSTALLATION MATERIALS
9.1 DELETED.
9.2 DELETED.
9.3 DELETED.
9.4 Cable trays and cable Ducts
9.4.1 Cable ducts shall be fabricated as per "Duct Fabrication Details"
9.4.2 Perforated cable trays shall be made out of GI sheets of 2.0 mm thickness. Ladder trays
shall be of mild structural steel and shall be painted with red-oxide primer, 50 mm x 50 mm x
5mm thick angle shall be used as a minimum.
9.4.3 The width shall be so selected that 50% of tray space is available for future use.
Page 556 of 564

9.4.4 Suitable cable clamps shall be supplied for binding the cables/tubes at every 500 mm.
9.5 DELETED.
10.0 INSTALLATION
10.1 DELETED.
10.2 DELETED.
10.3 DELETED.
10.4 DELETED.
10.5 DELETED.
10.6 DELETED.
10.7 DELETED.
10.8 DELETED.
10.9 DELETED.
10.10 DELETED.
10.11 DELETED.
10.12 DELETED.
10.13 DELETED.
10.14 DELETED.
10.15 DELETED.
10.16 DELETED.
10.17 DELETED.
10.18 DELETED.
10.19 DELETED.
10.20 DELETED.
10.21 DELETED.
10.22 DELETED.
10.23 DELETED.
10.24 DELETED.
10.25 DELETED.
Page 557 of 564

10.25.7 DELETED.
10.25.8 DELETED.
10.25.9 DELETED.
10.25.10 DELETED.
10.26 DELETED.
10.27 DELETED.
10.28 DELETED.
10.29 DELETED.
10.30 DELETED.
10.31 Installation of systems (DCS, PLC etc.)
10.31.1 The system shall be installed by the system vendor who would be responsible for installation
and termination of interconnecting cables in the system racks / cabinets. All interconnecting
cables shall be identified and the individual cores/wires shall be properly identified using
ferrules. Direct-cross ferruling method shall be used for identification.
10.31.2 All system communication cables shall be layed in covered GI (galvanised iron) trays away
from power cables. Prefabricated cables shall be avoided for interconnection if these are to
be routed out side the cabinets. If unavoidable these should be layed in covered GI trays.
10.31.3 All panels/cabinets and consoles shall be properly levelled and secured firmly with the base
supporting structure.
10.32 Grounding
10.32.1 Each cabinet, console and other equipment supplied as a part of system shall have earthling
lugs which shall be secured to the "AC mains earthing bus'.
10.32.2 All circuit grounds, shields and drain wires shall be connected to the 'system ground' bus
which is isolated from 'AC mains earth'. This bus shall typically be 25 mm wide and 6 mm
thick of copper.
10.32.3 The total resistance of system ground shall be less than 5 ohms unless otherwise
recommended by system manufacturer.
10.32.4 Safety barriers, if used, shall be secured to 'Safety ground' which shall have typically ground
resistance of less than 1 ohm. The bus shall be designed considering a fault level of 0.5 A
at 250 V r.m.s. per barrier.
10.32.5 All other installation guidelines as recommended by system manufacturer shall be followed.
11.0 SITE TESTING AND CALIBRATION
11.1 DELETED.
Page 558 of 564

11.2 DELETED.
11.3 DELETED.
11.4 DELETED.
11.5 DELETED.
11.6 DELETED.
11.7 DELETED.
11.8 DELETED.
11.9 DELETED.
11.10 DELETED.
11.11 DELETED.
11.12 DELETED.
11.13 DELETED.
11.14 DELETED.
11.15 DELETED.
11.16 DELETED.
11.17 DELETED.
11.18 DELETED.
11.19 DELETED.
11.20 DELETED.
11.21 DELETED.
11.22 After performing the calibration of all instruments, the entire loop shall be checked for proper
operation.
11.23 The entire shutdown scheme shall be simulated from the process trip switches and the
scheme shall be tested for its proper operation prior to start up of the unit.
11.24 DELETED.
11.25 DELETED.
11.26 Loop checking
11.26.1 Contractor is totally responsible for loop testing in co-ordination with control system vendor.
11.26.2 The division of scope of work related to loop checking between various sub contractors shall
Page 559 of 564decided by contractor.
be

11.26.3 Before proceeding for loop checking the calibration results of individual elements shall be
recorded on the contractor supplied proforma which shall be approved by owner for
correctness of installation / measurement and calibration results.
11.26.4 For calibration of special instruments and loop checking and for loop checking of sub vendor
packages contractor shall do necessary co-ordination with sub suppliers. The contractor
shall carryout the necessary loop checking to the satisfaction of Purchaser / Purchaser's
representative which shall be part of contractor's scope of work.
- For special instruments like analysers the contractor shall ensure the presence of
supplier's technical personnel during field testing / loop checking and during
commissioning to assist above activities.
- Loop testing for all control loops shall be generally by simulating process conditions for
atlest 0%, 25%, 50%, 75% &100% full scale inputs. Detailed procedure shall be
submitted to purchaser/purchaser's representative for approval before proceeding with
loop checking.
- In case of shut down system, field / receiver switches are simulated for abnormality by
disconnecting the wires at terminals. Function of all associated systems are check
including performance of solenoid valves, on/off control / shut down valves including
proper functioning of limit switches another accessories. Adjustments of limit switches
wherever necessary also from part of checking of loop performance.
- Performance of individual loop shall be accepted for an overall accuracy of +/- 1.0%.
Where deviation is found to exist more than specified limits, the contractor shall
recalibrate instruments, which shall also form part of loop testing at no extra cost and
time implications.
- Contractor shall complete all the entries in the loop calibration sheet related to field
instrumentation as well as the control system side after completion of calibration and
hand over the sheets to owner for final acceptance.
12.0 COMMISSIONING
12.1 This activity shall be carried out in a systematic manner so as to avoid any accident to plant
and operating personnel.
12.2 During the plant start up all the instruments calibration, controller alignment, trip point
settings shall be trimmed so as to meet the operation requirements.
12.3 Prior to guarantee run of any unit, the vital instruments as required by vendor have to be re-
calibrated and the results recorded.
12.4 As built drawings shall be prepared after installation and commissioning is over.
13.0 TRAINING
Unless specified otherwise the following shall be provided by contractor for system training
for owner.
Contractor shall arrange training for Owner's personnel. Different type of courses shall be
offered for operation / process engineers and operators, instrument maintenance engineers
and technician. Contractor shall indicate a detailed proposal for training in the offer. Apart
from the hardware and software maintenance training and site training, contractor shall also
offer operation training basically meant for operating personnel. The various facilities
available in the system for operation, actions required during emergencies and identifying the
various diagnostic messages shall be main contents of the operation training.
Page 560 ofHardware

564 and software maintenance training - At system vendors works

Operation Training - At system vendors works
Site Training - Operation and maintenance
14.0 DELETED.
Page 561 of 564

CCTV SYSTEM Part C
RESID UPGRADATION PROJECT A133-000-YE-VD-1501 Rev. 0
VENDOR DATA REQUIREMENT
0 17-01-2014 ISSUED with MR SP NZ AR

No by by

Page 562 of 564
CCTV SYSTEM Part C
RESID UPGRADATION PROJECT A133-000-YE-VD-1501 Rev. 0
POST ORDER
WITH DATA
S. WITH BID
NAME OF DOCUMENT BOOK (FINAL)
NO. FOR
FOR RECORD
REVIEW
Dimensional Details with mounting details and
1
model number
2 Block diagram for CCTV system
3 Wiring Diagram
4 Parts list
Recommended spare part list (for two years
5
operation)
Installation, operation and maintenance
6
manual
7 Nomograph and sizing calculation
8 Test certificate
9 Certificate from statutory body
10 Assembly details
11 Catalogue in English
12 Testing and inspection procedure
13 Final documentation in soft copy (CD)
14 Focal length calculation
15 Factory and site acceptance test procedure
16 Training course / Manual
17 CCTV system configuration drawing
NOTES:
1. Any drawing/document not indicated in the list above but required during erection,
commissioning or for reconfiguration of the system shall also be supplied by the
Vendor on demand.
2. X indicates required. Suffix Codes mean the following:

(i) For Information
(a) For Approval
3 Bidder to ensure the submission of all drawings / documents mentioned above in soft
copies through EIL eDMS portal only during detail engineering & no documents shall
be submitted through hard copies.

Page 563 of 564
NEW DELHI
Page 564 of 564
CCTV SYSTEM CABINET
REV.
DATE
REVISION
BY
CHK
APPROVED
APPROVED
DRAWING NO.
REV.

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A133 000 YE MR 1500 C 13/03/2014 16 51

JOB NO UNIT/ MAIN DOC. SR.NO. REV DIVN. DEPT.

REV DATE BY CHK APPD DETAILS

B 03/02/2014 RK ZH AR Issued for Bids

C 13/03/2014 RK ZH AR Revised & Issued for Bids

Project : RESID UPGRADATION PROJE

1 Design ,engineering,manufacture,procurement of materials and

Project : RESID UPGRADATION PROJE REQUISITION No. REV

specification and special instructions to vendor.

Project : RESID UPGRADATION PROJE REQUISITION No. REV

PROJECT : RESID UPGRADATION

e. Typical Installation details of Electrical panels 2

PART-C (CCTV SYSTEM)

PROJECT : RESID UPGRADATION

Item Description:Distributed PR No.: Review Status Code:

Anticipated (Ant) Date of submission by vendor

A 17.01.2014 Issued with MR PR AB AR

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved

PART C: - CCTV System

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved

A 17-01-2014 Issued with MR RK NZ AR

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved

LIST OF STANDARD SPECIFICATIONS

S. No. Document title Document no. No. of sheets

1. Standard Specification for Distributed Control 44NC-4600- 39

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved

SPECIFICATION NO: 44NC-4600-0000/J.SS/0102/A4

TITLE: STANDARD SPECIFICATION FOR DISTRIBUTED

- Project No: 44NC-4600

- Project Location: Manali, Chennai

- Project Title: RESID UPGRADATION PROJECT

- Client: Chennai Petroleum Corporation Limited

- Project Manager Authorization: B.B. DARAK Date:

- Client Authorization: Date:

0 12- Mar-10 39 Issued For Feed ADM MSD BSP

TITLE: STANDARD SPECIFICATION FOR DISTRIBUTED REV. NO / ISSUE DATE - 0 / 12-Mar-10

3.0 DESIGN AND CONSTRUCTION

4.0 SYSTEM CONFIGURATION & FUNCTIONAL SPECIFICATIONS

4.1 SYSTEM COMPONENTS

5.0 TESTING AND ACCEPTANCE

6.0 INSTALLATION, TESTING AND COMMISSIONING

7.0 PROJECT MANAGEMENT

TITLE: STANDARD SPECIFICATION FOR DISTRIBUTED REV. NO / ISSUE DATE - 0 / 12-Mar-10

11.0 MAINTENANCE CONTRACT

TITLE: STANDARD SPECIFICATION FOR DISTRIBUTED REV. NO / ISSUE DATE - 0 / 12-Mar-10

The purpose of this specification is to define the minimum requirements of a Distributed

- Manufacture, procure, supply, testing, installation, handling and commissioning of all

2.2.4 Vendor shall also supply the following items.

TITLE: STANDARD SPECIFICATION FOR DISTRIBUTED REV. NO / ISSUE DATE - 0 / 12-Mar-10

Mandatory spares as indicated elsewhere in this specification.

2.3.1 Distributed Control System

2.3.6 System Size

2.3.7 Operator Console

2.3.8 Engineering console

2.3.9 Switch Over time

TITLE: STANDARD SPECIFICATION FOR DISTRIBUTED REV. NO / ISSUE DATE - 0 / 12-Mar-10

2.3.10 Loop integrity

2.3.12 sers memory

2.3.14 Scan time

2.3.15 Data base

2.3.18 Real time trend

2.3.19 Call-up time