Uks’kuy QfVZykbtlZ fyfeVsM National Fertilizers Limited

¼Hkkjr ljdkj dk miØe½ (A Government of India Undertaking) fot;iqj&†‰…ƒƒƒ] ftyk% xquk ¼e-iz½

Vijaipur – 473 111, Dist: Guna (MP), India (An ISO 9001, 14001 & OHSAS 18001 Unit) CIN No. L74899DL1974GOI007417

Phone: ++91 (0) 7544 273 050/69 Fax: ++91 (0) 7544 273 089/109

Email: prvjp@nfl.co.in;ksuresh@nfl.co.in

Website: www.nationalfertilizers.com

Ref: NFV/PUR/BIU160645-V Dated: 16-11-2017

NOTICE INVTING TENDER (Two Part Bidding)

Online Tenders under Two Part Bid system are invited through e-Tendering process for the

supply of following material as per specifications mentioned in Annexure-C:-

Tender No. and Date NFV/PUR/BIU160645-V Dated: 16-11-2017 E-Tender ID: 1990

Description of Work Design, Engineering, Supply, Supervision, Erection & Commissioning of DCS & ESD System along with Spares for Ammonia-II and Urea-II Plants in NFL, Vijaipur as per Technical Annexure attached.

Type of Bid Two Part Bid

Earnest Money Deposit Rs. 1,00,000/- (Rupees One Lakh only) or equivalent amount in USD (as per prevailing exchange rate at the time of submission of bid).

Security Deposit-cum-Performance Bank Guarantee (SD-cum-PBG)

10% of Order Value

Offer Validity period Minimum 120 days from tender opening date Important Dates Important Dates

Start Date and Time for downloading of Tender Documents

16-11-2017, 12:30 Hrs

Pre-Bid Meeting 23-11-2017* 10:00 Hrs End Date and Time for downloading of Tender Documents

05-12-2017, 15:00 Hrs

Last Date and Time for submission of E-Bids

05-12-2017, 15:00 Hrs

Start Date and Time for opening of Part-I Tender (i.e. Un-priced Bids)

05-12-2017, 15:01 Hrs onwards

Date and Time for opening of Priced Bids (Part-II)

Will be intimated to those Bidders only whose bids are found technically suitable by NFL

List of Documents Annexure-A Special Instructions to Tenderers Annexure-B General Terms and Conditions of Notice

Inviting Tender Annexure-C Detailed Specifications of Indented Item

Annexure-I Eligibility Criteria Annexure-II Technical Specifications Annexure-D Online Techno-Commercial Template to

be completed/filled in by Tenderers Annexure-E Price Bid Format for Indian Bidders

(Supply) Annexure-F Price Bid Format for Overseas Bidders

(Supply) Annexure-G Price Bid Format for Indian Bidders

(Service) Annexure-H Price Bid Format for Overseas Bidders

(Service) Annexure-J Loading Criteria Annexure-K Integrity Pact Annexure-L BG Format for EMD

Annexure-M BG Format for SD-cum-PBG

(* If not concluded, shall be continued on 24.11.2017) For further details, visit our E-Portal Site https://nfl.etenders.in. Tender Particulars are also available on website https://eprocure.gov.in. Any future amendment/modification to the NIT will be displayed only on our E-Tender Portal https://nfl.etenders.in. Bidders are requested to visit our E-Tender Portal regularly in their own interest to check for any amendment/modification to the NIT.

Dy. General Manager – Materials

iathd̀r dk;kZy;% Ldksi dkWEiysDl] dksj 3] 7] baLVhV~;q’kuy ,fj;k] yks/kh jksM ubZ fnYyh & 110003] nwjHkk"k% 24360066] QSDl% 24361553 Regd. Office: Scope Complex, Core-III, 7, Institutional Area, Lodhi Road, New Delhi 110003 • Tel: 24360066 • Fax: 24361553

National Fertilizers Limited (A Government of India Undertaking)

Vijaipur – 473 111, Dist: Guna (MP), India (An ISO 9001, 14001 & OHSAS 18001 Unit)

CIN No. L74899DL1974GOI007417

Annexure-A E-Tender ID - 1990

NIT No. NFV/PUR/BIU160645-V Dated: 16-11-2017

SPECIAL INSTRUCTIONS TO TENDERERS 1.00 Mode of Tendering:

The Vijaipur Unit of National Fertilizers Limited has decided to do the procurement of ‘DCS & ESD Systems for Ammonia-II & Urea-II Plants’ through e-tendering process under Two Part Bid system.

2.00 In the E-Tendering process, Offers are required to be submitted electronically in place of offers in ‘Hard Copy under Sealed Envelope’ as is being done conventionally. Tender Submission, Tender Closing and Opening activities will be done electronically and online.

3.00 The NIT will be posted on our E-Tender Portal https://nfl.etenders.in from where our registered vendors will be able to download the tender documents free of cost for participation in the tender and submit their bids online.

4.00 Interested Vendors (viz. our Registered Vendors) shall visit the URL i.e. https://nfl.etenders.in

for downloading of tender documents, bid preparation, hash submission, bid submission etc. The Tenders shall be duly digitally signed and encrypted by the Tenderers using their Digital Signature Certificate.

5.00 No oral, email, telephonic, telegraphic tenders or tenders submitted in hard copies/physical form will be entertained.

6.00 Digital Certificate As per IT Act 2000, it is mandatory for the tenderer to have a valid Class II and above Digital Signature Certificate (Organization) with Encryption facility issued by any of the valid Certifying Authority approved by Government of India for participation in e-Tendering event at the time of submission of offer. The cost of Digital Signature Certificate will be borne by the respective tenderer.

Digital Signature Certificate (Class II or Class III Organizational) are being issued by many Govt. approved (CCA of India) agencies as per IT Act 2000. For your convenience, we have made arrangements to get the Digital Signature Certificates from M/s. NexTenders (India) Private Limited, who have been appointed by NFL as Service Provider for its e-procurement solutions, on payment of necessary fees.

List of E-Tokens supported on our E-Procurement Portal https://nfl.etenders.in is as under:- (A Tab titled as “Test Certificate” is available on the home page of our E-Tender Portal. Tenderers can check whether the E-Tokens they are going to use on our portal is acceptable or not by clicking on this Menu)

S.No. Manufacturers of E-Tokens Token Name 1 Feitian Technologies Co.Ltd ePass2003 2 eToken Aladdin E-Token 3 Giesecke & Devrient GmbH Giesecke & Devrient GmbH (Moser Baer) 4 Digipass Key Vasco 5 Rainbow Technologies Inc., Safenet iKey 2032 6 Feitian Technologies Co. Ltd Auto ePass 2003 7 WD Proxkey Grey/SPC Token WD Proxkey Grey/SPC Token 8 Trustkey (TKC) Trustkey (TKC) 9 Bit4id – Universal MW Bit4id – Universal MW

7.00 The entire responsibility of protecting their own Login ID and the Password and keeping their Digital Signature Certificates safe so that it is not misused by any other person rest with the Tenderers only.

8.00 All the vendors participating in the online e-procurement have to abide by the process involved in the entire workflow of the e-procurement.

9.00 System requirements to participate in the e-Tendering are as under:-

i. Computer with minimum i3 Processor or equivalent, having 1 GB RAM and 80 GB HDD Capacity (Minimum)

ii. Operating System required:- - Window 7 Ultimate / Professional / Enterprises / Ultimate - Window XP (Service Pack 3 and Above)

iii. Internet Speed of 512 kbps or above iv. Browsers: Preferred Browsers Mozilla Firefox/Google Chrome/Opera with latest

updates v. Adobe Acrobat Profession 6 or above for digitally signing the Document

vi. Java 7 Update 67 (Updated 32 bit Java version) & newer versions vii. Java Settings

i. Download and Install Java 7 Update 67 available under ‘System Requirement’ Tab on the home page of https://nfl.etenders.in

ii. After installation, open Control Panel and Click on Java Icon iii. Click ‘Security’ Tap on the Java Configuration Panel and bring the Security

Level to Medium. Click on Edit Site List Tab and add the URL name https://nfl.etenders.in and click ‘Add’ Tab and ‘Ok’ Tab

iv. Open the Java Control Panel and Click the tab ‘Advanced’ v. Select ‘Show Console’ under Java Console vi. Select ‘Always Allow’ under JNLP File/MIME Association vii. Select ‘Disable Verification (Not recommended)’ under Mixed Code

(Sandboxed vs. Trusted) Security Verification Once the above pre−requisites are configured/available in the system, users can click on https://nfl.etenders.in and the eProcurement portal will be available

viii. Download and Install Digital Certificate setup (NxtCryptoSetup.msi) available under System Requirement link of home page https://nfl.etenders.in using Administrator user access. Note:- Please refer Bidders’ Manual which is available on the home page https://nfl.etenders.in for system requirement, browser configuration, procedures etc.

10.00 For queries regarding e-tendering process, you may contact our Service Provider M/s. NexTenders (India) Private Limited, Mumbai or NFL. Contact details are as under:

i. National Fertilizers Limited (For Tender details)

i. Name: Shri V. K. Meena, Dy. Manager – Materials Contact No.: 07544-273528/29 Ext. No. 2307, 273050, Email: vkmeena@nfl.co.in

ii. Name: Shri K. Suresh, Senior Manager – Materials Contact No.: 094172 19992, Email: ksuresh@nfl.co.in

ii. M/s. NexTenders (India) Private Limited, Mumbai (For e-Tender

Process/ Procedure related matters)

Technical Support Contact (For Vendors): Name: Mr. Prateek Parashar, Email: prateek.parashar@nextenders.com Contact No: 098110 38892 Support Team: Desk No. 2, Email: support.nfl@nextenders.com

Contact Nos. 091672 46751 / Landline No. 020 – 30187500 Support Timings: 9.00 AM to 8.00 PM (Mon to Fri), 9.00 AM to 6 PM (Sat) For Digital Certificate Support: Name: Mr. Shailesh Vakil, Phone No. 022 – 2661 1117 Mobile No.: 098202 93499, Fax No. 022 – 2661 1285

11.00 Tenderers are requested to scrutinize the terms and condition of this tender thoroughly along

with the General Terms and condition etc. as given in tender documents before proceeding for preparation of Online Bid.

12.00 No amendment to the tender would be admissible under any circumstances, whatsoever after the closing date and time of receipt of tenders.

13.00 NFL shall not be held responsible for any mistake made by the vendor at the time of bidding process. In case any Vendor submits any invalid bid due to any reason whatsoever including typing mistake/human error, such invalid bid will be disqualified and such vendor shall not be allowed to further participate in that tender. The remaining process shall be completed considering the other valid bids.

14.00 For submitting price bid through e-Auction, the successful Pre-qualified tenderers will have to

use a Class II or Class III Digital Signature Certificate issued by any India CA approved by CCA of India as per IT Act 2000. The same can also be taken through NFL’s service provider i.e. M/s. NexTenders (India) Private Limited on payment of necessary fees.

15.00 It is mandatory for the vendors to use the digital certificate in all their bidding Process. 16.00 Tender Schedule:

The notice of issue of enquiry and detailed schedule for downloading the NIT documents, submission of bids, tender closing, tender opening, and subsequent clarification/ amendment in schedule etc. shall be communicated to registered vendors separately by emails/fax message. The same is also available on the above mentioned website against this tender.

Tender Schedule is as under:-

(* If not concluded, shall be continued on 24.11.2017) Note: After expiry of date & time for a particular activity as mentioned above, that particular activity cannot be done unless the schedule for the same is extended/amended. Similarly no activity can be done before start date & time specified for that particular activity unless the schedule for the same is preponed/amended

17.00 The activity defined for vendors are Download of Tender document, Bids Preparation and Hash Submission, Re-encryption of Online bid, uploading of bids.

18.00 During the Download sequence, the vendors who have been invited will be able to download

the main tender document and the supporting documents.

19.00 During the Bid Preparation and Hash Submission Stage, the bidders who have downloaded the tender document during the previous sequence will be preparing their bids and

S.No. Tender Stage Date and Time 1 Start Date and Time for downloading

of Tender Documents 16-11-2017, 12:30 Hrs

2 Pre-Bid Meeting 23-11-2017* 10:00 Hrs 3 End Date and Time for downloading of

Tender Documents 05-12-2017, 15:00 Hrs

4 Last Date and Time for submission of E-Bids

05-12-2017, 15:00 Hrs

5 Start Date and Time for opening of Part-I Tender (i.e. Un-priced Bids)

05-12-2017, 15:01 Hrs onwards

6 Date and Time for opening of Priced Bids (Part-II)

Will be intimated to those Bidders only whose bids are found technically suitable by NFL

submitting their bid signed hashed online. Additionally, hashes will be generated for each single document (files) that is committed to be part of the bid. The bids will be prepared and hashes will be generated and signed envelope-wise. The signatures will be done digitally using DCs.

20.00 During Re-encryption of Online Bid sequence the bidders will re-encrypt their bid data and

upload the documents for which hashes have been generated and submitted during the bid preparation and hash submission stage. The bids will be re-encrypted with the public key of the proprietary key pair that has been assigned to this tender.

21.00 Tender Opening:

The tenders will be opened electronically by NFL from Vijaipur Office in the presence of representatives of Vendors who wish to attend the price bid opening. The submission of bids may however be done by vendors from their office or from place of their choice or they can visit our Vijaipur Office and use NFL’s facilities for preparation and submission of their bids. However bids cannot be submitted after the bid submission due date & time as per the schedule. Price bid of all the vendors who are techno-commercially acceptable shall be opened electronically.

22.00 The quantity indicated in Annexure-C is our estimated requirement which may vary at the

time of ordering at the sole discretion of NFL. 23.00 The contract shall be finalized on ‘total delivered cost’ basis

24.00 NFL reserves the right to negotiate with the lowest bidder at its sole option. In such case, the negotiations shall be held with the lowest bidder only at NFL Vijaipur and prior intimation shall be given by NFL to such bidder.

25.00 NFL reserves the right to reject or accept any tender without giving any reason.

26.00 System failures and remedial measures thereof/course of action to be followed: NFL shall make all out efforts to rectify the problem(s) leading to system failure during the live tendering. However in case the system could not be restored within the reasonable time period as deemed fit by NFL, the following remedial measures shall be taken under such an eventuality:

1 Tender is prepared and released but vendors are not able to submit their bids.

The due date of closing/opening shall be extended suitably.

2 Bids have been submitted but the same cannot be opened by NFL.

The due date of opening shall be extended suitably.

27.00 Name & Address of the Consignee/Unit: Senior Manager (Materials) Stores

National Fertilizers Limited Vijaipur-473 111 Dist: Guna (MP)

28.00 GST of Vijaipur Unit

Taxpayer’s Trade Name: National Fertilizers Limited, Vijaipur, Guna Taxpayer’s Legal Name: National Fertilizers Limited Provisional ID Number: 23AAACN0189N2ZB

****

National Fertilizers Limited (A Government of India Undertaking)

Vijaipur – 473 111, Dist: Guna (MP), India (An ISO 9001, 14001 & OHSAS 18001 Unit)

CIN No. L74899DL1974GOI007417

Annexure-B E-Tender ID - 1990

NIT No. NFV/PUR/BIU160645-V Dated: 16-11-2017

General Terms and Conditions of Notice Inviting Tender

1.00 Detailed Specifications of ‘DCS & ESD Systems’ required by us are given in Annexure-C.

2.00 Rates are to be quoted on FCA, – International Airport, Country concerned basis by Overseas Bidders and on FOR – Destination basis by Indian Bidders indicating break-up of various components as per enclosed Price Bid proforma.

3.00 Price Firmness The quoted rates shall remain firm during the validity period of Purchase Order except for variation in statutory levies. The increase in statutory levies if any shall be borne by NFL provided the supplies are as per schedule. However in case of decrease in statutory levies if any, the payment shall be made on actual basis.

4.00 Tender Submission

4.01 The tenders will be submitted electronically on our E-Tender Portal https://nfl.etenders.in. No Oral, Email, Telephonic, Telegraphic tenders or Tenders submitted in hardcopies/ physical form will be entertained.

4.02 Tenders should be submitted online duly digitally signed and encrypted by the Tenderers using their Digital Signature Certificate.

4.03 Bidders are expected to examine all the instructions, forms, terms and conditions in the bidding documents. the invitation to bid together with all its attachments thereto shall be considered to be read, understood and accepted by the Bidders, unless deviations are specifically stated in the seriatim by the bidders. Failure to furnish all information required by the bidding documents or submission of a bid not substantially responsive to the bidding documents in every respect will be at bidder’s risk and may result in the rejection of the bid.

4.04 No amendment to the tender would be admissible under any circumstances, whatsoever after closing date and time of submission of tenders.

4.05 The tenderers must submit/upload online, one set of the tender documents duly digitally signed by using digital certificates in token of acceptance of all the tender conditions along with their techno-commercial bid failing which their tender may not be considered.

4.06 Overseas Bidders please note that in case they intend to submit the offer through

their Indian Agent (if any) or allow their Indian Agent to submit the offer on behalf of them in terms of INR, such offers must be accompanied by a valid Authorization Certificate issued by them. Offers received from your Indian Agent/s without proper authorization shall not be considered for acceptance/placement of orders.

4.07 Complete specifications of the Stores offered together with manufacturer’s name

brand, etc. of each of the item must be indicated in the Technical Bid and descriptive literature and samples (wherever necessary or required) should be sent separately by post immediately after uploading the tender documents.

5.00 NFL will have the right to issue addendum to tender documents to clarify, amend, modify, supplement or delete any of the conditions, clauses or items stated. Addendum so issued will form part of original invitation to tender.

6.00 Wherever the bidder is silent about the acceptance of NIT conditions such as Bank

Guarantee, Guaranty period, Liquidated Damages etc., it shall be presumed that the bidder has accepted NIT conditions and no further correspondence seeking specific confirmation about acceptance of these conditions shall be made.

7.00 In case of non-compliance of Commercial Terms & Conditions of NIT, loading criteria as per

Annexure-J shall be applicable.

8.00 Compensation for submission of Tenders: Tenderers shall not be entitled to claim any cost, charges, or incidentals for/or in connection with the preparation of and submission of their tenders, though NFL may withdraw invitation to tenders, or reject any, or all tenders without assigning any reason thereof.

9.00 Clarification of bidding documents

A prospective Bidder requiring any clarification on procedure, tender specifications etc. (both technical and commercial) can be had from NFL, Vijiapur (S/Shri K. Suresh, Senior Manager – Materials / V. K. Meena, Dy. Mgr (Mtls.) Phone Nos. 07544-273691 / 07544-273528/29 Ext. No. 2307, 273050) in writing by e-mail/fax so as to ensure submission of bid on or before the bid closing date.

10.00 Language of Bid The bid prepared by the Bidder and all correspondence/drawings and documents relating to the bid exchanged between the Bidder and the Owner shall be written in English language, provided that any printed literature furnished by the Bidder may be written in another language so long as accompanied by English translation in which case, for purpose of interpretation of the bid, the English translation shall govern.

11.00 Change in Tender Schedule:

NFL reserves the right to change/amend the tender schedule (date and/or time) and shall intimate all the tenderers well in time by email/fax/telephonically, of such changes along with notice of revised schedule. However, it shall be the responsibility of the vendor to visit the designated website regularly as per the time schedule to get the details of any such changes, as the same shall be available against this tender on the said website. NFL shall not be responsible if a vendor is not able to participate in any activity related to this tender due to change in tender schedule.

12.00 Acceptance/Rejection of Bids:

Notwithstanding anything to the contrary contained herein, NFL reserves the right to accept or reject, at its sole discretion, any Bid/all bids in whole or in part and/or accept other than the lowest bid without assigning any reasons thereof and to annul the bidding process at any time prior to award of Purchase Order without thereby incurring any liability to the affected bidder or bidders or of any obligation to inform the affected bidder or bidders of the grounds for NFL’s rejection. No correspondence will be entertained with regard to acceptance or rejection of an offer. NFL is also not bound to disclose the reasons for rejection of the offer to the tenderers.

13.00 Right to vary/split the order

NFL shall have the right to vary the quantities, split and place the order on more than one supplier wherever considered necessary without any liability of any kind whatsoever.

14.00 MSMED Declaration (For Indian Bidders only):

In case you are registered as MICRO, SMALL Enterprise (MSEs) under ‘The Micro, Small & Medium Enterprises Development Act, 2006 (MSMED Act)’ promulgated by Government of India vide Notification dated 16/06/2006, please indicate the relevant category of registration in your Offer and also enclose a copy of the valid certificate issued by the concerned

authorities as specified by the Ministry of MSME. The Micro & Small Enterprises (MSEs) shall be entitled for the benefits under the Public Procurement Policy for Micro & Small Enterprises subject to the terms and conditions indicated in Attachment attached herewith. It shall also be confirmed by the Bidders if the MSEs owned by SC/ST Entrepreneurs and in that case submit a copy of documentary proof issued by concerned authorities.

In case no information is given by you, it will be presumed that you are not covered by the MSMED Act and consequently not eligible to the benefits admissible under the Act.

15.00 Earnest Money Deposit: Rs. 1,00,000.00 (Rupees One Lakh only) 15.01 Tenderers must submit Earnest money deposit of Rs. 1,00,000/- (Rupees One Lakh

only) or equivalent amount in USD (as per prevailing exchange rate at the time of submission of bid). EMD will be submitted by way of:-

i) E-Transfer in NFL’s Bank A/c No. through RTGS/NEFT. NFL’s Bank A/c Details are as under:-

a. NFL's Account No. 1 0 3 4 6 6 7 3 3 1 1 b. Name of Bank: State Bank of India c. Branch Name: Bavrikhera (NFL Complex) d. Branch Code: 08455 e. IFS Code: SBIN 000 8455

or ii) Crossed Demand Draft favouring National Fertilizers Ltd. issued by any

Nationalized/Scheduled Bank payable at State Bank of India, Bavrikhera Branch (Code: 8455), NFL Complex, Vijiapur-473111, Dist. Guna (MP) (Details of DD No. & date, amount, bankers name etc. has to be submitted in relevant field/column of online module).

or iii) Bank Guarantee from any Scheduled/Nationalized Bank (except Rural/Co-

Operative Banks) as per our prescribed format (see Annexure-L). The Bank Guarantee should be valid for a period of 120 days from Tender Opening Date and you will give an undertaking for extension of the Bank Guarantee in case the same is desired by NFL (Details of BG No. &date, amount, bankers name etc. has to be submitted in relevant field/column of online module).

iv) Cheques shall not be accepted in any case.

15.02 Tenders without Earnest Money Deposit are liable to be rejected. In case of

submission of EMD by DD or Bank Guarantee, it should be ensured by the vendor that the original DD/Bank Guarantee is received by NFL before opening time of Techno-Commercial Bids for verification of the details of DD/Bank Guarantee given online by the vendors. There is no exemption to any category of tenderers from submission of Earnest Money.

15.03 Earnest money shall be forfeited at the sole discretion of NFL in case tenderer after

intimation from NFL of the acceptance of his tender, either wholly or in part, refuses to accept the Purchase Order/or changes any of the conditions of the tender or changes the price and/or terms and conditions of the tender within validity period.

15.04 Earnest Money of the successful tenderers shall be returned on submission of security deposit.

15.05 Earnest Money Deposited by unsuccessful tenderers shall be returned as early as possible.

15.06 No interest will be paid on the Earnest Money Deposit. 16.00 Security Deposit cum Performance Bank Guarantee: (10% of PO Value)

16.01 Successful Tenderer, for the faithful and proper fulfillment of the contract, shall have to furnish Security Deposit cum Performance Bank Guarantee (SD-cum-PBG) equivalent to 10% of Order Value within 30 days of receipt of Purchase Order. Security Deposit shall be furnished in the form of:-

a. E-Transfer in NFL’s Bank A/c No. mentioned in Clause 15.00 above OR

b. By way of a Bank Guarantee from any Nationalized/Scheduled Bank (except Rural and Co-operative Banks) in the format prescribed by NFL (see Annexure-M). The Bank Guarantee should be valid for the period covering the Delivery Period + Warranty Period plus a claim period of 3 months.

16.02 Security Deposit shall be retained by NFL during the currency of contract or till

settlement of all the accounts thereof, whichever is later. In case of any dispute or difference not settled within the validity of Bank Guarantee, Tenderer shall arrange to get the bank Guarantee extended as asked. NFL shall have the sole discretion to 'Call in' the Bank to pay the whole or part of the amount of Bank Guarantee.

16.03 The above deposit shall be deemed to be security for the faithful performance of the

contract and for the purpose of Section 74 of the Indian Contract Act, 1872 and for the extension of that section. The contract shall be deemed to be bond given by the tenderer for the performance of an essential duty.

16.04 In the event of breach of any of the terms and conditions of the contract, NFL shall have the right to draw from the Bank Guarantee/Security Deposit either the whole or part of value of Bank Guarantee or Deposit and tenderer shall make good the value of Bank Guarantee/Deposit to the extent of the amount so drawn within 15 days of receipt of intimation from NFL to this effect.

16.05 The amount so drawn shall not in any way effect any remedy to which NFL may otherwise be entitled or any liability incurred by tenderer under the contract or any law for the time being in force relating thereto or bearing hereupon.

16.06 In the event of forfeiture of whole or part of the Security Deposit, the tenderer shall deposit further sum/sums so as to maintain the full security amount deposit as per Clause 21.01 above

16.07 The Security Deposit shall be refunded after contract has been successfully completed and certificate to that effect has been issued by NFL. It shall be lawful for NFL, if any difference or dispute is likely to exist, to defer the release of Security Deposit or any portion thereof, which may be due for release until such difference and dispute had been finally settled or adjusted.

16.08 The Security Deposit amount shall not carry any interest.

17.00 Price Submission: 17.01 Overseas Bidders:

Overseas bidders shall quote the prices on FCA ___ International Airport of the country concerned basis as per INCOTERMS 2010® (Please indicate the name of Airport/) as per enclosed Price Bid format (Annexure-VI). The FCA, International Airport price basis shall be inclusive of all costs up to the point of Aircraft and the consignment shall be handed over to our Consolidation-cum-Freight Forwarding Agent located in the country of participating bidder after clearance of all formalities related to export of goods and all charges paid up to Aircraft which shall be to Seller’s account. Name and other details of our Consolidation-cum-Forwarding Agent shall be intimated at the time of placement of Purchase Order and their House Air Way Bill/Bill of Lading will only be acceptable in the event of placement of Order.

17.02 Indian Agency Commission:

Percentage of Agency Commission, if any, included in quoted prices and payable to your Indian Agents in Indian Currency must be clearly indicated. Agency Commission, if applicable, will be paid after satisfactory receipt and inspection of material at our site. The Name and Address of your Indian Agent should be given in the quotation.

17.03 NFL shall be responsible for the arrangement of Transit Insurance from the Port of Export to its Warehouse under NFL’ Open Marine Policy/NFL’s Open Policy. The rates quoted on FCA basis shall be exclusive of transit insurance.

17.04 For Indian Bidders:

i. Indian bidder quoting on behalf of their Overseas Principals shall quote the rates on FOR – NFL Stores, Vijaipur basis giving the break-up of prices as per the enclosed Price Bid Format for Indian Bidders (Annexure-V).

ii. If for any reason, prices tendered are for delivery FOR - Forwarding Station, the freight charges together with the gross weight of the material should be clearly mentioned in the quotation. In case the rates quoted are Ex-Godown/ Ex-Factory, the packing and forwarding charges should either be included in price or stated separately in definite terms (if applicable).

NFL, shall, however, reserve the right to enter into a contract either on Ex-Works, F.O.R. Despatch Station or F.O.R. Destination basis at its sole discretion.

17.05 GST: In case IGST/CGST/SGST chargeable extra and to be paid by NFL should be clearly in the Price Bid. The above taxes shall be reimbursed against submission of documentary evidence. Rates prevailing on the date of submission of Tenders shall be specified by Tenderers. In case any Tax/Duty is not clearly specified in the Price Bid, then it will be presumed that no such Tax/Levy is applicable or payable by NFL

Tenders shall also mention their GST Registration Number and the HSN Code of offered items invariably in their Quotation

17.06 Packing and Forwarding Charges:

P&F Charges should either be included in the quoted price or stated separately in definite terms (if applicable).

17.07 The rates should be exclusive of transit insurance from Despatch Station to our warehouse. The goods shall be covered under NFL’s Open Marine Policy/NFL Open policy

17.08 Tenderers must mention their GST Identification Number/PAN allotted by statutory

authorities in the Technical Bid positively. Tenderers must invariably mention the HSN Code of the offered item

17.09 Quoted rate(s) on FCA, International Airport (Overseas Vendors) and Ex-works/FOR

prices (Indian Vendors) should remain firm till complete execution of the order. Vendors should confirm the same in their offers.

17.10 The tenderer shall quote the price strictly as per the Proforma enclosed for schedule

of prices. Parties should quote one rate for specific quantity quoted by them. Tenders with quotation of different rate for different quantities shall be rejected without any further reference

18.00 Conversion to Single Currency

To facilitate evaluation and comparison, NFL will convert all bid prices expressed in the amounts in various currencies in which bid price is payable, to Indian Rupees based on the exchange rate for TT Selling prevailing on the date of price bid opening as notified by any Indian Nationalized/Scheduled Bank / published in reputed / largely circulated Newspapers such as Economic times (India)/Financial Express (India) etc. However, evaluation may be rechecked with such exchange rate as on the date of decision on vendor selection.

19.00 No enhancement of rates will be allowed once the quotation is submitted/accepted and the

order is placed. Withdrawal of the quotation after its acceptance will entail forfeiture of earnest money, if any, and/or risk purchase without prejudice to our rights of legal remedies.

20.00 No escalation will be allowed due to any increase in duties/levies in case of extension sought

by the parties beyond stipulated delivery period.

21.00 Payment Terms & Mode:

21.01 NFL will not make any advance/progressive payments. Offers with advance payment terms are liable to be ignored / will be loaded suitably.

21.02 For Overseas Bidders: Our Standard Terms of Payment for Overseas Bidders are as under: (a) Supply Portion: “70% of supply portion through Irrevocable Letter of Credit.” The LC will be established through our Bankers – Bank of India, Large Corporate Branch, Parliament Street, New Delhi. (b) Installation/Erection & Commissioning: 100% payment including taxes towards Installation & Commissioning along with balance payment of supply potion (i.e. 30%) within 30 days after successful installation & commissioning of supplied material at our site through Wire Transfer.

21.03 Please note that Seller’s Banker’s charges including confirmation charges of Letter of Credit shall have to be borne by the Seller. However, Bank Charges in India shall be borne by NFL. Also in case of an Order, if validity of Letter of Credit is required to be got extended/amended for reasons for which NFL is not responsible then the Bank Commission for such extensions/amendments of Letter of Credit shall be borne by the Seller

21.04 For Indian Bidders Our Standard Terms of Payment for Indian bidders are as under: (a) Supply Portion: “70% of Purchase Order value towards supply portion plus 100% taxes towards supply portion within 30 days after Receipt & Acceptance of material at our site through RTGS.”. (b) Installation/Erection & Commissioning: 100% payment including taxes towards Installation & Commissioning along with balance payment of supply potion (i.e. 30%) within 30 days after successful installation & commissioning of supplied material at our site through RTGS. Our Bankers: State Bank of India, Bavrikhera Branch (Code: 8455), NFL

Complex, Vijaipur – 473111, Dist: Guna (MP)

22.00 Validity of Tenders: The tenders must be valid for acceptance for 120 days from the tender opening date.

23.00 Final Acceptance & Warranty:

Client shall take over the system from BIDDER after final acceptance test. The integrated system shall run uninterruptedly for four weeks from date of commissioning of the whole plant. Any loss of time due to reasons like power failures, forced shutdowns etc. which are due to no fault of the BIDDER shall also be counted as run time. However, if any major software/hardware failure of the system occurs due to which the system or a part thereof has to be shut-down the test shall be conducted afresh on the whole system. The warranty period shall be 12 months from final acceptance of the system. During warranty period BIDDER shall make good all failed components of any part of the system and depute his service engineer to site if required free of cost. Warranty Certificate shall be submitted along with despatch documents. Tenderers shall confirm the same in their quotations.

24.00 Delivery Period Bidders shall indicate the shortest and firm delivery period for the supply of material from the date of issue of Purchase Order

Tenderers may note that in case of delayed delivery beyond the stipulated delivery even though normal extension of completion time is allowed by NFL, all extra costs on account of changes of statutory regulations/Acts, or increase in price on any other account including price, if any, shall not apply to the Purchase Order Price and shall be borne by the Supplier.

25.00 Liquidated Damages Charges/Penalty for Late Delivery:

It shall be obligatory on the part of suppliers to adhere strictly to the deliveries quoted and accepted by us in our orders. In case of delay in supplies, unless extension of delivery has been granted by us on application by the suppliers, we may at our option either:

(i) recover liquidated damages from supplier at a sum equal to ½% per week or part thereof of the value of stores not delivered subject to a maximum of 5% of the value of the order, or

(ii) purchase elsewhere on account and at the risk and cost of the suppliers the stores not delivered or

(iii) cancel the contract without prejudice to our rights under (i) & (ii) above. 26.00 Tenderers shall confirm that they will supply the material securely packed in a good transport

worthy packing so as to avoid damage to the material during transit and storage. 27.00 Destination for booking:

For Foreign Vendors: a. By Air - IGI Airport, New Delhi, India b. By Sea - Mumbai/Nhava Sheva/JNPT Seaports, Mumbai, India

For Indian Vendors: a. By Road: - DOOR DELIVERY AT NFL VIJAIPUR SITE b. Consignee: - SR. MANAGER - MATERIALS (STORES)

NATIONAL FERTILIZERS LIMITED, VIJAIPUR DIST. GUNA (MP), PIN: 473111 28.00 Inspection of Material

The material will be inspected at NFL Stores, Vijaipur only after receipt and its report shall be final and binding.

29.00 Acceptance/Rejection of Material: Subsequent to an order being placed against your Quotation, received in response to this Enquiry, if it is found that the material supplied are not of the right quality or not in accordance with our specifications (required by us) or received in damaged conditions, not satisfactory owing to any reason of which we (NFL) shall be the sole judge, we shall be entitled to reject the material, cancel the contract and buy our requirement from open market/other sources and recover the loss, if any, from the supplier reserving to ourselves the right to forfeit the security deposit, furnished by the Supplier against the contract. The supplier will make his own arrangements to remove the rejected material within a fortnight of instruction to do so. Thereafter, material will lie entirely at the supplier’s risk and responsibility and storage charges, along with any other charges as applicable, will be recoverable from the supplier.

30.00 For Foreign Vendors

30.01 Goods received short or in damaged condition will have to be replaced by the Supplier FREE OF COST with Custom Duty, Freight & Insurance Charges to the Supplier's account, if such shortages or damages are not due to peril in transit.

30.02 In case of an Order, Vendors will have to furnish following dispatch documents: (a) Signed Invoice

(b) Air Way Bill/ Bill of Lading (c) Packing List (d) Certificate of Origin [Please specify Country of Origin in your quotation]

(e) Test/Conformity/Interchangeability Certificate (f) Guarantee Certificate (g) Prior Fax/Cable Advice to Insurance Company giving details of shipment (h) Phytosanitary Certificate

30.03 In case the quantities of material shipped are not found as per Invoice, the Custom

Duty and other Charges in case of foreign bidders, if any, payable by NFL on the short supplied items will have to be reimbursed by you to NFL

30.04 Requirement of Phytosanitary Certificate: i) As per the orders of Government of India, no article packed with raw/solid wood packaging material shall be allowed to be imported in India unless the wood packing material has been properly treated and marked as per ISPM-15 or is accompanied by a Phytosanitary Certificate with the treatment endorsed.

ii) The treatment of raw/solid wood packing material prior to export shall include either Methyl Bromide (MB) @48 g/m3 for 16 hours at 21oC and above or any equivalent thereof or heat treatment (HT) of 56oC for 30 min. (core temperature of wood) or Kiln Drying (KD) or Chemical Pressure Impregnation (CPI) or any other treatment provided that these meet the HT specifications of the ISPM-15.

iii) Any article, if found packed with raw/solid wood packaging material without specified treatment and without marking as per ISPM-15 or if not accompanied by phytosanitary certificate with treatment endorsed, as the case may be, shall be considered untreated and import of material shall not be allowed and such material shall be released by the Custom Authorities only after ensuring that wood packaging material has been properly treated at the point of entry under the supervision of Plant Quarantine Officer which shall result in extra cost and delay in clearance of material resulting in levy of penalties/wharfage etc. All such extra cost/penalties/wharf-age shall be recoverable from the supplier. iv) Provided that above conditions shall not be applicable to wood packaging material wholly made of processed wood products such as plywood, particle board, oriental strand board or veneer that have been created using glue, heat and pressure or combination thereof. Also the above conditions shall not be applicable to wood packaging material such as veneer peeler cores, saw dust, wood wool and shavings and thin wood pieces (less than 6 mm thickness), unless they are found to be harbouring any regulated pests specified.

31.00 Clear understanding:

When a tenderer submits his tender in response to this tender document, he will be deemed to have understood fully about requirements terms and conditions. No claim from tenderer shall be entertained whatsoever on the plea that the tenderer did not have a clear idea on any particular point and/or a clause of the tender.

32.00 One person will be allowed to represent only one company during discussions/ negotiations

with NFL. If same person is representing different companies with authorisation letter from more than one company, such person will be allowed to represent only the first company called for negotiations.

33.00 The prospective tenderers having any common partners/Directors/Managing partners, etc. or

having any other common criteria shall be considered as Sister/Group/Associate Company. In such cases, only one of them will be eligible for participating in the tender.

Tenderers have to submit a declaration along with the Technical Bid declaring:-

(a) That no other Firm/Sister Concern/Associate belonging to the same group is participating/submitting offer against this tender.

(b) That the bidders, their associates, sister concerns etc. have not been blacklisted by any Institutional Agency/Government Department/Public Sector Undertakings in the last two years.

In case of concealment of any fact, if detected later on, such tenderer will be debarred from all future dealings with NFL.

34.00 It shall be certified by the tenderer that none of the NFL employee is related to

owners/directors. (In case any relative is working in NFL, furnish details separately).

35.00 It shall be certified by the tenderer that none of NFL’s ex-employee is employed with them. (In case any ex-employee of NFL is employed, furnish details separately).

36.00 It shall be certified by the tenderer that none of blood relation of the owners/directors is participating in this tender in the name of other firm.

37.00 Should a tenderer or contractor have a relation/s or in case of a firm or Company of contractor’s one or more of its shareholders or relations of shareholders employed in the N.F.L., the tenderer must disclose the names of such relation/s while submitting his offer, failing which, N.F.L. may at its sole discretion reject the tender or rescind the contract.

38.00 Debarment of Tenderers

If a tenderer resorts to any frivolous, malicious or baseless complaints/allegations with an intent to hamper or delay the tendering process or resorts to canvassing/rigging/influencing the tendering process, NFL reserves the right to debar such tenderer from participation in the present/future tenders up to a period of two (2) years.

39.00 Award of Contract:

Award of contract will be made at the sole and absolute discretion of National Fertilizers Limited, which shall not be disputed. Purchase Order issued on the basis of this tender will be called ‘CONTRACT’. The terms and conditions as embodies in the Purchase Order shall be final and shall supersede any other terms and conditions that might have been indicated in the Tender submitted by the Tenderers.

40.00 The tenderer shall comply with all statutory requirements and laws in performing the

contract. The responsibility for action/safety or his employees while performing the contract by the tenderer shall be solely his.

41.00 The supplier shall indemnify and legally protect NFL and/or its employees against all claims,

actions, proceedings, demands, costs, expenses, causes of action or suits arising out of incidental to and/or consequent upon the services provided by the seller under the contract or due to the failure of the seller in performance of his/its obligations under the contract. If the NFL is called upon to make any payments as aforesaid due to any act or omission or failing of the seller, NFL shall be entitled to recover the said amount from any security or other guarantee available with the NFL under the contract.

42.00 The seller shall comply with all Central/State Laws as well as the rules, regulations, by-laws

as may be in force, from time to time. Any failure on their count on the part of the seller and the consequence thereof shall be solely on account of the seller. Liability, if any, under this head shall be solely borne and paid for by the seller.

43.00 Laws Governing Purchsase Order

The purchase order shall be governed by the Laws of Union of India for the time being in force.

44.00 Secrecy Any information delivered or otherwise communicated by NFL to supplier in connection with the contract shall be regarded as secret and confidential and shall not without the written consent of NFL be published or disclosed to any third party or made use of by the supplier except for the purpose of implementing the contract.

45.00 Subletting of Contract: The successful tenderer shall not sublet or assign the contract or any part of it without obtaining the written permission of NFL in advance. In the event of the successful tenderer subletting or assigning the contract or any part thereof without such permission, NFL shall be entitled to cancel the contract and to purchase the goods elsewhere and successful tenderer shall be liable to the National Fertilizers Ltd for any loss or damage which NFL may sustain in consequence or arising out of such purchases. Even in case subletting is permitted, NFL shall

not recognize any contractual obligation with the person or party to whom subletting is permitted and shall look to the successful tenderer for satisfactory and due and proper fulfillment of the contract.

46.00 Force Majeure:

Neither party shall be liable for any claim on account of any loss, damage or compensation whatsoever arising out of any failure to carry out the terms of this contract where such failure is caused due to war, rebellion, mutiny, civil commutation, fire, riot, earthquake, draught, floods, crop failure, strike, major break down of the plant or Acts of God or due to any restraint or regulation of the State or Central Government or a Local Authority/ies, provided a notice of such occurrence is given to the other party in writing within 10 days from the date of occurrence of the force majeure condition furnishing therewith-documentary evidence supporting the working of force majeure clause.

On cessation of the force majeure the party invoking force majeure shall inform the other party of the period for which force majeure to be effected.

47.00 Disputes:

In all cases of disputes, the decision of National Fertilizers Limited shall be final. Failing this, the matter will be referred to the Arbitration in accordance with the Indian Arbitration Act and amendments thereof (Applicable for Indian Bidders) and in accordance with Rules of ICC (for Overseas Bidders).

48.00 Arbitration: 48.01 For Indian Bidders:

Except where otherwise provided in the contract all matters, questions, disputes, or differences whatsoever which shall at any time arise between the parties hereto, touching the construction, meaning, operation or effect of the contract or out of the matters relating to the contract or breach thereof, or the respective rights or liabilities of the parties, whether during or after completion of works or whether before or after termination shall after written notice by either party to the contract be referred to the arbitration of Chairman and Managing Director of National Fertilizers Limited or his nominee.

The Arbitration proceedings shall be governed by the Arbitration & Conciliation Act, 1996, The Arbitration and Conciliation (Amendment Act 2015) or any further statutory modification or re-enactment thereof and the rules made thereunder.

If the arbitrator to whom matter is referred, vacates his/her office by any reason whatsoever then the next arbitrator so appointed by the authority referred above may start the proceedings from where his predecessor left or at any such stage he may deem fit.

It is agreed by and between the parties that in case a reference is made to the

Arbitrator or the Arbitral Tribunal for the purpose of resolving the disputes/ differences arising out of the contract by and between the parties hereto, the Arbitrator or the Arbitral Tribunal shall not award interest on the awarded amount more than the rate of SBI PLR/Base Rate as applicable to NFL on the date of award of contract.”.

48.02 For Foreign Bidders:

All disputes arising out of or in connection with the present contract shall be finally settled under the Rules of Arbitration of the International Chamber of Commerce, India by one or more Arbitrators appointed in accordance with the said Rules.

It is agreed by and between the parties that in case a reference is made to the

Arbitrator or the Arbitral Tribunal for the purpose of resolving the disputes/ differences arising out of the contract by and between the parties hereto, the Arbitrator or the Arbitral Tribunal shall not award interest on the awarded amount more than the rate of SBI PLR/Base Rate as applicable to NFL on the date of award of contract.”.

48.03 Execution of Purchase Order shall be continued by the Supplier during the Arbitration proceedings unless otherwise directed in writing by NFL.

49.00 Patent Rights

In the event of order, the Tenderer shall agree to indemnify the NFL or/and hold it/them harmless from against all claims, liability, loss, damage or expense including counsel fees arising from or by reasons of an action or claimed trade mark patent or copyright infringement or any litigation based hereon with respect of any part of the quoted items and such obligation shall survive acceptance of and payment for the items.

50.00 Indemnity

In the event of order, the Tenderer shall indemnify and save harmless NFL and or customer from all claims, losses, demands, causes of action or studies arising out of the services, labour, equipment and material supplied.

51.00 Jurisdiction

All actions at law or suits arising out of or in connection with this contract or the subject matter thereof will be instituted in Guna courts in the Guna district in the State of Madhya Pradesh, India.

52.0 Signing of Integrity Pact Bidder will sign and submit the Integrity Pact as per enclosed Annexure-K, which is an integral part of Tender Documents, along with Un-priced Techno-Commercial Bids, failing which the Bidder will stand disqualified from the tendering process and the bid of the bidder would be rejected. Details regarding Integrity Pact can be viewed on our website www.nationalfertilizers.com

****

National Fertilizers Limited (A Government of India Undertaking)

Vijaipur – 473 111, Dist: Guna (MP), India (An ISO 9001, 14001 & OHSAS 18001 Unit)

CIN No. L74899DL1974GOI007417

Annexure-C E-Tender ID – 1990

NIT No. NFV/PUR/BIU160645-V Dated: 16-11-2017

S. No.

NFL Item Code

Item Description UOM Quantity Required

1

JA0170100

Design, Engineering, Supply, Supervision and Erection & Commissioning of Distributed Control System (DCS) & Emergency Shutdown System (ESD) System along with Spares for Ammonia-II and Urea-II Plants in NFL, Vijaipur as per Technical Annexure attached.

ST

1.000

Note:

1. The Eligibility Criteria shall be as per Annexure-I. 2. Bidders will be required to give your comments/confirmation on all the points

mentioned in Technical Specifications Annexure-II.

*****

ANNEXURE-I

ELIGIBILITY CRITERIA FOR PROCUREMENT OF DCS & ESD SYSTEM

Sr. No. Conditions Documents Required 1 The bidder must be the OEM of offered DCS

& ESD or the authorized representative of OEM. The OEM should be in the manufacturing field of DCS & ESD for at least 10 years. Bidders must have supplied and commissioned at least one full-fledged DCS & ESD of quoted model in India in Ammonia plant during last seven (07) years i.e. after 31stMarch’2010.

I) In case of authorized representative an undertaking from OEM on his letter head in support of being an authorized representative. II) The copies of Purchase Orders as a proof of OEM being in DCS & ESD manufacturing field for at least 10 years. III) Copy of Purchase Order as a proof that the quoted model is supplied in last seven (07) years. IV) Detailed address and contact No. of the company and concerned person to whom this equipment has been supplied.

2 The quoted model should be latest & must have given satisfactory service for a minimum period of 2 years during the last seven (07) years i.e. after 31stMarch’2010.

The satisfactory performance certificate on official Letter Head of user for at least one DCS & ESD System for a minimum period of 2 years on continuous basis, during the last seven (07) years i.e. after 31stMarch’2010. All the relevant documents if any shall also be furnished in support of the satisfactory performance.

3 The bidders must have manufacturing facilities / Centre of excellence in India for carrying out complete Engineering, execution of job & after sales support.

I) Details indicating complete address of their establishments in India with their contact person name, address and phone numbers etc. on its letter head pad. II) Undertaking on their letter head pad that they shall provide spare & service support for quoted DCS System for a period of at least 15 years from the date of supply of the DCS & ESD System.

4 Average annual financial turnover of the company during last three (3) years ending 31st March-2017 should be at least Rs.5.22 Crores. Net worth of the bidder should be positive during financial year ending on 31.03.2017.

Party shall submit financial standing through Audited Balance sheet / Profit & Loss account for the last three years (for the year 2014-15, 2015-16 & 2016-17).

ANNEXURE-II

GENERAL PROJECT INFORMATION

OWNER : NATIONAL FERTILIZERS LTD

ADDRESS CONTACT PERSON (COMMERCIAL)

: :

NATIONAL FERTILIZERS LTD P.O. VIJAIPUR, DIST.: GUNA (M.P.)-473111. DY. GENERAL MANAGER (MATERIALS)

NFL, VIJAIPUR CONTACT PERSON

(TECHNICAL) : DY. GENERAL MANAGER

INST. DEPARTMENT NFL, VIJAIPUR

NAME OF PROJECT : UPGRADATION OF DCS & ESD

SYSTEM OF AMMONIA-II AND UREA-II PLANTS

SITE ADDRESS : NATIONAL FERTILISERS LTD

P.O. VIJAIPUR, DIST: GUNA (M.P.)-473111.

PREAMBLE

DESCRIPTION OF EXISTING PLANTS National Fertilizers Limited, Vijaipur is having two streams of Ammonia plant based on M/S HTIAS, Denmark know how with a capacity of 1750 MTPD & 1864 MTPD of Ammonia-I & Ammonia-II Plants respectively and four streams of Urea plants based on M/S SNAMPROGETTI, Italy know how with a capacity of 1515 MTPD each of two streams in Urea-I and 1615 MTPD each of two streams of Urea-II Plant. These projects are located at Vijaipur Dist. Guna, Madhya Pradesh, India. Line-II Ammonia and Urea Plants were commissioned in year 1997 with M/s Yokogawa make Centum-XL DCS, M/s Stahl make Multiplexer (for open loops) and M/s HIMA make Emergency Shutdown System. Now we are upgrading Line-II plant DCS Control System and Emergency Shutdown System to latest and proven instrumentations with state of art technology, which shall guarantee from obsolescence for at least 15 years.

CONTROL ROOM Ammonia Plant Control Room and Urea Plant Control Room are located in the same Control Room Building. Following control rooms shall be available for installation of control system or part of control system to meet operation control philosophy.

i) Ammonia Plant Control Room ii) Urea Plant Control Room iii) Urea Plant 31/41 Compressor House Control Rooms

ENVIRONMENTAL CONDITIONS The equipment will be installed in a Non-Hazardous Air Conditional Central Control Room and it shall be suitable for operation during a normal life time under the conditions mentioned below. The condition classifications are in accordance to ISA-S-71.01 for temperature and humidity and ISA-S-71.04 for air borne contaminants.

The normal temperature and humidity conditions are Class A2 (Normal 24 degree Celsius and 50% R.H.). In abnormal situations e.g. air conditioner failure, the conditions will be class B3 (Max. 40 degree Celsius and 90% humidity). The Airborne Contaminants in the atmosphere are-

Liquids : Class LA1, LB1, LC1 Solids : Class SA1, SB1, SC1, SD1 Gases : Class G1

RFI (Radio frequency interference) and EMI (Electromagnetic interference) tolerance and noise immunity of DCS shall have less susceptibility than 0.5% of span for a frequency range 20-500 MHZ in a field strength of 24 V/M and common mode rejection ration of 80 dB at 50 Hz.

TECHNICAL SPECIFICATIONS

FOR UPGRADATION OF DISTRIBUTED CONTROL SYSTEM (DCS), EMERGENCY SHUTDOWN SYSTEM (ESD) AND ASSOCIATED INSTRUMENTATION OF AMMONIA-II & UREA-II PLANTS

AT NATIONAL FERTILIZERS LIMITED, VIJAIPUR UNIT, GUNA-473111 (MP)

CONTENTS

SECTION DESCRIPTION

SECTION-I CONTROL PHILOSOPHY SECTION-II SPECIFICATIONS OF DCS SECTION-III SPECIFICATIONS OF ESD SECTION-IV MARSHALLING/SYSTEM/PDB CABINETS SECTION-V BASIC SPECIFICATIONS OF INSTRUMENTS

SECTION-VI GENERAL CABLE LAYING, TRAY LAYING , LOOP CHECKING GUIDELINES

SECTION-VII SPECIAL TERMS & CONDITIONS FOR ERECTION AND COMMISSIONING

SECTION-I

CONTROL PHILOSOPHY

INDEX

SR. NO. TOPIC 1.0 Scope 2.0 Abbreviations Used in this Document 3.0 Control and Operation Philosophy 3.1 Operation 4.0 System Integration 4.1 Power Supply 4.2 Alarm Management 5.1 Expandability 5.2 DCS Design Criteria 5.3 ESD Design Criteria

1.0 Scope

Design, Engineering, Supply, Supervision, Erection & Commissioning of DCS & ESD System in Ammonia-II & Urea-II Plants.

Supply & erection of Cables, Junction Boxes, Cable Tray with structural steel for removal of MUX and taking signals directly to new DCS/ESD in Ammonia-II & Urea-II Plants.

The scope also includes removal of existing DCS & ESD cabinets, re-routing of existing cables from old systems to new system cabinets, Tray laying, Cable laying, Junction Box Mounting, Cable re-routing in Cabinets and field etc.

As this is an up-gradation of existing DCS & ESD control system of main plants and other package control systems, for exact assessment of scope of supply & services, bidders have to visit the NFL Vijaipur site to see the site conditions in respect of field instrumentation, cabling, control rooms, installation space, existing documentation etc. at vendor’s cost and NFL will not entertain any claim on this account.

1.1 The existing DCS CENTUM–Control system of Ammonia-II and Urea-II has to be up graded. The existing PLC based ESD Model H51q-HRS (Main PLC) & H41q-M (Fast SOE PLC) of HIMA make Including Marshalling cabinets of Ammonia-II &Urea-II main plants respectively has to be upgraded with latest & Proven ESD System. The System offer shall be made separately for Ammonia-II and Urea-II Plants. The Urea-II plant consists of three sections 31,41 and Common. The system cabinets including Controllers, I/O Modules, and Marshalling cabinets for 31,41 & common sections will be separate and Independent. All the Three sections will be Controlled Independently. Tripping of one section will not affect other section.

2.0 ABBREVIATIONS Used in this document:

AMS = Asset Management System APC = Advanced Process Control CPU = Central Processing Unit DCS = Distributed Control System ESD = Emergency Shutdown System FAR = Field Auxiliary Room HMI = Human Machine Interface IMCS = Intelligent Motor Control System

MCC = Motor Control Centre MCR = Master Control Room MOS = Maintenance Override Switch MS = Microsoft OPC OLE = (Object Linking and Embedding) for Process Control PLC = Programmable Logic Controller SER = Sequence of Events Recorder TÜV = TechnischeÜberwachsungsVerein VDU = Video Display Unit (Always 22” TFT /LED/LCD type colour monitor)

3.0 Control and Operation philosophy: 3.1 Operation: 3.1.1 The existing DCS CENTUM XL Control system of Ammonia-II and Urea-II has to be upgraded.

The existing PLC based ESD Model H51q-HRS (Main PLC) & H41q-M (Fast SOE PLC) of HIMA make including Marshalling cabinets of Ammonia-II & Urea-II main plants respectively has to be upgraded with latest & Proven DCS & ESD systems. The offer shall be made separately for Ammonia-II and Urea-II Plants. In case of Urea-II, the system cabinets, Marshalling cabinets etc. shall be separate for 31, 41 and common sections.

3.1.2 All process and utility units and related facilities for the entire project shall be monitored and controlled from the Central DCS located at Central Control Room. This Control Room shall provide adequate space and means to ensure safe and efficient control and monitoring of the plant.

3.1.3 The Purge Gas Recovery Plant’s DCS Controller (Yokogawa Centum-VP) to be integrated with offered DCS system of Ammonia-II plant for control & monitoring through all operating stations.

3.1.4 The DCS operator interface (VDU based) shall be the primary integrated window for operation of the control and safeguarding systems and shall provide access to:

- Process control - Sequence control status - Equipment status - Alarm overview - Trip status overview (This shall be via ESD SER PC, located at Central Control room.) - Override status (Visible from Aux. hardwire console and DCS graphic via ESD) - Real-time trending - Historical data trending - Machine Monitoring

- Environmental Monitoring etc.

3.1.5 All the major critical trip parameters shall have Soft Override switch. ESD shall Provide Digital Output contact to drive the group LED lamp on auxiliary console for positive assertion of Override switch condition.

3.1.6 Controllability of all the Controllers in control group page shall be provide through Function key board for each controller.

3.1.7 All the Control Nodes shall be directly connected to the Control Bus.

3.1.8 Functional Key Boards shall be of OEM Make.

3.1.9 Historian Facility: This shall be available on all operator station. In case, the same is specialized node on the network, the same shall be provided in redundant separately for ammonia & separately for urea.

3.1.10 No Temperature module shall be used in DCS or, ESD system. Thermocouple and RTD signal shall be converted to Analog signal (4~20 mA) through barriers.

3.1.11 Separate controller for demo node along with required software and hardware such as one I/O Card of each type along with the associated termination modules shall be provided for DCS and ESD.

3.1.12 Integrated Alarm & Event display: The operator shall have capability to display both DCS & ESD alarms and events

3.1.13 All control and interlocks shall be monitored, controlled, and engineered through work stations as given below-

3.1.14 Installation Capabilities: Vendor shall have capability to replace the equipment & commission the equipment in the shortest period of time. This results in shorter shutdown period.

DCS SYSTEM - AMMONIA-II :

Eight sets of Operator Stations (Six in CCR, One in Shift In-charge Room &One in Plant In-charge Room). Operator Station Consoles to be placed in the CCR will be Double tier type.

Two sets of Operator Stations Consoles with VDU (22” minimum, TFT/LED/LCD Colour Monitors) shall be provided for monitoring of Third party control systems (HRU & System-I) in the Central Control Room of Ammonia-II Plant.

One 65” wall mountable type monitor for process overview shall be provided in the Central Control Room of Ammonia-II Plant.

Two Redundant sets of DCS Engineering stations in Engineering room of Ammonia-II Plant.

ESD SYSTEM - AMMONIA-II :

Two Redundant sets of ESD Engineering station in engineering room of Ammonia-II Plant.

Two-sets of ESD operator Station in CCR.

Operator HMI station will have soft Override switches through ESD Operator stations

One set of Sequence of Events (SOE) Station along with PC will be kept in Central Control Room of Ammonia-II plant.

Two Auxiliary Consoles ( Double Tier) shall be provided for mounting Group trips bypass indication lamps, emergency trip switches (with built in lamp indication) and to mount boilers level remote indicators (4-nos. Hydrastep).

DCS SYSTEM - UREA-II :

Eight sets of Operator Stations (Six in CCR, One in Shift In-charge Room & One in Plant In-charge Room). Operator Station Consoles to be placed in the CCR will be Double tier type.

Two Operator Stations each with consoles (single tier type) shall be placed in 31 & 41-sections’ CO2 Compressors Control room for control & monitoring of DCS and ESD systems. It shall be connected through Fiber Optic cables (redundant). These stations shall be placed in 31/41-

CO2 Compressor Control Rooms of Urea-II plants situated approximately 500 meters from the Urea-II Central Control Room.

Two sets of Operator Stations Consoles with VDU (22” minimum, TFT/LED/LCD Colour Monitors) shall be provided for monitoring of Third party control systems in the Central Control Room of Urea-II Plant.

Two Redundant sets of DCS Engineering stations in Engineering room of Urea-II plant.

One 65” wall mountable type monitor for process overview shall be provided in the Central Control Room of Urea-II Plant.

ESD SYSTEM: - UREA-II :

Two Redundant sets of ESD Engineering Station in engineering room of Urea-II plant.

Two-sets of Operator Station will be placed in CCR.

Operator HMI station will have soft Override switches through ESD Operator stations.

One set of Sequence of Events (SOE) Station along with PC will be placed in Central Control Room for each section 31 & 41 of UREA-II.

Two Auxiliary Consoles (one each for 31 & 41 section) shall be provided for mounting trips bypass indication lamps, emergency trip switches (with built in lamp indication) and to mount CO2 compressor’s Antisurge Controllers (CCC make).

Additional Requirement

One View only operator HMI station each shall be provided in the office of Head of Technical Services group for monitoring of DCS & ESD parameters for Ammonia-II & Urea-II plants. Office of head of TS is located in site office building situated approx. 1000 meters away from Central Control Room. All these stations will be view only stations.

Redundant Controllers for DCS:

The Controllers shall be of latest upgrade version. Following number of controllers are installed in the existing system:

Ammonia-II: Redundant Controllers - 8 Pairs

Urea-II: Redundant Controllers - 4 Pairs

Max. 50% controller loading is allowed. In case additional Controllers are required to meet the loading criteria, the same will be in bidder’s scope without any price Implication.

3.1.15 SOE (Sequence of Events Recorder): Stand Alone SER of 600 Inputs and 500 Inputs are required for Ammonia-II and Urea-II respectively. Additional 20 % wired spare points shall be provided for future uses. The SER will be M/s Rochester make. The SER will be kept in CCR.

3.1.16 Philosophy of Connection of AI & DI from Field/MCC to SER & ESD. Case 1: In case of Digital Input from MCC: The Input will be connected to Relay. From Relay One Contact will go to SER and another to ESD.

Case 2: In case of Digital Input from field, The Input signal will be connected to Dual Channel Barrier. One Contact output will be connected to SER and another Contact output will be connected to ESD. Case3: In case of AI, The Analog Input will be connected to Dual channel Barrier. One Analog output of Barrier will be connected to Trip Amplifier. The Trip amplifier Output will be connected to SER. Another output of Dual channel Barrier will be connected to ESD. The SER will be connected to PC and all the events will appear on SER PC. DI from Field, MCC and AI from Field will be terminated in separate Marshalling cabinets as per signal segregation philosophy.

Schematic Drawing:

3.1.17 Power supply for Field Solenoid valves are 110V AC.

3.1.16 Bidder to Quote Model and System Name of DCS and ESD system along with system Architecture and Manual with offer. No Client Server Architecture is acceptable.

4.0 SYSTEMS INTEGRATION 4.0.1 The DCS and ESD systems shall be engineered as one integrated control and safeguarding

system with respect to operator presentation. Communications of the ESD with the DCS shall be accomplished via dedicated redundant, single fault tolerant communication bus. Both ESD and DCS system shall be sitting on same Ethernet/control bus.

4.0.2 An Open Control Systems Network shall allow the integrated control and safeguarding system

to communicate with third party control systems, auxiliary information systems and higher-level automation systems utilizing OPC connectivity standards. The DCS shall have the capability to be seamlessly integrated with an APC whenever required. Special attention shall be given to network security of the Open Control Systems Network. Firewall shall prevent unauthorized access from the office network to the Open Control Systems Network.

4.0.3 Only non-critical information shall be exchanged via the Open Control Systems Network.

Critical information shall be transferred with hardwired connections. 4.0.4 It shall be possible to connect with the integrated control and safeguarding system with

redundant OPC servers.

4.0.5 Although the DCS and ESD systems are to be engineered as an integrated control and safeguarding system, each system shall have its own connection to the Open Control Systems Network.

4.0.6 Essential and continuous control commands and statuses to the MCC shall be hardwired and

be routed via Interposing Relay Cabinets. 4.0.7 Special attention shall be given to network security of the Open Control Systems Network.

Firewall shall prevent unauthorized access from the office network to the Open Control Systems Network.

4.0.8 All work stations should be directly sitting on plant communication loop as Independent node.

No Operating stations should be connected to plant communication loop through server. All work stations should be directly connected to main plant communication loop as Independent Node. Each OWS should have Independent process Tag data base. The Minimum Bandwidth of main system communication Network shall be 1 GBPS.

4.1 POWER SUPPLY

Owner shall provide Two Redundant feeders each of 115 V AC +/- 10% at 50 Hz –3/+1 Hz, UPS grade, floating power supply separately for complete DCS system and ESD system at one location in cabinet room up to PDB panels.

The bidder will lay the cables and terminate them in designated PDB cabinets complete with required breakers & terminals, indicators, switches etc. There shall be multiple PDB panels for 115 V AC UPS supply, located at central cabinet room from where all other panels shall be fed with 110 V AC power supply. These panels shall be of the same size/make and model like DCS/ESD panels.

The 24 V DC redundant power supply shall be generated from these 115 V AC UPS supply by individual system vendors, wherever it is required. These shall also be accommodated in the panels at central cabinet room, having the same specifications of panels. BPS for 24V DC shall be provided for each process controller separately as per segregation philosophy having redundant bus bar. If 24 V DC Bulk power supply is required for DCS/ESD or relay panels, the same shall be provided in diff. panels with full redundancy in such a way that one power supply must be capable of catering the predefined load. BPS for 24VDC shall be provided for each process controllers separately as per segregation philosophy having redundant bus bar. System shall withstand transient voltage spikes of 140% for a period of 10 ms. System shall withstand momentary loss of complete power for 40 mili seconds. 220 VAC utility supplies for various cabinets shall be distributed via central PDB located at central cabinet room only.

4.2 ALARM MANAGEMENT

The purpose of an alarm is to bring the operator's attention to an abnormal event, such that he can take action to rectify the situation. During normal operation the Alarm Philosophy shall be that there are no active alarms present. To enable the operator to respond appropriately, alarms shall be categorized according to the following three priorities reflecting the severity of the abnormal situation, as a minimum. An ESD alarm is an indication that a trip has occurred. A "First Failure” indication shall discriminate between related ESD alarms to identify the first initiator of a trip with 1 mili second time resolution on SER PC monitor located at central cabinet room in the operator console.

A shutdown level alarm indicates that immediate operator action is required to prevent a trip condition (in this case it is also referred to as a pre-alarm), or is used for essential parameters for proper operation of the plant (e.g. quality alarms) in DCS operator console with diff. hooter/sound.

Secondary alarms draw only attention to an abnormal situation that could result in a severe operational upset if not acted upon. This shall also be reported at DCS operator station with diff. hooter/sound

Alarm acknowledgement and first failure resetting shall be from the DCS keyboard, not locally from equipment panels or solenoids.

On measurements that can lead to a trip, pre-alarms shall be implemented, provided the operator has sufficient response time to take corrective action.

The alarm management of the DCS shall be developed with the following objectives: - Minimize the number of active alarms; - Optimize the information contained in the alarms; - Obtain effective alarm presentation by using Human Factor design principles and practice. Further techniques shall be employed to optimise the operator interface to the alarm system. Back Panel Alarm on Operator stations shall be provided. Methods to be used are suppression techniques (static or dynamic), first failure indication and alarm overview displays in addition to the alarm list. The overview displays provide a layered structure of related alarms in annunciation screens. A Sequence of Events Recording system shall log all safety related alarms, commands and status changes for post-mortem analysis. This shall be installed in one operator console in central control room and it will directly interface with ESD/SOE PLC. This station shall have common access to all operators.

5.1 EXPANDABILITY 5.1.1 Minimum 20% spare Modules of all types shall be installed. These spare Modules shall be

completely pre-wired with all the intermediate accessories like pre-fab cable, cable connector, barrier / isolator/relay up to marshalling terminal.

5.1.2 In addition, minimum 20% spare space in cabinets for installation of spare I/O cards shall be available throughout the system for allowing undefined future expansion

5.1.3 Communication networks and cables shall have a spare load capacity of 50% as a minimum. 5.1.4 Plant wide networks shall have a node connection spare allowance of 50 % as a minimum. 5.1.5 Local networks shall have a node connection spare allowance of 30 % as a minimum. 5.1.6 No Module in ESD / DCS shall be loaded more than 80 %. 5.2 DCS DESIGN CRITERIA 5.2.1 The system shall enable process monitoring, control, safety detection & protection to be

achieved, at several equipment nodes, with serial high-speed communications to the operator's console employing VDU's, keyboards, print server & printer, data storage devices, etc. All VDU shall be minimum 22” TFT/LED colour monitors with Touch Screen.

5.2.2 TheDCS, by employing distributed intelligence and database techniques, shall provide highly

secure, safe, reliable, maintainable, effective process / safety monitoring and control of the production facilities, from a permanently manned Central Control Room (CCR).

5.2.3 The DCS & Safety Systems shall employ Dual redundant (single fault tolerant)

communications links. The system supplier shall prove that the system hardware redundancy, will achieve an availability figure better than 99.99% per control loop using his chosen hardware configuration.

5.2.4 Process and sequential control shall be achieved using plant wide multi-loop microprocessor based digital controllers, with full functional interfaces being provided by the operator's consoles.

5.2.5 The operator's VDU/keyboards shall provide latest MS windows HMI. 5.2.6 The system shall be built on the latest state-of- the-art hardware and software platform

and hardware/software/firmware revisions of complete system will be latest at the time of supply. The system architecture shall have latest Windows based system or latest version of 32 bit or 64 bit operating systems and compatible RISC hardware. All the operator station and engineering station shall equipped with minimum 22” TFT, COLOR, LED monitors. There shall be a facility to operate these loops from the adjacent Operator station in case of any failure. Client Server Architecture is not acceptable. All Workstations should be directly sitting on Plant Communication Loop as INDEPENDENT NODES. No operating Station should be connected to Plant communication loop through a server.

5.2.7 The system shall be fully configurable without specialized programming knowledge, using proven, fully de-bugged and tested Supplier's standard software packages. Sufficient online storage shall be included to accommodate the database and alarm, event and historic data logs. To achieve the reliability/availability targets required, redundancy requirements shall be calculated and employed. Operational control of the plant will normally be from the CCR.

5.2.8 The system shall be 100% fault tolerant and dual redundant for control processor,

system bus, data highway, I/O for closed loops, power supply and communication. This means, all central control processors, all communication processors and all other central rack and individual node’s common cards, all the communication cards, networks and cables, etc. shall be 100% fault tolerant. All the hardware including control/communication processors, networks, cables, all type of system cards, all type of I/O cards and power supply shall be hot swappable.

5.2.9 Analog input/output cards shall be galvanically isolated and digital input/output cards

shall be optically isolated. Group isolated type or bulk I/O cards shall not be accepted in the whole system architecture. All I/O cards shall be intelligent type with microprocessor/microcontroller based hardware and capable of all type of signal conditioning, self-diagnostic, fail safe value configurable (programmable) and time stamping at I/O card level.

5.2.10 I/O cards’ Channel density shall not exceed the following limits

Analog Input - 16 Channels Analog Output - 8 Channels Digital Input -16 Channels Digital Output -16 Channels

All I/O cards in individual category shall be of same type/model/revision only. No diff bulk I/O cards or I/O cards with degraded features shall be accepted in any of the category in a mix mode supply.

5.2.11 The scan time of all type of analog / digital cards & DCS algorithm (Scan time means

the sum of total time required for reading an input, running control algorithm, writing the output values and running the fault diagnostic) shall be better than the required scan time of the fastest running control/closed loop like anti surge algorithm in the plant for various turbo machinery etc. However, in any case, this shall not be more than 250 mili-seconds for any type of channel.

5.2.12 There shall be 4 nos. of engineering station software/personalities in overall DCS

architecture, 2 no for Ammonia-II Plant and 2 no for Urea-II Plant., from where the complete DCS project can be developed and deployed on any other operator/control station, independently. These engineering stations shall be used as operator station also. However non-availability of these engineering stations shall not affect the plant normal operation and shall neither cause any historical/trend data loss. All operator

station shall be independent of engineering stations, self-bootable and do not require engineering station for putting them into normal operation or restoring them after rebooting, once the developed project is deployed. System should allow on-line modification, addition / deletion or change (controller loading) in any control loop or part thereof.

5.2.13 All operator stations and engineering stations shall be OPC compliant without any upper

limit on number of tags. However, if there is any specific limit applicable on the proposed system, it is to be specified.

5.2.14 Complete system hardware/software and communication load shall not exceed 50%

system load even after the complete implementation of project and running at peak load. This includes redundant control processor peak load also.

5.2.15 System shall have 50% spare margin in software memory/load for future spare addition

without replacing/upgrading any existing system hardware/software at all the levels. System shall be capable of loading up to 100% without any overrun/degradation of performance, etc. System shall report all type of load limit alarms, diagnostic alarms up to channel level, communication alarms, system hardware failure alarm and other global information with alarm facility on engineering/operator station in real time with 1 second resolution.

5.2.16 System shall support various Hourly/Shift/Daily/Monthly Reports/Logs, Totalizers

reports, SNAP shot reports, etc. in Microsoft excel format only. The layout and type of reports/data, nos. of tags per report, etc. shall be as per owner’s requirement. All the operator station, engineering stations shall be equipped with MS Office license copy. System shall support min.10000 (Urea-II) tag historian software, out of which 4000 points shall be configurable for 1 second resolution, 3000 points shall be configurable for 2 seconds interval and remaining shall be configurable from 5 to 10 seconds. System shall support min. 15000 (AMMONIA-II) tag historian software, out of which 6000 points shall be configurable for 1 second resolution, 5000 points shall be configurable for 2 seconds interval and remaining shall be configurable from 5 to 10 seconds. There shall be no limit on historian data retention time, except the hard disk size. All the stations, wherever engineering database of complete project and historical/run time data is stored, shall be equipped with redundant hard disk with RAID1 configuration, to prevent any data loss. This may include not only the engineering station but all the operator station also, wherever applicable.

5.2.17 System shall support 1 second time resolution real time trend for all the system

tag/parameters, without any time limit. The minimum x–axis time span for real time trend with 1 second sample rate shall be 30 minutes. Also, all PID loop face plate display shall have real time/historical trend window by default for min. three parameters, i.e. measured or process variable, operator entered or remote/calculated set-point and output value or manipulated value for that particular loop.

5.2.18 DCS system shall have latest; windows based alarm manager with 1 second or better

time resolution. In addition to various process alarms, the system shall also store operator action journal, system error messages, any other event, etc. Alarm manager shall also have historian facilities and there shall not be any storage limit except hard disk size for retention period of various alarms/events.

5.2.19 Complete system hardware shall be certified for ISA G3 class corrosion level protection

and shall be compatible with various RFI/EMI immunity as per IEC.

5.2.20 DCS system shall have fast MODBUS I/O cards/Communication gateways for interconnecting with other various types of control systems like HRU PLC, Compressors control systems, Speed/Vibration monitoring system, etc. via RS485 interface and MODBUS protocol. The link shall be one way, i.e. the information in DCS shall be used as view only purpose. No remote writing facilities from DCS to other system via MODBUS are permissible. The communication module and links shall be 100% fault

tolerant. The signal exchange between various other system and DCS shall be hardwired if they are to be used for control/decision making purpose in DCS.

5.2.21 All digital input shall have 24 V DC interrogation voltage level. All Analog cards shall be capable of accepting 2 wire and 4 wire Analog inputs and shall supply 24 V DC to field transmitters. All Digital output cards shall drive 24 V DC, OMRON make, 4 NO/NC, socket mounted, interposing relays with 230 V AC/5 Amp contact ratings. All field loads from Digital Output cards, including Solenoid valves, MCC switch gear signals, etc. shall be interfaced via these interposing relays only. The digital output cards driving the MCC related output relays (which are to be wired to MCC/Substation) shall be accommodated in Digital Interface panel as specified above, separately to avoid any interference problems in low voltage instrument signal cables. No Thermocouple /RTD cards shall be used in DCS/ESD system. No Temperature module shall be used in DCS or, ESD system. Thermocouple and RTD signal shall be converted to Analog signal (4~20 mA) through barriers.

5.2.22 The offered system shall be supported by the DCS vendor for min. 15 years for all type

of hardware and software spares and service supports.

5.2.23 Barriers of P&F make with SIL-3 Integration shall be used in entire project.

5.2.24 All Hardware Modules shall be latest Model and Version.

5.2.25 All Software shall be latest and upgraded version. 5.3 ESD SYSTEM DESIGN CRITERIA 5.3.1 The safeguarding system shall automatically bring the relevant equipment or part of the plant

to a safe condition, when a critical process variable reaches the limit of an acceptable control value.

5.3.2 Safeguarding systems shall work independently of the control system with their own initiating

and actuating devices. Process variables used for safeguarding shall be directly measured where possible.

5.3.3 The ESD System will be based on a fault tolerant programmable system design and will utilize

proprietary QMR / TMR Programmable Logic Controllers with Duplicate/triplicated input/output modules. The system may be sub-divided into sub-systems for example processing trains and common facilities etc. The system shall be designed, manufactured, tested and commissioned to comply with the requirements of IEC 61508/61511. The ESD system shall be approved for use in SIL 3 classified loops.

5.3.4 ESD Safety critical signals shall comply with the following:

• Signals to/from the ESD shall be hardwired always. • ESD circuits shall be de-energized to trip and be "fail safe". • In the whole system there shall not be any Non-safety signals/cards, used. • Hardwired critical circuits shall be arranged in such a way that probable failures e.g.

cable / termination faults, power supply loss, etc. will not cause shutdowns or prejudice the systems safety integrity.

• The processing cycle time shall be compatible with the requirements from the process safety time and the required resolution of the sequence of events recorder, but shall be as a maximum, including 30% processor spare capacity and taking I/O spares in account, <250 mSec.

• Signals to/from the ESD for alarms, Sequence of Event Recording (SER), reset switches, Operational Override Switches (OOS) and Maintenance Override Switches (MOS) be always hardwired from auxiliary console located at central cabinet room.

5.3.5 The ESD panels and all system hardware shall be located in central cabinet room in the close

vicinity of Central control room. This cabinet room shall accommodate all marshalling panels, PDB panels, ESD hardware panels, Barrier panels, relay panels. All these panel

size/make/model shall either 1200mm (W) x 800 mm (D) x 2100 mm(H), or 800mm (W) x 800 mm (D) x 2100 mm(H), ( size will be based on requirement), RITTAL make with RAL7035 colour shade, as specified below. All the field instrument signal/power and control cables shall be brought to this central cabinet room, from where it shall be catered to different individual destination marshalling panels and corresponding ESD hardware panels. There shall be dedicated marshalling panels for ESD. Also, diff. type of signal category shall have different marshalling cabinets. There shall be 20% space margin available in all the panels on marshalling and relevant system hardware side panels.

5.3.6 The relevant ESD hardware shall be installed in dedicated panels. The panel

make/model/size is specified in detail specification of DCS/ESD. There shall be panel segregation for various I/Os meant for DCS and ESD system. Also there shall be panel segregation for different type of I/Os for ESD. This means that analog input and analog output shall be accommodated in a separate marshaling panel of DCS & ESD panel. Digital I/O and all interposing relays shall be accommodated in a separate marshalling panel of DCS & ESD panel.

5.3.7 ESD system shall be completely separate from DCS but both systems shall be in same Domain

i.e. on common network 5.3.8 The emergency shutdown system shall be a state-of-the-art; Programmable Logic Controllers

with QMR/Triple Modular Redundant (TMR) based Fail Safe architecture. Irrespective of process hazards/safety class, the ESD (Emergency Shutdown System) System shall be certified for Safety Class – 6 as per TUV and DIN19250/VDE0801 and SIL3 as per IEC61508, as a minimum. The complete application cycle time of ESD / ESD shall be less than the 25% of the Process Safety Time, specified by Process licensor, when system is fully loaded and running at peak load. (i.e. if Process safety time is 1 second, complete application cycle time of proposed safety ESD shall not be more than 250 milliseconds)

5.3.9 ESD system application software shall allow incremental download to carry out online

modifications, without affecting the running plant. There shall be facilities to monitor the running logic in FBD format in real time mode from engineering station. Also the engineering station of ESD shall allow forcing of any of the hardware input/output or intermediate local variables in complete system by software method.

5.3.10 ESD program will reside in Flash ROM in ESD main processor/memory cards.

Downloading in one of the central part of a redundant QMR or TMR system shall educate the remaining CPUs and equalize the memory/data of other redundant components in the system.

5.3.11 ESD shall have 4-20 ma Analog input cards (capable for accepting 2 wire and 4 wire

transmitter signals and capable of powering up 24 V DC, 2 wire field transmitters), 24 V DC Digital Input cards and 24 V DC Digital output cards only. No other analog signal input types like RTD/ Thermocouple, etc. are envisaged at I/O Level. All the I/O and DI/DO cards and all the central part hardware of complete ESD system shall be fully redundant and fault tolerant only. All I/O cards shall have microprocessor/microcontroller based architecture and intelligent with full diagnostic feature up to individual channel level with time stamping of 1 milli second time resolution. All I/O Modules shall be of fail-safe type. NO Non-fail safe modules shall be installed anywhere in the proposed ESD system.

5.3.12 All the Digital output cards shall drive 24 V DC , OMROM make , 4 NO/NC, socket mounted

Interposing relays located in a dedicated relay panels having the same specifications as that of ESD hardware panels. All digital output, be it either Solenoid valves or MCC output, shall be driven via interposing relays only. The contact rating for interposing relays shall be 230 V AC/5 Amps. All the Relays pertaining to MCC shall be installed in MCC Digital Interface cabinet and other process interlock relays like Solenoid and other loads shall be mounted in a separate Relay Panels. There shall not be any interposing relays for Digital inputs.

5.3.13 If there is a solenoid valve installed on the control valve and if this solenoid valve is driven by

ESD logic/interlocks via Digital Output cards/interposing relay, there shall be another Digital Output channel /interposing relay configured in ESD for using the same interlock output as

secondary means of de-energizing in DCS for that particular PID loop. This means, on actuation of trip logic, the ESD shall close the control valve with the help of solenoid valve and at the same time, the another digital output channel will drive an interposing relay and this relay’s dry contact shall be wired to DCS as Digital Input for driving that PID loop into manual mode and setting the analog output signal to Zero.

5.3.14 Rochester make SOE recording system should have software running on a dedicated PC with

Windows GUI features, to find out the cause of the trip with 1 milli-second time resolution. Storage of various system alarms, process events with proper time stamp with 1 milli-second resolution and sorting, exporting various event reports into Microsoft Excel, Access or DBF format is a must for later on analysis of any event/trip. This SOE PC shall be located near operator station in the central control room to have round the clock access by operation group. SOE summary display should be available on every DCS operator station with no limitation on number of tags or points.

5.3.15 The various I/O cards shall not exceed the following I/O channel density.

Analog input cards :- 16 Channels Digital Input cards :- 16 Channels Digital Output cards :- 16 Channels

5.3.16 The complete ESD system hardware and software of safety ESD system shall be fail safe type and shall guarantee the fail safe operation all the time, ensuring 99.99% availability. Total hardware of ESD system shall conform to ISA G3 level corrosion protection and RFI/EMI immunity as per IEC standards.

5.3.17 The offered system shall be supported by the ESD vendor for min. 15 years for all type

of hardware and software spares and service supports. 5.3.18 ESD shall have facilities to communicate with proposed DCS and it should sit on DCS

network as one of the DCS node, so that seamless integration of DCS - ESD could be achieved. All ESD system events shall be monitored on DCS with the seamless Integration or better solution as prescribed above. These include the entire Digital input/output channel’s real time status, intermediate local/global ESD variables, timers, counters, all the analog input channels real time values in floats, etc. There shall not be any tag/parameter limits on DCS/ESD gateway communication and the update time of complete ESD parameter sets on DCS shall not take more than 1 second.

5.3.19 For a group of interlocks, having common cause of trip, shall be grouped together and will drive a digital output channel from ESD, which will be wired to Central Control room located auxiliary console lamp. Once after actuation of a trip, the final output shall not resume, unless all the input parameters are normal and operator presses a RESET button. The ready to reset condition (healthiness of all input parameters) shall be indicated to operator from above mentioned lamp. Also the RESET push button switch shall be hard wired to ESD from auxiliary console.

5.3.20 Barriers of P&F make with SIL-3 Integration shall be used in entire project. 5.3.21 All Hardware Modules shall be latest Model and Version.

5.3.22 All Software shall be latest and upgraded version

SECTION-II

DISTRIBUTED CONTROL SYSTEM SPECIFICAITONS

INDEX

Sr. No. TOPIC

1 GENERAL

2 BIDDER'S RESPONSIBILITY

2.a&b GENERAL REQUIRMENT

3 SYSTEM OVERVIEW

4 FUNCTIONAL SPECIFICATIONS

4.1.a OPERATOR STATIONS/ENGINEERING STATIONS/SOE

4.2 DISPLAYS

4.3 KEYBOARDS

4.4 PRINTERS

4.5 COLOR HARD COPIER CUM SCANNER

4.6 MULTILOOP CONTROLLERS/DATA ACQUISITION SYSTEM/CONTROLLER SUB SYSTEM

4.7 BULK STORAGE MODULES

4.8 COMMUNICATION NETWORKS

4.9 ENGINEERING / CONFIGURATION STATIONS

4.10 GATEWAYS/COMMUNICATION NODES

4.11 SUPERVISORY CONTROL DEVICES

4.12 PROJECT SPECIFIC REQUIREMENT

5 TRAINING

6 INSPECTION

7 INSTALLATION,PRE-COMMISSIONING AND COMMISSIONING

8 FAT

9 DOCUMENTATION SCHEDULE

10 INFORMATION REQUIRED WITH BID

PART-II 1.0 COMMUNICATION NETWORKS

2.0 COMMISIONING ASSISTANCE

3.0 BIDDER’S SCOPE OF SUPPLY

DISTRIBUTED CONTROL SYSTEM SPECIFICATIONS

Part-I This part covers the general requirements of Distributed Digital Control System (DCS) like

scope of work of selected BIDDER, general hardware & software requirements, documentation, training requirements etc.

Part-II This part covers specific project requirements of the system. Part-III This part covers the details of I/O requirements.

PART- I

This specification calls for design, manufacturing, Factory Acceptance Test, delivery at site, erection and commissioning the Distributed Control System (DCS) with the functional and hardware requirements as specified in this document.

This DCS specification defines the functional requirements, the extent of the hardware needs. Bidder shall include the warranty period for the instruments as outlined in OWNER’s General

Conditions of Contract. Bidder shall undertake replace any defective or inappropriate equipment supplied with warranty period and shall make good such deficiency within one day from the date the same is brought to his notice by the Owner at Bidder’s cost.

Any deviation from the general terms and conditions attached herewith and the technical

specification shall be clearly indicated.

1 GENERAL It is envisaged that requirements of this specifications are met using standard proven

software and hardware of the BIDDER and it is latest at the time of shipment 2 BIDDER’S RESPONSIBILITIES 2.a General Requirement:

The DCS/ESD panels and all system hardware shall be located at a central cabinet room in the close vicinity of Central control room. This cabinet room shall accommodate all marshalling panels, PDB panels, DCS/ESD hardware panels, Barrier panels, relay panels. All these panel size/make/model shall either 1200mm (W) x 800 mm (D) x 2100 mm(H), or 600mm (W) x 800 mm (D) x 2100 mm(H), (size will be based on requirement), RITTAL make with RAL7035 colour shed, as specified below. All the field instrument signal/power and control cables shall be brought to this central cabinet room, from where it shall be catered to different individual destination marshalling panels and corresponding DCS/ESD hardware panels. There shall be dedicated marshalling panels for DCS or ESD. Also, different type of signal category shall have different marshalling cabinets. There shall be 20% space margin available in all the panels on marshalling and relevant system hardware side panels.

All the operator stations shall be accommodated in the central control room in the close vicinity of central cabinet room. In addition to central control room and central cabinet / panel room, there shall be a separate engineering room for accommodating all DCS/ESD and other system’s engineering stations in the close vicinity of central cabinet room & control room. Complete engineering activity of whole plants instrumentation & control system, downloading, online monitoring, changes, etc. shall be carried out from this engineering room.

There shall be panel segregation for various I/Os meant for DCS and ESD system. Also there shall be panel segregation for different type of I/Os for DCS, ESD and other control systems. This means that analog I/Os input and analog output and Digital I/Os along with all interposing relays shall be accommodated in a separate marshalling panel of DCS/ESD Control systems panel. Digital input shall be accommodated in a separate marshalling/DCS/ESD panel. Digital output and all interposing relays shall be accommodated in separate panels. Similarly, RTD & T/C signal shall be accommodated in separate DCS Panels. RTD/TC Input signal shall not use. RTD & T/C Inputs will be converted to 4~20Mausing Temperature Transmitters. No Head Mounted TT shall be used in entire Project. Yokogawa make Temperature Transmitter shall be used.

i. The signal exchange between electrical and instrumentation shall be via Electrical/Instrument interface panels, located in the existing cabinet area. There shall be two categories of Interface cabinet, viz. Analog and Digital. Analog Interface panel shall be used for various Motor Bearing/Winding RTD current inputs (4-20mA) from electrical/field devices to Instrument Control systems Electrical Substation, etc. Digital Interface panel shall be used for various Digital input and Digital output signals from / to Electrical/Instrument systems like various pump/motor running indication, stop command to MCC, etc.

All field cables exchange between plant and cabinet room shall be from cabinet room only. The cable entry in the cabinet room shall be provided with MCT blocks. Inside the cabinet room, engineering room and control room, cables shall be laid in perforated aluminium cable trays below false flooring. The cable entry for all the panels shall be from bottom only. There shall be physical segregation of various type/signal of cables like power cables, signal cables, communication and system cables. All system/communication cables shall run in closed, flexible, PVC conduit only inside cabinet/control and engineering room, below the false flooring.

ii. The operator console shall be table top type furniture with all TFT/LED/LCD monitors. The

relevant operator station hardware/PC, Servers, communication cables, etc. shall be accommodated in closed console enclosures. If the required earth pit resistance is not achieved with existing earth pits like System Ground, Safety Ground, Intrinsic ground, Additional earth pits has to be made to achieve the designed resistance, which will be in bidders scope. The additional system earth pits like System Ground, Safety Ground, Intrinsic ground, etc. shall be constructed in the peripheral area of cabinet room outside the control/cabinet room building. Enough space shall be dedicated for various earth pits. one earth pit, there shall be multiple earth pit connected in parallel. Similarly, if diff. system requires diff. earth pits, there shall be a group of multiple earth pits in the area outside the control room/cabinet room All the DCS system hardware cards, including I/O Cards shall be provided with protective coating as per ISA G3 level protection.

iii. BIDDER shall quote for the technologically superior and for the latest version system.

BIDDER shall quote for technologically superior and updated hardware and software options wherever applicable. BIDDER to inform OWNER for the updates in software/hardware releases as and when released in future also. The system reliability shall be stated in terms of MTBF in hours. BIDDER shall state the mean times to repair assumed in the calculation of MTBFs (The minimum mean time to repair possible shall be assumed to be 4 hours). Where a failure rate is derived from that of more than one item, the calculation method and supporting data shall be presented along with the results. In addition to these, BIDDER shall provide data from MTBF hours of each single module supplied in the system. Reliability calculations shall be based on the occurrence of random failures or single devices and communications channels only, BIDDER shall advise the experience data they have for common cause failures (CCFs) in redundant systems and the methodology they have used for calculation of CCFs. Also the defences they have adopted to minimize common cause effects.

iv. As part of their tender, BIDDER shall present a comprehensive quality plan for the overall

supply of the DCS hardware and software based on ISO9001, including all phases of design and constructions. OWNER reserves the right to audit the actual implementation of the Bidder’s QA/QC procedure from time to time.

v. It is anticipated that Un-interrupted power supply of high integrity shall be provided by

OWNER, 2-nos. of feeders for DCS at any one location and further all distributions required for system/sub-system and Field Solenoids shall be carried out by BIDDER. This supply shall have 30 minutes back up time.

vi. BIDDER shall supply all standard/optional software and firmware which are necessary to built up all application software concerned with DCS hardware and software.

vii. Complete database generation including dynamic graphics shall be in BIDDER’s scope.

Further to this application software shall be successfully implemented and optimized till the plant operations are stabilized. Any modification changes required shall be done by BIDDERs concerned engineer.

viii. System and application software shall be made available in two set of DVD/CD-ROM. This is

apart from the DVDs/CDs downloaded in the system. BIDDER shall also supply 3 set of E-Doc and DVD/CD for the complete system which shall cover all standard system documentation.

ix. Power supply for each system/sub-system shall be 100% redundant with capacity to accept two feeders. BIDDER has to indicate where these redundant power supplies are installed and where it is not installed.

2.b BIDDER’s responsibilities shall include, but are not limited to, the following: a. Supply of system hardware and software, system cabinets, consoles, mounting facilities. b. System programming and configuration. c. Implementing control strategies given by the Licensor/Clients/ d. Implementing any advance level control strategies given by the Licensor/Clients/ e. Configuration of various displays. f. Generation of history data base and reports. g. Generation of logging reports and other management information reports. h. Factory testing. i. Configuration of various Alarms for both the sections. j. Transport to site. k. Installation at site. l. Supply and termination of various interconnecting cables between marshalling racks

and between marshalling racks and system hardware cabinets. m. Powering up, Loop checking and commissioning. n. Providing assistance during commissioning like implementing control strategies,

tuning of loops etc. o. It shall be possible to alter history function parameters to add / delete points,

change of frequency etc. Averaging for predefined time, min, max and this type of other simple elementary calculations shall be possible in the history. History should display either these manipulated variables or real time variables as per user choice. Total retention time for all tags shall be 1 sec, BIDDER to specify considering unified database i.e. 1000 points. It shall be possible to scroll time forward as well as backward without any loss of historian data. BIDDER to comment on this topicIn a circular buffer nature of the historian files maintained on main hard disk, while the retention time is over, it shall automatically dump the data on an archival media like tap before rewriting that location. This shall be scheduled as per user defined time base.

p. Providing documentation in required number of sets during engineering and also as-

built documents after commissioning, supplying the same on soft copies/electronic media& Hard Copies.

r. Providing training for clients’ operation & maintenance personnel in BIDDER’s works

and also at site. s. Ensuring hardware support (supply of spare parts) and software support (including

supply of periodic updated software versions) for a minimum period of 15 years after commissioning.

t. Preparation of specifications, procurement, inspection, erection, integration and

commissioning of all bought out items included in BIDDER’s scope of supply.

u. It is preferable to have DCS & ESD in control system manufactured outside china. China make items are not acceptable.

v. Packing and forwarding. 3.0 SYSTEM OVERVIEW 3.1 The DCS shall have the following main components. The system shall be dual redundant

and 100% fault tolerant. This means, all central control processors, all communication processors and all other central rack and individual node’s common cards, all the communication cards, networks and cables, etc. shall be 100% fault tolerant and dual redundant. All the system hardware of DCS shall have ISA G3 level corrosion protection. All the hardware including control/communication processors, networks, cables, all type of system cards, all type of I/O cards shall be hot swappable.

3.2 The system shall be built on the latest state-of- the-art hardware and software platform

and hardware/software/firmware revisions of complete system will be latest at the time of supply. The system architecture shall have Windows 7 or latest version of 32 bit or 64 bit operating systems and compatible RISC hardware. All the operator station and engineering station shall equipped with 22” TFT, COLOR, LCD/LED monitors. All Workstations should be directly sitting on Plant Communication Loop as INDEPENDENT NODES. However, “View only remote monitoring stations" which are meant for monitoring only and no plant operation is to be performed from these, can be connected to plant communication loop through LAN

Multi-loop controllers & Data acquisition system.

a) It shall be fully redundant and fault tolerant with hot-swappable redundant modules.

The scan time of the analog control loop shall be 200 ms max and monitoring signals shall be 1000 ms max. The scan time for digital interlock shall be 250 ms max. The system shall support various types of control/ sequence/ interlocks algorithms and shall also be capable of supporting inputs from various high level programming languages like VB, C/C++ in real time applications, in addition to standard control algorithms available within the DCS system.

b) The system shall support all various type of control/interlock/sequence algorithm and shall also support various high level programming language like VB, C/C++ in real time control application, in addition to standard control algorithms available in the DCS

c) All the I/O cards shall have individual channel to channel as well channel to field

isolation. Analog input/output cards shall be galvanically isolated and digital input/output cards shall be optically isolated. Group isolated type or bulk I/O cards shall NOT be accepted in the whole system architecture. All I/O cards shall be intelligent type with microprocessor/microcontroller based hardware and capable of all type of signal conditioning, self-diagnostic, fail safe value configurable (programmable) and time stamping at I/O card level.

d) All I/O cards in individual category shall be of same type/model/revision only. No diff

bulk I/O cards or I/O cards with degraded features shall be accepted in any of the category in a mix mode supply.

4.0 FUNCTIONAL SPECIFICATIONS In design of each node on the system the following minimum features shall be applicable:

1) The main processor shall be min. 64 bit (frequency BIDDER to specify) architecture with CMOS/SMD TECHNIQUE adopted.

2) Parallel, independent processing of each station.

3) BIDDER to specify the variable scan time and minimum scan time available, in case of control station.

4) BIDDER to specify total memory and detailed sizing. 5) BIDDER to specify memory back up time. 6) BIDDER to specify method of redundant/fault tolerant modules and any hardware switching

devices are not acceptable BIDDER to conform the same. 7) BIDDER to specify the method of Peer-To-Peer communication of each control station with

other control station and any limitations.

4.1.a Operator Stations/ Engineering Stations/SOE

Standard specifications for operator workstations for DCS and ESD: The minimum configuration shall be server grade workstation machine based on 64 bits

INTEL processor min. 2 nos. of free 64 bit PCI slots, 1no 64 Bit 100 MBPS Ethernet LAN card. They shall be of DELL make only. These shall be supplied with the best befitting furniture with good system ergonomics and aesthetic with printer tables. The hardware configuration and specifications of all operator stations and engineering station shall be identical so that they shall be interchangeable. Make: DELL

Processor: Latest and Proven 64 bits supporting latest Windows based Operating System. HDD: 1TB minimum RAID-I Redundant & Hot Swappable RAM: 8GB minimum Graphics: Graphic card with 2GB dedicated memory

DVD writer: required Display: 22” wide screen TFT /LED/LCD type colour monitor, 2-tier monitors for operator consoles. Connectivity: serial, parallel and USB ports. Supply voltage: 110VAC

All Operator Stations will be Touch Screen type with Enable and disable facility.

4.1.1 Each 22”, TFT/LED type colour VDU shall be standalone type with its independent operator’s keyboard, touch screen, mouse, memory, CPU, communication interface and power supply to HDD, CDROM/DVD, DAT along with 64-function keys operation key boards. This shall be equivalent to one node on the highway.

4.1.2 In case a forced cooling device like a cooling fan is provided for each VDU the failure of the

same shall be annunciated either directly or indirectly (through temperature sensor). 4.1.3 Each VDU shall have its own power supply isolator, preferably HRC fuse. 4.1.4 Controls for brightness adjustment& contrast adjustment should be available on each VDU,

for operator

Following minimum specifications shall govern for Operator stations: 4.1.5 Each operator station shall be accommodated in its own independent furniture with the best

befitting furniture with good system ergonomics and aesthetic with good system ergonomics and aesthetic.

4.1.6 The “touch screen” option is specified in Part-II of the specification the same should have the

following features: a. “Touch Screen” facility should operate only when a “touch target” is accessed by a device

and the device is withdrawn i.e. the facility should not operate on mere touching.

b. It should be possible to disable the facility. This should be an operator function. c. In case of failure of the “touch screen” it should be possible to operate the plant through the

displays (including graphics) by positioning of cursor on the screen through mouse. This should be a standard feature of the system and no additional software may require to be written for the purpose.

4.1.7 Failure of any one workstation should not affect more than one operator station VDU 4.1.8 Auto "Time synchronization" feature will be available for all Operator Station/ Engineering

Station.

4.2 Displays 4.2.1 Display call up time for various displays shall be a maximum of 2 second irrespective of

displays’ total dynamic I/O points, density. BIDDER to specify the display updates times. 4.2.2 The system shall have the following types of displays with their brief requirements as

explained below: a. Overview Display This shall give an idea of the overall plant status with less emphasis on details. This can

either be in the form of a deviation overview, overview of various plant units, alarm status of all tags etc. This display shall not be used for plant control. Similarly no alarm shall be acknowledged from this display. It should be possible to approach any other operating display from overview with minimum of operations. All these features shall be user configurable.

b. Group Display This shall be a group of tags; analog or digital in any mix. It should be possible to

control/monitor any loop from this display. Loop parameters like alarm status, PV, SV, MV values, mode status (Auto/Manual/Cascade) etc. shall be displayed prominently for each loop. This display should be conveniently linked to the plant overview display, detailed loop status display and also to the relevant graphic pages of the plant, for ease of operation.

c. Detailed Loop Status Display This shall give in analog/digital form all the parameters of a particular loop like alarm set

points, P, I, D values bias, loop status, PV, SV, MV values, limits on output or set point, algorithm description, controller action, other configuration details etc. This display shall be used mainly by engineers for changing constants, tuning a loop etc. Real time trends of PV, MV, SV for tuning purposes shall be available in this display. The sampling frequency for trends in this display shall be minimum 1s with configurable dead band for each parameter and the display time minimum 10-30 minutes.

d. Displays For Alarm Handling

This shall be one of the most important displays of the system. This shall have following features as a minimum. DCS system shall have latest; windows based alarm manager with 1 second or better time resolution. In addition to various process alarms, the system shall also store operator action journal, system error messages, any other event, etc. Alarm manager shall also have historian facilities and there shall not be any storage limit except hard disk size for retention period of various alarms/events.

i. A list of alarms based on occurrence with most recent alarm on top. ii. A common list of latest 100 alarms for the whole plant in chronological order.

iii. Ack/scrolling ALM history and most recent alarms shall be possible through software targets on the same display.

iv. The alarm list in each case shall give the tag no., the service description, type of alarm and

the time of occurrence, status, acknowledgement information. BIDDER to specify total number of alarms per page.

v. It shall be possible to assign alarms on PV, SV, MV, rate of change (PV, SV), deviation, ratio

as well as on any intermediate computed value in case of a complicated algorithm. vi. The system should have minimum 3 levels of alarm priority with different colour and tone.

Emergency, high & low. Following are the characteristics of each level:

Emergency Alarms

These shall be grouped for the plant separately from other alarms. Acknowledgment of these shall be through a separate key with LED, dedicated for the purpose and a separate hooter shall be provided for the same. These shall be logged automatically on the printer. The security level should be such that these cannot be disabled by operator or supervisor but only by engineer through a key switch and password.

High Priority Alarms

These shall be similar to emergency alarms except that all high priority alarms shall be acknowledged through a separate key with LED assigned for the purpose. Those shall be logged automatically on the printer and can be disabled only by supervisor/engineer through a key switch and password.

Low Priority Alarms

These should be acknowledged through a separate dedicated key with LED. It should be

possible for operator to disable the alarms. However, logging of the same should not be disabled.

vii. It should be possible to disable alarms one by one (i.e. tag-wise) or globally in a unit of the

plant through a single command. viii. It should be possible to assign different priorities to more than one alarm for the same tag.

(e.g. it should be possible to assign different priorities to “high” & “low” alarms of the same loop).

ix. The system software should automatically histories all alarms earlier than the latest 100

alarms.. x. All system alarms (hardware & software) shall be available in a separate alarm summary with

its own acknowledgment key and a dedicated hooter. In alarm system, a common list of all defeated alarms shall appear disregarding their alarm

types, priorities, grouping, unit etc. e. Trend Displays Trend displays shall have following minimum features: i. Facility to group/delete a variable from a group. This should be an operator function. ii. Scrolling of time axis on X- axis and scrolling of range on Y-axis. iii. Tag no., alarm status and the dynamic value of the variable in digital form on the trend

page.

iv. Facility to read precisely any value of the variable being trended by positioning the cursor at any point on time axis.

v. Y-axis zooming facility. vi. It shall be possible to trend any variable, analog or digital and any parameter of any

particular tag.

vii. For an analog tag it shall be possible to trend PV, SV, MV deviation, ratio or any intermediate calculated value in an algorithm and any standard block parameter.

viii. Minimum Sampling Time For Any Trend Shall Be 1s or or less. ix. It shall be possible to assign different sampling times tag wise independently without any

limitation with user configurable DB. x. It shall be possible to store all trends for long time historian without any time limit on

retention period, except the hard disk size. If diff. operator stations are storing trend data of diff. trend group, all these stations shall be equipped with min. 1TB RAID-I HDD with mirroring facilities. It shall be possible to dump data older than 120 hours automatically to a data storage device like RAID-I HDD folders and from which it can be retrieved for viewing at later date.

xi. BIDDER to give more details regarding data storage and retrieval. xii. On-line archiving of trends shall be possible. Real time trends of 2 hours’ time base shall be generated perfectly from the control stations.

This should not need any history. In case of power failure, no loss of real time, historical and trend data shall occur.

f. Graphic Displays These displays shall be used most frequently for control and monitoring of the plant by

operators. They shall have the following features as a minimum. i. Graphics shall be fully dynamic & interactive. BIDDER to inform the maximum number of

dynamic targets any display can accommodate. ii. Overlays feature shall be provided to superimpose windows of various types and sizes on a

graphic. The overlay can be a face plate of a loop, a part of any graphic, a trend, a message etc. It should be possible to have more than one overlay of different type on any graphic and they all are should be freely movable within main graphic window.

BIDDER to explain the same particular to the system quoted. BIDDER have to specify the maximum numbers of overlays of different sizes, opened on a

standard base graphics and any other limitations. It is Owner’s intention to have “WINDOWS” based graphics facilities. this is over and above

the overlaying facilities of the system by windowing facilities mean system shall support any standard windowing feature like OPENLOOK/OSF/MOTIF/WINDOWS-NT GUI to operator, where simultaneously more than one (at least four WINDOWS) windows can be opened and kept aside for operator action on a single VDU. It shall be possible to scale the window size as per operator need and the placement of the window on the screen shall be freely selectable. BIDDER to specify the limits on numbers of windows that can co-exist on a single Operator Station with all interactive features.

iii. BIDDER to confirm the total number of colours available (minimum 45). Font size shall be

freely configurable.

iv. Background colour of graphic shall be freely selectable. v. It shall be possible to build frequently used symbols and store the same in a library through

which they can be recalled for future use. Graphics builder shall have all ISA symbols in library form, so that standard, uniform graphics

can be generated in a less time. vi. It shall be possible to assign at least 4 modifier conditions to a graphic character/object. By

modifier conditions it is meant change of colour, size, filling & visibility of a pattern etc. vii. Graphic builder package shall be easy to operate without any detailed knowledge of

hardware/software. In particular following features are desirable: - It shall be possible to build graphic through “touch screen” and mouse. All features of

interactive menu driven graphic builder like drag and drop , edit , copy , paste with on line program sensitive help shall be available.

- Software shall have facilities to change/modify either at a global level or discrete level and

the same can be updated in all places with minimum key strokes. - Common graphic builder tools (e.g. intersection, end point, mid-point, centre, tangent etc.)

found in AutoCAD should be available for effecting quick changes. - Graphic builder package shall have command / script support for complex graphic

which can manipulate control strategy . - Facility to “zoom” a picture for better visibility shall be available. - Security features like masking / access lock shall be available for graphics or parts

thereof. - It shall be possible to save pictures or parts thereof in the symbol library (to be used again)

directly from the picture being drawn & the same need not be drawn once again for the purpose.

BIDDER shall size the hardware with 60% spare software capacity available to the user

based on the requirements given in Part-III. BIDDER shall furnish the detailed sizing calculations along with offer:

1) 60% of total nos. of analog I/O at 1 sec scan time. 2) 40% of total nos. of closed loop at 250 msec. time. 3) 40% of total nos. of digital I/O at 50 msec. time. 4) 60% of total nos. of digital I/O at 250 msec. time.

g. Configuration Displays These shall be used for configuring a loop and shall be mainly used by engineer. These

should also be dynamic and should show the various loop intermediate parameters in the loop in digital form. (e.g. a temperature indicating loop should display the mV signal being received, the value after conversion to temperature units and so on). It shall be possible to effect “on line” configuration changes using these displays.

Online changes made in the controller sub system, shall not affect the output of a closed

loop or process. BIDDER to categorically clarify the limitations if any.

Changing of units, ranges, alarm values, dead bands, alarm priority, linearization etc. Of one I/O shall not affect the others. The last good values hold feature shall be implemented in the system with alarms.

The access to these displays shall be protected by key lock switch and/ or a password. It shall be possible to log any tag, calculated results or any block standard parameter in the

freely formatted manner and log scheduling shall be user defined interval or on demand. BIDDER to specify the total nos. of log/reports and total point per log limit. Elementary calculations like min., max., averaging, addition, subtraction, rounding off, division, etc. shall be possible in the free format logs with time and date functions. It shall be possible to transfer all these type of reports/logs in a simple ASCII format in a CD/DVD/USB automatically.

. High level programming language support - The system shall provide proper and secure facilities for developing, modifying, compiling

and running of user written programs in any high level language like C, C++, VB or any other 3rd party optimization package etc. It shall be possible to modify, compile and download the program without affecting the normal controller operation. BIDDER to specify the residency and run time platform of these programs, if it requires any extra hardware, then BIDDER to quote for the same with full technical details and limitations.

h. System Diagnostic Displays These shall be arranged in a hierarchical fashion such that a fault in any of the units of the

system can be traced up to module level by suitable annunciation. Modules and individual channel level fault diagnostics with immediate alarms on all operator stations are a must. The following information shall be available through these displays as a minimum.

BIDDER to explain the various diagnostic features/facilities/to stays available in the system

including maintenance procedures. i. Type and location of malfunctioning unit. ii. Nature of fault. Internal Security The system shall carry out regular and extensive self-testing. In general, transient errors

shall be handled either by immediate re-try or by the inclusion of additional information within the systems which allows minor fault recoveries. Errors which cannot recover in such a way shall result in an audible system alarm of high priority on operator station, historian and alarm printers and smooth changeover to the redundant unit shall occur wherever provided. In all cases, the transfer of control, communication etc. To the backup equipment shall be totally transparent to the control and monitoring of the process and shall not result in any spurious bumps or changes to process output states. In case of control node failure, the output shall be configurable in a fail safe manner by default (or predefined) configuration value/status. Items which shall network and regularly thereafter shall include:

- Control processor, I/O processor and communication processors. - System communication network modules. - Links to other network devices. In particular, BIDDER has to give details about system failure mode and causes which system

attains this mode.

4.3 Keyboards

Operation Keyboard

The Operation Keyboard shall dedicated keyboard for operation & monitoring of processes. This shall be used by plant operators along with each Operator station display unit for operation of the plant.

This shall be membrane type fully dust proof and spill proof & corrosion proof.

The following shall be main keys and their functions-

- Function Keys: The array of function keys comprises 64 dedicated one-touch operation keys that shall be used to call windows, start application programs and other operations. One each key there shall be section in which operator can write a name for the assigned service function.

- Control Keys: Eight pairs of control keys shall be provided for the eight instrument face plates displayed on the screen. These keys shall be used to increase/decrease the amount of operation and switch between automatic and manual modes of operation. In addition to eight pairs of control keys, a target key shall be provided to increase the speed with which the operation is increased or decreased or to switch a data item to be operated.

- Window Call Keys: These keys shall be used to call various windows.

- Data Entry Keys: These keys shall be used to designate the tag name and enter data.

4.4 Printers 4.4.1 There shall be Six Dot Matrix Printers- Two for Ammonia-II, Four for Urea-II (Two each for

Section 31&41). Dot Matrix Printer shall be used for printing operator actions, alarms, logs in various formats, as also to print all the self-documentation of the system. Printer with both engineering station shall be of “A3” size, local USB, Laser type colour printers, which shall be used to print colour graphic hard copies and real / historical trend, etc. dedicatedly from engineering stations. t Laser Printers to be supplied is given at clause 4.5.8,P-46.

4.4.2 Printers shall be supplied with self-standing enclosure and acoustic cover. The enclosure

shall be provided with an additional shelf to stack papers/logs etc. 4.4.3 Printers shall be freely accessible from any VDU in the system. These printers shall be

network printers with Ethernet connectivity. 4.4.4 In case more than one printer is specified per operator station, (e.g. one exclusively for logs

and the other for alarms, operator actions etc.) it shall be possible to select and allot functions to each printer. This should be a supervisor’s function.

Also in the event one printer is out of action it shall be possible to assign functions of the failed printer to the second printer automatically.

4.4.5 Fan fold type paper is preferred for report/log/alarms and A3 / A4 size copier papers are

preferred for A3 size colour LASER printers 4.4.6 Each printer should have its own power supply isolation, related furniture. 4.4.7 All other Printer shall be of Laser Type. The qty is as under:

Consolidated requirement of printers for each AMM-II &Urea-II unit is as under

A3 size Laser color for DCS 2 No. A3 size Laser color for DCS Engg station 2No. A4 size Laser color for DCS 2 No. A3 size Laser color for ESD 2 No. A3 size Laser color for ESD Engg station 2 No Dot Matrix Printer 132 x 24 pin 6 Nos

It may be noted that all printers shall be network printers with Ethernet connectivity

4.5 Color Hard Copier cum Scanner 4.4.1 This shall be “A3” Laser colour printer, Copier cum scanner used to copy images of various

screens from any VDU’S of a system, or a group of stations; on command. Separate scanner shall be required for each section Amm-II and Urea-II. This shall be with Ethernet print server port and additionally USB and Centronics parallel port inbuilt in the printer.

4.4.2 Buffer memory capacity to be such that down loading time is less than 5 sec. 4.4.3 It shall be possible to take colour prints on both white & black background. 4.6 Multiloop Controllers/Data Acquisition System/Controller Subsystem 4.6.1 This shall be one of the nodes of the DCS and shall be used for closed loop control and also

for data acquisition of all analog open loop inputs. It shall be 32 bit or 64 bit, microprocessor based /RISC processor with real time control system software with 100% redundancy and fault tolerant. It shall be possible to replace the redundant control processor or any of the cards from control processor unit, while the plant is running, without affect the plant operation. All modules of control processors shall be hot swappable type. All communication links with I/O subsystem shall be 100% redundant and fault tolerant type. In case of failure of communication of control processor with I/O subsystem via one of the I/O link, the second link should take smooth control, without any plant disturbance or signal, data loss.

This shall also have capabilities to execute process sequences and interlock logic using digital inputs and outputs.

4.6.2 The system shall have the capabilities to execute the following control algorithms as a

minimum. A list of algorithms available shall be submitted along with quotation. a. P, PI, PID with external bias. b. PID gap. c. Two position On/Off control. d. PID On/Off. e. PID with cascade, ratio. f. PID with adaptive gain & reset. g. Lead/lag compensation. h. Dead time compensation. i. Manual loader. j. Low/high signal selection. k. Temperature/pressure compensation for flow. l. Pulse inputs scaling. m. Integration/totalizing (both resettable & non-resettable. Min. 6 digit counter) n. Elapsed time computing. o. Signal selector for min./max./mid value p. Velocity limiter.

q. Self-tuning. r. Ramp generation. s. Alarm generation on input, set point, output, deviation, intermediate computed value, rate of

change etc. (Min. 4 Alarms/PV). t. Analog inverter u. Input/output characterizer. 4.6.3 Following mathematical functions shall be available in the system as a minimum: a. Addition. b. Subtraction. c. Multiplication. d. Division. e. Sq. rooting/square. f. Moving average. g. Piece-wise linearization for input/output. h. Cold junction compensation for all T/C inputs. i. Exponential functions. j. Logarithmic functions. k. Absolute value. l. Comparator (i.e., greater than, less than, equal to etc.) m. Pressure & temperature compensation for flow loops. 4.6.4 Following logic operations shall be possible in the system as a minimum: a. AND, NAND b. OR, NOR c. EX-OR d. Inverter e. Flip Flops (SR, JK, Toggle, etc.) f. Timers (On delay/Off delay type up to 24 hours)/counters/software flags/numeric etc. 4.6.5 All the above mentioned algorithms/operations shall be resident in the controller EPROMS

itself and no external device shall be required to be called to execute these functions. 4.6.6 In case the system accepts only 1~5 VDC or 4~20 mA DC analog signals the necessary

terminal boards are included in BIDDER’s scope of supply. No other signal converters like R/I

converters, shall be accepted in the system. In case of T/C & RTD Signals, Temp Tx shall be used to convert mv signal to 4~20mA.

4.6.7 Two wire transmitters shall be powered from 24V DC 0.25% supply floating which shall be

derived internally from analog input cards by the BIDDER. Earth fault detection circuit is a part of input card.

4.6.8 Independent channel shall be provided for each transmitter with necessary current limiting

30mA max. circuit to guard against short circuit/accidental earthing of field wires. 4.6.9 Interrogation voltage for all status inputs shall be 24V DC and the same shall be derived

internally by the BIDDER. . 4.6.10 For all types of alarms dead band shall be configurable individually between 1%~5% of

span. 4.6.11 Two modes of variation of set points and output values shall be available on controllers and

manual loaders for fast/slow ramping through the keyboard. 4.6.12 It shall be possible to have latched as well as pulse outputs from the system. In case of

pulse output it shall be possible to have positive as well as negative pulse. Pulse width shall be adjustable individually from 0 - 10 sec

4.6.13 A/D converter shall have a minimum resolution of 13 bits. 4.6.14 D/A converter shall have a minimum resolution of 10 bits. 4.6.15 The controller and data acquisition system shall have full peer to peer communication with

other nodes of the system without any limitation. 4.6.16 In case a forced cooling device like a cooling fan is provided, failure of the same shall be

annunciated on VDUs either directly or indirectly (through temperature sensor). 4.7 Bulk Data Storage Modules 4.7.1 DCS shall be provided with one or more data storage modules. This shall be used to

maintain the following data: a. History of the plant like trends, alarm messages, set points, controller constants, operator

guide messages etc. b. Entire application software of the plant like configuration of each node, source & object files

of various displays like graphics, group, etc. configuration of control loops. c. Storage of any user written program for plant control. d. Storage of advanced control program if any. Wherever, engineering data/ complete plant/project database and real time/historical trend

data are stored, all these station shall be provided with RAID-1 redundant HDD with min. 1TB capacity in each station. All of these RAID-I units shall be hot swappable type.

4.7.2 The data storage modules shall consist of non-volatile storage media like HDD disk,CD/DVD

&DAT, etc. which is available in open market. 4.7.3 1:1 backup is required for all data storage modules to preserve vital system configuration

and all historical / long term trend data. 4.8 Communication Networks - Comm. protocol shall confirm to IEEE802.X/OSI standards

with 7 layer open system model. .

4.8.1 This shall mean all the hardware and software needed for communication between various system nodes as well as devices within a node. In general it can be classified broadly into following categories: All the nodes of DCS including control processor, operator station and engineering stations, other communication gateways, etc. shall be peer to peer nodes, sitting on the same dual redundant communication network. No double layered communication with one common redundant gateway server is acceptable. In the proposed system, failure of any of the peer node, shall not affect any of the functionality of other nodes. The minimum bandwidth of main system communication network shall be 1GBPS or better.

a. Main data highway on which various nodes of the system shall communicate will be 100%

fault tolerant with 100% redundancy at all component level. b. Internal communication bus on which various intelligent devices within a node shall

communicate and this shall also be 100% redundant / fault tolerant c. Communication interface between a node and a peripheral device like printer, copier etc. 4.8.2 Main Data Highway a) This is the most important communication network. Vendor to specify latest speed.

This shall facilitate peer to peer communication with all the nodes in the system viz., operator station, control & data acquisition system, bulk I/O processing unit, bulk data storage modules, gateways and other devices if any and peripherals like networked printers, etc. All these node are referred to as peer to peer nodes. No layered architecture is acceptable with common gateway units.

b) This shall be a 100% redundant highway system for operational security. The system

diagnostic display shall indicate load and the status of active & standby highway at any given time. The total load in worst condition shall be defined by BIDDER.

c) In case of a fault with active highway the redundant one shall take over communication

functions automatically, instantaneously and smoothly, without any loss of information.

d) The health of both highways shall be checked continuously and faults annunciated through a system alarm.

e) The system architecture and software shall be such that it shall be possible to physically add

or remove a node, on/from, highway without interrupting ongoing communication with other nodes.

f) Similarly in case of a failure of one or more nodes, the same shall be automatically bypassed.

The communication with other nodes carries on uninterrupted.

g) The communication transmission shall be fast enough so that even during plant upsets, shutdowns or start-ups, the highway is not jammed.

h) Sufficient spare capacity ( min 80 % on active bus ) shall be provided for transfer

efficiency of the data highway to ensure full functionality in the event of load fluctuation/worst conditions, BIDDER to define worst conditions.

i) Each of the communication highways shall be routed differently to prevent damage to both in

case of an accident. 4.8.3 Internal I/O Communication Bus

a) This shall connect various I/O modules within a node to the master CPU executing control, data acquisition, logic execution and other tasks.

b) This shall be a 100% redundant bus system.

c) Health of the active and standby bus shall be available on system status display.

d) In case of a fault with active bus the redundant shall take over communication functions

automatically, instantaneously and smoothly without any loss of information.

e) It shall be possible to add, remove or change I/O modules on-line, without interrupting ongoing communication with other modules.

f) In case of a failure of one or more modules, the same shall be automatically bypassed.

Communication with other modules carries on uninterrupted.

g) In case the system architecture is such that I/O modules can be located remotely from the master CPU, the data transfer rate shall be fast enough to ensure that there is no compromise on scan time.

-BIDDER to inform distance limitations if any. 4.9 Engineering/Configuration Station 4.9.1 There shall be 4 nos. (2 nos each for Ammonia-II & Urea-II) engineering stations in the

complete DCS system. Engineering, development of complete plants DCS project, database building, graphic generation, compilation, downloading etc. shall be done from these two stations independently. These Engineering stations can be used as Operator stations also.

a. To build graphics using the graphic builder programme. b. The configure control loops/monitoring loops c. To assign I/O’s to various I/O modules during generation of application software. d. To configure shutdown logic/sequence logic. e. To write/edit user written programme in higher level languages. f. To download the generated application software to various system nodes. g. To generate “self-documentation” i.e. It should be possible to store the generated

information on a CD/DVD as well as to enable user to take a printout of the system configuration.

h. To Simulate generated control loops/scheme/graphics, etc. before it is downloaded to any

control processor or operator stations. i. The graphic and database equalization of all the operator station shall be performed from

engineering station with a single command. It should not require manual copy/paste intervention by user.

j. Both of this engineering station shall be accommodated in the central engineering room

along with other control systems engineering station. This central engineering room shall be in the vicinity of cabinet room and central control room. Both of this engineering station should also have standard operation and monitoring software also, so that they can be used as operator stations also, if required.

k. The minimum configuration shall be server grade machine based higher Intel processor, 8 GB

DDR RAM, 22 “ TFT/LCD/LED monitors, 1TB RAID-1 Redundant & Hot swappable HDD, DVD Writer, min. 2 nos. of free 64 bit PCI slots, 1no 64 Bit 100 MBPS Ethernet LAN card. They shall be of DELL make only. These shall be supplied with the best befitting furniture with good system ergonomics and aesthetic with printer tables.

4.10 Gateways For Communication With External Devices 4.10.1 This shall be either a node of the system or a I/O subsystem part of controller system’s node,

in case of 2 wire, RS485 communication link and shall be offered as per requirements of Part-II. The communication port/gateways with ESD shall be fully redundant with dual redundant communication link. If there are dedicated gateways available for proposed DSC/ESD, which can seamlessly integrate the both systems, it is preferred over a normal 2 wire RS485 serial link.

4.10.2 However, following minimum specifications shall apply in case redundancy is specified: a. Both the gateways (active & redundant) shall communicate with both the highways of the

system. b. Health of each shall be monitored by the other and in case of failure of active gateway the

other shall take over its functions smoothly and instantaneously without loss of information. c. Redundancy shall be such that this shall not bring down the availability of system or cause

any false alarms/trips in the system on both sides of the gateway. This is particularly true for digital signals to & from PLCs. Logical ANDing/ORing of parallel signals to/from PLC/DCS to achieve desired actions shall not be treated as a fully redundant system.

d. The communication time delay or total scan / cycle time for transferring all ESD parameters to DCS shall not be more than 1 second. If required, BIDDER to include additional gateways to achieve this scan time.

4.11 Supervisory Control Devices System shall be capable of running any 3rd party optionization package seamlessly with host

DCS. 4.12 Project Specific system requirements 1) The system should have a truly distributed architecture , both functionally & physically ,

designed following the philosophy of providing an open system using hardware , software and communication standard to maintain a long lived architecture.

2) All platforms on the system should use the same operating system and base system software so that operators , maintenance people , engineers and managers utilize consistent software tools and interact with the information in the same manner.

3) Time and date format shall be uniform throughout the system and it shall be as per

HH:MM:SS and DD:MM:YYYY (or DD:MMM:YYYY) format with 24 hours clock. 4) All hardware shall be protected against RFI , typical freq. are 0.15Mhz ....1212 MHz

and especially 146 ....174 MHz by walky-talky of 6 ... 10 watts power in 1 m distance. 5) System’s software shall also include the software to configure the communication link

between DCS & any PLC based or other 3rd party control system capable of communicating on MODBUS RTU/ASCII/ETHERNET protocol. Significant features and characteristics of the interface include

a) Availability of data in the interconnected PLC which allows the DCS to integrate in

displays data from PLC and to centralize monitoring of PLC operating status. b) Ability to write data parameters from DCS gateway into selected locations of programmable

logic controllers. 5.0 TRAINING 5.1 Supplier shall train Clients’ maintenance engineers in their works and operational staff at

owner’s site. The training imparted shall be by qualified and experienced staff available. It shall be exhaustive and aimed at making clients’ maintenance staff self-reliant for most of the day to day applications. For training, supplier shall make available as close a model of

the system with all the representative nodes, as the actual system to be installed. It is envisaged that following be covered in the training:

5.1.1 Maintenance Staff Training (at vendor’s works) a. System architecture. b. Functions of each node. c. Hardware in each node. d. Complete application software. This shall cover everything from basics like generation of various system nodes to advance

language programming, configuration and debugging etc. e. Commonly occurring hardware problems and the maintenance procedures to be followed. f. Various diagnostic programmes available and their use and interpretation. g. Routine preventive maintenance procedures. h. Maintenance of various peripheral devices like printers, copiers etc. For purposes of training, detailed literature, instruction & maintenance manuals in English

shall be arranged by the BIDDER. The requirement of Maintenance staff training shall be total for 60-mandays at their works.

Training shall be in two batches of engineers for 5 days each. 12 engineers x 5 days each = 60 man days

Boarding, Lodging and to & fro Fare will be in bidders scope. 5.1.2 The requirement of maintenance/configuration training at their centre of excellence shall be as

given below Two Weeks training for Six Instrument engineers (in 1-batch) for DCS & ESD Systems, at

OEM’s centre of excellence should be included.

Boarding, Lodging and to & fro Fare will be in bidders scope. 5.1.3 Operations Staff Training (at NFL Vijaipur site) This shall be restricted to the operation of the system. This shall broadly cover the following: a. System architecture. b. Functions of each node. c. Functions of various keys in the keyboard. d. Generation of displays like graphics, group and trend groups, etc. e. Display hierarchy, access methods for various displays, switching between different types of

displays etc. f. Control of plant from various displays. g. Alarm handling. h. Developing special programmes for plant control and their debugging (Restricted to

supervisory staff only).

i. Logging software. 5.2 For purposes of training, detailed literature, instruction & maintenance manuals in English

shall be arranged by the BIDDER. The requirement of operational training shall be total for 60-mandays at their works. Training

shall be in two batches of engineers for 3 days each 20 engineers x 3 days each = 60 man days 6.0 INSPECTION 6.1 The system and all (100%) its associated components shall be inspected and tested at the

BIDDER’s works by Licensor/Client/OWNER 6.2 Clients/OWNE reserve the right to inspect any bought out items by the BIDDER at the sub-

BIDDER’s works. 6.3 Cost of inspecting/testing shall be borne by the BIDDER. 6.4 For final integrated inspection of the system, the BIDDER shall give a minimum notice of 3

weeks to Clients/Owner Throughout the factory acceptance test, BIDDER shall provide all necessary test equipment’s

and consumables and shall make all necessary connection to all hardwires as many times required. OWNER shall carry out 100% functional checking of all hardware/software modules. BIDDER to co-ordinate with Third party PLC/Control system for system integration and SAT.

Site acceptance test (SAT)

After transportation to plant site the BIDDER has to investigate and prove all system components and devices against transportation and erection damages.

This level of testing will take place on site after the system has been installed and certified as

operational by the BIDDER. The BIDDER shall have the responsibility to ensure that the installed hardware including the

software supplied is fully operational. The testing procedure shall include mechanical checks of the system including all system links

connected according to the BIDDER's specification. After this the software will be loaded and self-test routines of the ESD-system shall ensure

that all system components are in acceptable condition as well as the communication links are working properly.

The application software will be loaded. If the system shows no deviation to the normal

operation, the system will be ready for loop checks. When the system operates normally for continuously 30 days, after completion of the loop

checks and all simulation tests, the ESD-system shall be considered as accepted by the Owner.

All guarantee performance data which are specified (CPU spare capacity, spare capacity of

hardware, scanning time of process variables etc.) will be proven by BIDDER. A certificate of acceptance shall be signed by the representatives of the Owner and BIDDER. 6.5 The inspection shall briefly envisage the following:

6.5.1 Hardware Inspection a. Checks on general workmanship like fabrication quality, paint quality, whether paint shade

identical to all cabinets etc. b. Dimensional inspection for base frame, height, depth, gland plates etc. c. Power supply, wiring checks for fans, tube lights etc. d. Supply/signal wiring checks including colour code checking, checking of ferrules, correctness

of wiring, size of wires, proper segregation of wires etc. e. Provision of terminals of correct size and type. f. Operation of various lamps, push buttons, HRC fuses, annunciators, relays, ammeters and

other instruments mounted on the consoles or within the cabinets. g. Megger test for power distribution cabinets. h. Provision of earthing bus bars for safety earth/intrinsic safety earth. i. If a group of panels/consoles is to be mounted and bolted together in the final layout frozen

the same shall be offered for inspection exactly in the same fashion to check inter panel wiring, mechanical alignment etc.

j. All system modules shall be checked for their correct mountings in respective slots as per

configuration frozen. k. Redundancy wherever specified shall be checked for: i. Power supply. ii. I/O cards ( if applicable). iii. CPU/CPUS. iv. Communication (between nodes as well as within a node). l. Scan times as specified shall be checked for all inputs/outputs. m. Individual modules wherever possible shall be checked for their performance. n. All volatile memory shall be checked for battery backup by tripping power for the duration

given in the BIDDER’s specifications. o. For all items a~n inspection shall be 100% on all items. 6.5.2 Software Checks These shall include, but not limited to, the following: a. 100% check on the generated data base. This includes checks on: i. Correctness of tag number and description. ii. Measuring range. iii. Input type, input conditioning. iv. Algorithms to be executed.

v. Output type and conditioning if any. vi. Other details if required. b. All graphics shall be checked 100% for static and dynamic details. These include: i. Checking all graphics for correctness w.r.t. P&ID. ii. Checks on line thickness, colour, equipment’s, tags, and units of measurement. iii. Checking of modifier conditions wherever specified. iv. Switching between various operating pages as per philosophy frozen. v. Operation of all touch targets. c. Operation of all keys on the keyboard shall be checked. Various printing operations like,

operator changes, alarms, guide messages, screen printing etc. shall be simulated and checked at random.

d. Group displays shall be checked for correctness of grouping. e. Alarm priorities shall be checked for all alarms. f. All complicated loops shall be checked 100% from input stage to output for correctness of

configuration. g. All logic & sequence operations shall be checked 100% from input to output by

forcing/enabling various I/Os through software. h. Any higher language programmes shall be checked 100% either by simulation or by feeding

requisite inputs and checking the outputs. i. Logging operation shall be checked. j. Communication between PLC and DCS shall be checked at site. k. Prices quoted shall be inclusive of all tools , tackles , resources required to conduct FAT/

SAT . BIDDER to submit detailed FAT/SAT procedure along with offer. 7.0 INSTALLATION, PRE-COMMISSIONING AND COMMISSIONING. 7.1 BIDDER shall depute a team of experienced engineers, technicians and other staff for the

purpose of installation, pre-commissioning and commissioning of the system at owners site. Following activities are included in the BIDDER’s scope: a. Receipt of system at site, Transportation of system from site stores to central cabinet/control

room. b. Unpacking the system and inspection of the same for any damages. c. Erection of system in control room/cabinet room; including welding of channel supports in

trenches if required. d. Inter cabinet wiring/cabling for all signal, power supply and system cables. Wiring of all

console push buttons, lamps, alarm windows, etc. to/from DCS marshalling/system panel. e. Safety earthing of all panels in a redundant loop form, from a bus bar given at one point in

control/cabinet room.

f. Intrinsic safe earthing of all panels from a separate bus bar given at one point in

console/cabinet room. BIDDER to specify how many earth pits will be required and shall provide the drawings of

earthing scheme. g. Installation of JB, cable glanding, cable tray laying, clamping, cable termination will be in

vender scope. h. Mounting of all hardwired instruments like controllers, trip amplifiers, barriers, etc. in various

cabinets; calibration & programming of these instruments for ranges, set points etc. Complete wiring of all these devices with DCS marshalling or system panel.

j. Routing of all data highway cables/internal bus cables for DCS &ESD through rigid GI conduits within control room below false flooring and inside all consoles as well as between various control room/MCC rooms of the plant. This work may involve routing in trenches, over plant pipe racks in cable trays, etc. All system cables outside control room should be armoured. No GI conduits/ trays to be used.

k. Powering up the system, loading the system configuration and carry out internal loop checks

for correctness of wiring in BIDDER’s scope. This shall be carried out from marshalling cabinets/dummy consoles etc. upto VDUs. The completion of this activity marks the “mechanical completion” of the system and the protocol to this effect shall be jointly signed by the Clients/OWNER and the BIDDER.

l. Coordinate with Client/site erection contractor during complete loop/interlock checking of the

plant. This shall be done at least at 4 points in instrument range and with printer online. m. Consolidate all loop checking reports with OWNER. n. Correction of all drawings to make them “as built”. o. Provide commissioning assistance to Clients/Licensor/OWNER in the form of tuning of loops,

implementing any configuration and graphics, interlock changes etc. required during commissioning of the plant.

p. During commissioning assistance, the BIDDER shall provide required manpower to carry out

the activity in “n” above till the above activity is completed. BIDDER shall include all costs that will be incurred for this assistance in the quotation. Deputation beyond this period shall be paid on man day basis for which the BIDDER shall quote separately.

q. During this period of commissioning assistance, if any time is lost due to fault in the system or

any other reason attributed to the BIDDER, the assistance period shall be extended by that period at no additional cost to the client.

Tools, Tackles 1. BIDDER will arrange all necessary tools and equipment’s line welding machine etc., for

erection of system cabinets/consoles and cable laying, glanding and terminations. 2. BIDDER will arrange for adequate number of test equipment’s like meggers, multi meters,

CROs, 2 wire transmitters, simulators, thermocouples and RTD simulators etc., as required. Supervisory control loops and cascade loops which may need minor than one input/output must be kept in mind while deciding number of each such test equipment’s.

3 BIDDER shall arrange test equipment of adequate specifications to monitor main system

power supply from UPS which will be arranged by OWNER , to establish proper power quality before system power on.

7.2 Activities in OWNER’s Scope a. Laying and termination of incoming power supply cables from MCC/UPS up to incomer of

power distribution cabinet. b. OWNER’s responsibilities:- 1) OWNER shall provide 1 no. of 230 VAC, 5/15 AMP. Utility power supply at one point in

control room for all construction jobs. 2) OWNER shall provide suitable storage space, ware house for temporary storage of all

items till construction. 8.0 FINAL ACCEPTANCE & WARRANTY Client shall take over the system from BIDDER after final acceptance test. The integrated system shall run uninterruptedly for four weeks from date of commissioning

of the whole plant. Any loss of time due to reasons like power failures, forced shutdowns etc. which are due to no fault of the BIDDER shall also be counted as run time. However, if any major software/hardware failure of the system occurs due to which the system or a part thereof has to be shut-down the test shall be conducted afresh on the whole system.

The warranty period shall be 12 months from final acceptance of the system. During warranty period BIDDER shall make good all failed components of any part of the

system and depute his service engineer to site if required free of cost. 9.0 DOCUMENTATION/DRAWINGS Documentation/drawings shall be supplied as per requirements given below separately for

both Ammonia-II and Urea-II each.

S.NO.

ITEM NO. OF COPIES

With Quotation

For approval after P.O.

After approval for information

Final As-built (Hard Copy +CD)

a. Architecture (one line diagram) of the quoted system. 2 1 2 1 2 1 5+2

b. Detailed bill of material upto module level & including all bought out auxiliary items. 2 1 2 1 2 1 5+2

c. Bill of material, make/model number, with catalogues for all bought out items. 2 1 2 1 2 1 5+2

d. Proposed organisation chart for job execution. 2 1 - - - - -

e. Detailed schedule of job execution. 2 1 2 1 2 1 - f. Colour video copy (palate) of all colours

available in the system in the form of identical bars.

2 1 2 1 2 1 -

g. Colour video copy/printout of standard letter sizes available in the system. 2 1 2 1 2 1 -

h. A copy of unfilled standard engineering formats which shall be filled in by Clients/OWNER during engineering.

- - 2 1 2 1 -

i. A coloured copy of various displays available; one of each type.

2 1 - - - - -

j. Standard dimensional drawings for: i) Operator/dummy consoles. 2 1 2 1 2 1 5+1 ii) System cabinets/

marshalling cabinets/ power distribution cabinets.

2 1 2 1 2 1 5+1

iii) Peripherals like printers, hard copiers etc. 2 1 2 1 2 1 5 k. Final layout drawings including internal

hardware mounting details for item (ii) in (i).

2 1 2 1 2 1 5+2

l. Calculation of total power requirement. 2 1 2 1 2 1 5+1 m. Expected heat dissipation. 2 1 2 1 2 1 5+1 n. Schematic drawings for: 2 1 2 1 2 1 5+1 i) Safety ground. 2 1 2 1 2 1 5+1 ii) Intrinsic safe/shield/reference

ground. 2 1 2 1 2 1 5+1

o. Typical loop schematic for: i) Analog closed loops. 2 1 2 1 5+2 ii) Analog open loops. 2 1 2 1 5+2 iii) Bulk I/O loops. 2 1 2 1 5+2 iv) Digital I/Os 2 1 2 1 5+2 p. Final loop wiring diagrams. 2 1 2 1 5+1 q. Loop configuration drawings. 2 1 2 1 5+1 r. Nest loading and I/O assignments. 2 1 2 1 5+1 s. Copy of different log formats available. 2 1 2 1 t. Logic/Ladder drawings. 2 1 2 1 5+1 u. Printouts of all higher language

programmes. 2 1 2 1 5+1

v. Printouts of all generated graphics. 2 1 2 1 5+1 w. Software loading calculations for various

system nodes with spare margins available.

2 1 2 1 2 1 5+1

x. Factory acceptance test (FAT) plan. 2 1 2 1 3 y. Standard system documentation available

for all system nodes like:

i) Instruction manuals. 2 3+1 ii) Software reference manuals. 2 3+1 iii) Installation instructions. 2 3+1 iv) Algorithm library. 2 3+1 v) Standard symbol library. 2 3+1 vi) Any other documents. 2 3+1

As a final documentation one set shall be provided in CD/DVD/ Hard Disc MSOffice

environment. 9.1 As-built Drawings Bidders’ site representative shall mark up all engineering modifications done at site on THREE

master copies to be maintained by him at site. BIDDER shall incorporate all the changes made at site in his “master copy” and submit as-

built documentation to Clients/OWNER as per requirements given above. 10.0 INFORMATION REQUIRED WITH THE BID 10.1 Clarifications/Confirmations *Indicates that the information is to be given by the DCS BIDDER

BIDDER is required to confirm point by point whether requirements of specification are met partly or fully. Any deviations from the specifications are to be highlighted by the BIDDER in his offer. Silence on the part of BIDDER shall be deemed as a deviation from specifications and the same shall reflect in the technical comparison. Similarly if the BIDDER is above to offer some extra useful features over and above the specification the same should be highlighted by him in the offer which shall help in bid evaluation.

Following Additional Categorical Confirmations Are Required: 10.1.1 BIDDER shall indicate (along with relevant documents) installations of the quoted system in

India/abroad and the period for which these are in operation. Any equipment with less than 2 years’ operating experience shall be identified by BIDDER.

10.1.2 BIDDER shall highlight any special or non-standard hardware/software quoted. 10.1.3 BIDDER shall indicate whether any advanced software versions of the offered system are

being introduced by him or his principals in India/abroad. Also in case a completely new version of the system (of the same clone or otherwise) is to be introduced into the market in the next 6-12 months, the same shall be identified by the BIDDER.

10.1.4 A copy of various displays available for operation/maintenance shall be given by the

BIDDER. 10.1.5 BIDDER shall indicate the trade-off between storage time, server load and number of tags if

1s sampling rate is specified uniformly for all tags and assuming a single/unified database for history for all the 5000 points in historian database.

10.1.6 BIDDER shall indicate the maximum number of graphic pages available in the system

assuming a single/unified data base. 10.1.7 BIDDER shall describe in detail, diagnostics provided for each node of the system and the

mode of annunciation. 10.1.8 A picture of operators’ keyboard layout with brief description of each key shall be furnished

by the BIDDER. 10.1.9 For “controller & data acquisition system” BIDDER shall state: a. Algorithms/functions must be executed in the system and external devices are not

acceptable. b. Trade-off between scan time and controller/data acquisition algorithms (typically for scan

times of 1 s, 500 ms, 250ms). c. Trade-off between scan time and logic/sequence blocks (typically for scan times of 1 s, 500

ms, and 250ms). d. BIDDER to specify the individual power consumption of each node at various supply level

with detailed calculation. BIDDER to also specify total power calculations in terms of kcal/Hr. The lowest power consuming system shall be given a premium.

e. BIDDER to specify surge withstand capacity of each module and susceptibility of each

module with EMI and RFI interference, which should conform to prevailing International Standards.

f. After the loss of complete 115 VAC UPS supply, on resumption of the power the system shall

boots automatically on its own with the latest check pointed data without any user intervention. BIDDER to specify the total boot time required for complete system and normal operations to be resumed. It shall be possible to reboot the system and download other node in case of unavailability of main file server or hard disk failure, with the CD-ROM and DAT. BIDDER to state any limitations.

g. In case of mains powers fluctuations, the system shall be capable of withstand the complete

loss of supply up to 100 msec. In other words, the holdup time for the system shall be 100 m sec without affecting its normal operation.

Documentary Proof Substantiating BIDDER’s Claims Shall Be Attached For b & c above. 10.1.10 BIDDER shall indicate the communication error detection methods used for: a. Main data highway. b. Internal I/O communication bus. 10.1.11 BIDDER shall indicate the maximum number of nodes possible on main data highway,

maximum number of I/O modules possible on one I/O communication bus; and the distance limitations for each.

10.1.12 BIDDER shall indicate the maximum permissible distance between a node and a peripheral

device like printer/copier, operator console, storage unit etc. 10.1.13 For gateways BIDDERs shall indicate: a. Communication protocols supported along with complete performance details. b. Names of PLC and other BIDDERs with whom established communication protocol exists

along with a list of such installations in India. c. Distance limitation between gateway and other devices. 10.2 Spare Parts BIDDER shall include in his offer spares which shall be required to be maintained by the

clients for satisfactory operation of the system for a period of two years after final acceptance. Following guidelines shall govern:

SI No.

Description Quantity

Ammonia II Urea II (SECTION 31 & 41) DCS, ESD 1 All type of Communication

Cards, Processor cards (Controllers)

2 Nos of each type 4 Nos of each type

2 All type of System Pre-fab cables, I/O Cards cables, Network Cables

5 sets of each type with all connectors, plugs, etc.

5 sets of each type with all connectors, plugs, etc.

3 Racks, Backplane units 2 No of each type. 2 No of each type. 4 Complete operator Station, 22’’

/LEDLCD/TFT type Colour Monitor with all type of cables/power chords

2 Nos. 2 Nos.

5 1TB RAID-I HDD unit 2 sets of each type with all connectors, plugs, etc.

2 sets of each type with all connectors, plugs, etc.

6a Various Keyboards/mouse 2 nos. of keyboard and 5 nos. of mouse

2 nos. of keyboard and 5 nos. of mouse

6b Operation Function Key Board 2 sets of each type with all connectors, plugs etc.

2 sets of each type with all connectors, plugs etc.

7 Relays Including OMRON MAKE, 4NO, 4NC

5% of each Type of relays, including relevant terminal modules /sockets.

5% of each Type of relays, including relevant terminal modules /sockets.

8 All types of system/PDB/Marshalling cabinet/console filters

100% 100%

9 All types of system/PDB/Marshalling cabinet/console fan

2 nos. of each Type including relevant terminal modules/pre fab system cables.

2 nos. of each Type including relevant terminal modules/pre fab system cables.

10 All types of system/PDB/Marshalling cabinet/console Tubelight

2 nos. of each Type 2 nos. of each Type

11 All types various PDBs Voltmeters/ Ammeters

2 nos. of each Type 2 nos. of each Type

12 I/O cards 20% of each Type of card, including relevant terminal modules/pre fab system cables etc.

20% of each Type of card, including relevant terminal modules/pre fab system cables etc.

13 Various System Battery, Terminators

10 no. of each Type 10 no. of each Type

14 All system fuses and various glass fuses

100% of imported fuses 100% of imported fuses

15 All PDB fuses like HRC, GSA fuses

100% of total quantity of each type

100% of total quantity of each type

16 MCBs 5 nos. of each Type& Rating 5 nos. of each Type& Rating 17 Terminal Blocks Spare Terminal blocks along

with DIN rail-100 nos. of each type

Spare Terminal blocks along with DIN rail-100 nos. of each type

18a Cables for wiring inside Marshalling Racks of DCS of relevant size

100 mtr of each colourand size 100 mtr of each colourand size

18b Cables for wiring inside Marshalling Racks of ESD of relevant size

100 mtr of each colour and size

100 mtr of each colour and size

19 24V DC bulk power supply modules

Min. 2 no. of each Type Min. 2 no. of each Type

20 24V DC bulk power supply for DCS

Min. 2 no. of each Type Min. 2 no. of each Type

21 24V DC bulk power supply for ESD

Min. 2 no. of each Type Min. 2 no. of each Type

22 Safety Barriers, active isolators, signal convertors, trip amplifiers

10% of each type of instruments, subject to minimum 5 nos. of each type

10% of each type of instruments, subject to minimum 5 nos. of each type

23 Hubs, Bus units, Switches, Routers, Network switches

20% or minimum 2 nos. of each type

20% or minimum 2 nos. of each type

24 OPC/Modbus Interface cards 1 no. along with connectors/cables

1 no. along with connectors/cables

25 DCS operator and Engineering Subsystem

1. Communication card operator station communication bus-1 no.

2. Communication card for Engineering Station communication bus-1 no.

3. Motherboard for operator workstation-1 no.

4. Motherboard for engineering workstation-1 no.

5. SMPS- 2 no. of each type

1. Communication card operator station communication bus-1 no.

2. Communication card for Engineering Station communication bus-1 no.

3. Motherboard for operator workstation-1 no.

4. Motherboard for engineering workstation-1 no.

5. SMPS- 2 no. of each type

26 PLC operator/engineering subsystem

1. Communication card for PLC programming Station communication bus- 2 No.

2. Communication card for PLC operating station communication bus-2 no.

1. Communication card for PLC programming Station communication bus- 2 No.

2. Communication card for PLC operating station communication bus-2 no.

27 Media Converters, 2 nos 2 nos

28 22 “ colour Touch Screen Monitor

2 Nos 2 Nos

29 DCS Engineering Station loaded with Operating Software and other software’s like Excels, Word , Adobe etc.

2 No. min.

For imported fuses (if any) 100 percent of each type and rating shall be considered as spares. Batteries used for protection of memories (RAMs) shall be considered as spares (one of each type).

Consumables Printer papers For 6 month usage, min. 10 boxes of each type Ink Cartridges For 6 month usage, min. 2 sets for each printer CDs / DVDs, Pen Drive 2nos each500GB &2 Nos1TB DAT Drive for

Ammonia-II & Urea-II, CD:200 Nos, DVD: 200 Nos, Pen Drive: 16GB (8 Nos)

2 No of laptops Dell Make For programming/Software loading/testing purpose Printer Ribbons For 6 month usage, min. 2 sets with each type of

printer External Hard Disk For Back-Up

of Logics etc. 1TB ---4 Nos

NOTE:

The above spares do not include installed spares as well as commissioning spares. The above shall be purely ware house spares Wherever "Each Type" is specified, it is means "of the Type/make/model/size and exactly replaceable Wherever "% qty." is specified, BIDDER to quote in next higher rounded figure Any other item which is in the opinion of the BIDDER is required for smooth operation of the plant be considered in the spares.

PART-II

INDEX

CLAUSE NO. ITEM

1.0 COMMUNICATION NETWORKS

2.0 BOUGHT OUT ITEMS INCLUDED INBIDDER’S SCOPE OF SUPPLY 3.0 AMC

1 COMMUNICATION NETWORK

1.1 Main Data Highway

a. Number of data highways expected : *

b. Maximum possible nodes on a highway : Vendor To Specify

c. Highway configuration : Fully Redundant, 100% fault tolerant

d. Distribution of nodes on various data highways:

: All nodes shall be strictly peer to peer to only, sitting on the same network. No other configuration is acceptable.

e. No. of control rooms in plant connected to one highway

: 1

i. Whether all control rooms on a highway are in single enclosed building

: Yes

ii. Maximum route length expected for data highway

: 300 m

iii. Type of cable

: Vendor to specify

iv. Type of routing:

: Below False flooring, all communication, networks and system cables shall be laid in perforated aluminium cable trays with proper segregation from other power/signal and control cables. All these cables shall be laid in closed PVC rigid conduits only.

2.0 BIDDER’S SCOPE OF SUPPLY BOUGHT OUT ITEMS INCLUDED IN BIDDER’S SCOPE OF SUPPLY. These

Hardware shall be mounted on Auxilliary console/ Cabinets 2.1 Following items are to be supplied along with the system by BIDDER. The

makes of these items shall strictly be adhered to and concurrence of OWNER shall be taken before purchasing these from alternative sources. OWNER reserve the right to reject/accept any BIDDER suggested by DCS supplier.

2.2 P&F make SIL-3 Signal Isolators/Safety Barriers along with Mounting Accessories.

S.NO. DESCRIPTION MAKE MODEL AMMONIA-II UREA-II

a. 2 Way Selector switch with

illuminated lamp ( 2 NO/NC contact

and Two LED lamp, Swiss tec/EOA

make), Colour Lamp Indication : Red

and Green

Swisstec / EAO

16 mm bezel dia., Green & Red LED, 2 position Lever type

60Nos LED Lamps of Red and Green Colour. 30Nos 2 Way Rotary Switch

50Nos LED Lamps of Red and Green Colour each for 31 & 41 Section each. 25Nos 2 Way Rotary Switch each for Section-31 & 41 each

Selector switch

b. Lamp Indicator for Bypass of any

Trip Tag

25 Nos 25 Nos

Mushroom type Emergency Switch.

(Make Swiss tec/EOA, having min. 2

no 4 NO/NC contacts)

SwissTec / EAO

1 NO 2 NOS

Mushroom type LAMPS to be

mounted on Auxiliary console for

Trip Bypass Indication

20 nos 40 nos

c. Relays with L.E.D OMRON 24 V DC, Socket Mount, Coil with LED, 4 NO/NC Contact rating 230 V AC/5 amp

For all Digital Output of complete DCS system

All Digital output channels shall drive these interposing relays only. Further load shall be connected through these relays pot free contact like SOV, MCC Output, Lamps, DCS DO as ESD DI, etc.+10% spares

d. Contactors Siemens 3TH As required e. Timers

Not required

Fjf. Voltmeters AE

As required

g. Ammeters As required h. Current to Current Converters ABB As required Qty will be given

during detail engineering

i. MCBs Not required

j. 2 POLE ROTARY SWITCH L&T/ Crompton

As required +10% spares

k. HRC fuses GE

As required +50% spare

PART-III

SUMMARY OF DCS / ESD I/O LIST (A) INPUTS AND OUTPUTS - UREA-II PLANT

Actual Total 31 sec 41sec Com Sec DCS 1 AI (Closed loop, 4-20 mA) 93 92 40 225

AI (Open loop, 4-20 mA) 154 110 27 291 AI From MCC 16 16 10 42 AI T/C Closed loop 18 15 05 38 AI RTD Closed loop 2 2 00 4 AI T/C Open loop 107 111 51 269 AI RTD Open loop 41 53 22 116 AI Frequency Open loop 5 5 3 13 AI Resistance Open loop 30 30 00 60

2 AO (Control output) 98 93 41 232 3 DI From Field 222 140 63 425

DI From MCC 45 22 17 84 4 DO From DCS to field 14 14 18 46

DO From DCS to MCC 24 26 54 104

Total 1949

ESD

1 AI From Field 26 24 00 50 AI From Thermocouple 2 00 00 2

2 DI From Field 240 211 00 451 DI From ESD Switch (Rotatory Switch) 30 30 00 60 DI From MCC/LCP with relay 71 41 00 112

3 DO From ESD to Field with relay 50 46 00 96 DO From ESD to MCC/LCP with relay 68 58 00 126 DO Lamp indication etc. 24 24 00 48

Total 945 1 AI SOE PLC

26 24 00 50

2 DI 155 145 00 300

Total 350

Note: No T/C or RTD Inputs signals shall be used in entire project. These signals will be

converted to 4 ~ 20mA using P&F SIL-III Barriers.

(B) INPUTS AND OUTPUTS - AMMONIA-II PLANT DCS I/O COUNTS OF AMMONIA-II

S.No. Description Total I/Os Used

1 AI for Closed loop with Active isolation 298 2 AO for Closed loop with Active isolation 346 3 AI for open loop with Active isolation 388 4 AI with Passive isolation 24 5 Frequency Input with Passive isolation 15 6 T/C inputs for closed loop (K-type) 70

7 T/C inputs for open loop (K-type) 420 8 RTD inputs (3 wire PT-100) 180 9 Digital inputs from field with isolation to DCS 383 10 Digital inputs from MCP/LCP with Relay to DCS 89 11 Digital outputs from DCS to field with Relay 40

12 Digital outputs from DCS to MCP/LCP with relay signal 32 Total 2285

ESD SYSTEM I/O COUNTS OF AMMONIA-II

S/N Type of I/O Description Total I/Os used

1 Analog input (4 to 20mA) with isolation 224

2 Temperature inputs (mV signal) with isolation 53

3 Digital inputs from field with isolation to ESD 298

4 Digital inputs from MCC/LCP with Relay to ESD 34

5 Digital outputs from ESD to Field with Relay 123

6 Digital outputs from ESD to MCC/LCP with Relay 140

Total 872

1 DI/AI for SOE PLC AI = 74 & DI = 336 410 BIDDER shall size the hardware with 60% future spare software capacity and 40% future spare

hardware capacity available to the user. BIDDER shall furnish the detail sizing along with offer, Based on the requirements given in part - III. 1) 60% of Total no of analog I/O at 1 sec scan time. 2) 40% of total no of closed loop at 250 msec time. 3) 40% of total no of digital I/O at 50 msec time. 4) 60% of total no of digital I/O at 250 msec time

BIDDER shall quote Price in the following formats only.

(A) AMMONIA-II

SR. No.

DESCRIPTION BASIC PRICE

GST APPLICABLE

TOTAL

1 OFFERED DCS SYSTEM

2 OFFERED ESD SYSTEM

3 SPARES AS PER CLAUSE 10.2, PAGE NO: 58 TO 60

4 ERECTION AND COMMISSIONING CHARGES

5 DESIGN AND ENGINEERING CHARGES

6 P & F CHARGES GRAND TOTAL

(B) UREA-II SR. NO.

DESCRIPTION BASIC PRICE

GST APPLICABLE

TOTAL

1 OFFERED DCS SYSTEM

2 OFFERED ESD SYSTEM

3 SPARES AS PER CLAUSE 10.2, PAGE NO: 58 TO 60

4 ERECTION AND COMMISSIONING CHARGES

5 DESIGN AND ENGINEERING CHARGES

6 P & F CHARGES GRAND TOTAL

C. AMC

AMC for Ammonia-II & Urea-II Comprehensive AMC (without resident engineer) for five years after expiry

of the warranty period with minimum five visits (including emergency & periodic visits) of the service engineer per year. The AMC shall include supply, replacement / repairs of all the system modules / cards etc. including all IT products (HMI consoles, printers, switches etc.). Any Software modifications and Software patches released by vendor shall be included in vendor’s scope. Vendors to indicate yearly breakup of comprehensive AMC.

Comprehensive AMC Break-Up

S. NO Break-Up Year Wise

Unit Qty Rate Total Amount

1 1st Year 2 2nd Year 3 3rd Year 4 4th Year 5 5th Year

SECTION-III

EMERGENCY SHUTDOWN SYSTEM (ESD) SPECIFICATIONS

PART-I

INDEX

S. No. TOPIC 1.0 GENERAL REQUIREMENT/DESIGN CRITERIA

2.0 BIDDER'S RESPONSIBILITY

3.1 STANDARDS AND SPECIFICATIONS

3.2 REQUIREMENTS OF SYSTEM SONFIGURATION AND HARDWARE ESD SYSTEM

4.0 OPERATIONS AND FUNCTIONS

4.1 OVERVIEW

4.2 SYSTEM STATUS

4.3 TRANSIT FAULT ALARM

4.4 MANUAL RESET

4.5 SEQUENCE OF EVENT RECORDER

5.0 ESD SYSTEM SOFTWARE

5.1 SECURITY

5.2 PROGRAMMING

5.3 SOFTWARE UTILITIES

5.4 CONFIGURAITON

5.5 DIAGNOSTICS

6.0 CABINETS / PANELS

6.1 INTERNAL WIRING

6.2 POWER SUPPLY

7.0 SYSTEM AVAILABILITY

8.0 INSPECTION 9.0 INSTALLATION, PRE-COMMISSIONING AND COMMISSIONING

10.0 FAT

11.0 DOCUMENTS AND DRAWINGS

12.0 AS BUILT DRAWINGS

13.0 INFORMATION REQUIRED WITH THE BID

PART-II 1.0 SPECIFIC PROJECT REQUIREMENT

2.0 SCAN TIMES

3.0 INTER CONNECTION CABLES

4.0 FURNITURES

5.0 BOM

6.0 DEVIATION

1.0 GENERAL REQUIREMENT / DESIGN CRITERIA SCOPE The offered system shall be of either QMR or Triple modular redundant (TMR)

Safety ESD (PLC) System approved for Safety Class-6 (AK6)/SIL-3 as per TUV. Though the specifications of ESD in this and specification of DCS specified in relevant section

are different, all Common items like cabinets, bought out items like marshalling panels, system hardware panels, fuses; terminal blocks, etc. shall be identical. Documentation shall be maintained uniform. Material, wiring and ferruling philosophy shall be same. However no DCS and PLC hardware shall be mixed/ combined in any single cabinet. Both the systems shall be designed as separate entityfor Ammonia-II and Urea-II plants.

This specification calls for design, manufacturing, testing at shop, delivery at site, erection

and commissioning the ESD system with the functional and hardware requirements as per TUV (AK6)/SIL-3 class as per DIN 19250 and VDE 0801 of protection with 2003 architecture or 1OO2D type fail safe architecture with multiple sensors and as specified in this document with availability of more than 99.99%.

BIDDER to provide TUV certificate confirming to safety class VI for the system quoted along

with TUV reports and restrictions list in original without which offer will not be considered complete.

This ESD specification defines the functional requirements, the extent of the hardware needs. Main plant shall be controlled by modern distributed control system (D.C.S.). All the

interlocks shall be realized in a failsafe Emergency Shutdown System (QMR)or TMR Programmable Logic Controller (ESD/PLC). The system layout shall be made keeping in mind the aesthetics and operational conveniences especially during emergencies. The DCS/ESD panels and all system hardware shall be located at a central cabinet room in the close vicinity of Central control room. This cabinet room shall accommodate all marshalling panels, PDB panels, DCS/ESD system hardware panels, Barrier panels, relay panels.

This central ESD shall be responsible for the realization of total plant interlocks and no other ESD system is acceptable at individual package unit/machines, etc at other location, other than main ESD system at central control room. All the field instrument signals from various field instruments, package units, machines, etc. shall be brought to central cabinet room for realization of safety interlock in this central ESD only.

All the field instrument signal/power and control cables shall be brought to this central

cabinet room, from where it shall be catered to diff. individual destination marshalling panels and corresponding DCS/ESD hardware panels. There shall be 20% space margin available in all the panels on marshalling and relevant system hardware side.

ESD shall be completely separate from DCS. The cable entry in the cabinet room shall be provided with MCT blocks. Inside the cabinet

room, engineering room and control room, cables shall be laid in perforated aluminium cable trays below false flooring. The cable entry for all the panels shall be from bottom only. There shall be physical segregation of various type/signal of cables like power cables, signal cables, communication and system cables. All system/communication cables shall run in closed, flexible, PVC conduit only inside cabinet/control and engineering room, below the false flooring..

There shall be panel segregation for various I/Os meant for DCS and ESD system. Also there

shall be panel segregation for diff. type of I/Os for DCS and ESD and other control system. This means that analog input/ analog outputs shall be accommodated in a separate panel of respective ESD and DCS panel. Digital input shall be accommodated in a separate respective ESD / DCS panels. Digital output and all interposing relays shall be accommodated in separate panels for both the ESD/DCS.

There shall be 115 V AC UPS PDB panels located inside cabinet room, from where all other

panels shall be fed with 115 V AC power supply. OWNER shall provide 115 V AC UPS feeders at only PDB panels. PDB panel size shall be standard 1200 (W) x 800 (D) x 2100 (H), RITTAL

make, with RAL7035 colour shed and open able from front and back side. The qty. shall be as required. Further sub-distribution to all others panels & and Field Solenoid Valves shall be carried out by BIDDER/DCS/ESD vendors. If 24 V DC Bulk power supply is required for DCS/ESD or relay panels, the same shall be provided in different panels with full redundancy in such a way that one power supply must be capable of catering the predefined load.

The signal exchange between electrical and instrumentation shall be via Electrical/Instrument interface panels, located in the existing cabinet area. There shall be two categories of Interface cabinet, viz. Analog and Digital. Analog Interface panel shall be used for various Motor current inputs (4-20mA) from electrical/field devices to Instrument Control systems Electrical Substation, etc. Digital Interface panel shall be used for various Digital input and Digital output signals from / to Electrical/Instrument systems like various pump/motor running indication, stop command to MCC, etc.

All field cables exchange between plant and cabinet room shall be from Cabinet room only. The cable entry shall be provided MCT blocks. Inside the cabinet room, engineering room and control room, cables shall be laid in perforated aluminium cable trays below false flooring. The cable entry for all the panels shall be from bottom only. There shall be physical segregation of various type/signal of cables like power cables, signal cables, communication and system cables. All system/communication cables shall run in closed, flexible, PVC conduit only inside cabinet/control and engineering room, below the false flooring.

Central control room is designed with state-of-the-art DCS/ESD operator consoles with

proper system ergonomic and overall aesthetic of the system. BIDDER shall undertake replace any defective or inappropriate equipment supplied with

Warranty period and shall make good such deficiency within one day from the date the same is brought to his notice, by the Owner at BIDDER’s cost.

2.0 BIDDER’S RESPONSIBILITIES

It is envisaged that for the plant continuous control a separate DCS is required and for safety and interlock separate Emergency shutdown system (FAIL SAFE QMR/TMR PLC) is required. The DCS and ESD system will be communicating with each other through a dedicated gateways protocol in such a way that seamless integration of both systems can be achieved in DCS MMI/Operator station. There shall be no MMI package unit required for ESD. All ESD input/outputs and internal memory variables, timers, counters, etc. shall be communicated to DCS in real time environment via this communication. This link will be one way only, hence there is no write command from DCS to ESD is allowed. The total scan time for all the ESD parameters to DCS shall not be more than 1 second. This includes all installed spare I/Os status also. The Plant policy is one continuous control system development to match changing process requirements and to exploit new techniques as they emerge. The ESD shall provide the necessary facilities to allow control system development to take place in a high safe and available manner. BIDDER shall quote for the technologically superior and for the latest version system. BIDDER shall quote for technologically superior and updated hardware and software options wherever applicable. BIDDER to inform OWNER for the updates in software/hardware releases as and when released in future also. The system reliability shall be stated in terms of MTBF in hours. BIDDER shall state the mean times to repair assumed in the calculation of MTBFs. Where a failure rate is derived from that of more than one item, the calculation method and supporting data shall be presented along with the results. In addition to these, BIDDER shall provide data from MTBF hours of each single module supplied in the system. Should the reliability calculations be based on the occurrence of random failures or single devices and communications channels only, BIDDER shall share their experience and data they have for common cause failures (CCFs) in redundant systems and the methodology they have used for calculation of CCFs. ALSO THE DEFENSES THEY HAVE ADOPTED TO MINIMIZE COMMON CAUSE EFFECTS.

As part of their tender, BIDDER shall present a comprehensive quality plan for the overall supply of the ESD hardware and software based on ISO9001, including all phases of design and constructions. OWNER reserves the right to audit the actual implementation of the BIDDER’s QA/QC procedure from time to time.

Un-interrupted power supply of high integrity (refer PART- II for quality of power supply) shall be provided by OWNER, with required nos. of main feeders from UPS at any one location in the PDB panel at Central Cabinet room. BIDDER shall carry out further distributions required for system/sub-system. This supply shall have 30 minutes back up time. Power supply requirement - BIDDER shall comment on requirement of above mentioned power supply, including separate earth pit, earthing requirement, etc. Power supply for each system/sub-system shall be 100% redundant with capacity to accept two feeders. BIDDER has to indicate where these redundant power supplies are installed and where it is not installed. BIDDER shall supply all standard/optional software and firmware which are necessary to all application software concerned with ESD hardware and software.

Complete database generation shall be in BIDDER’s scope. Further to this application software shall be successfully implemented and optimized till the plant operations are stabilised. Any modification changes required shall be done by BIDDERs concern Engineer, without any limit on the amount of modifications/change and it will not be considered as a separate work order. System and application software shall be made available in two set of CD-ROM and DVD respectively. This is apart from the diskettes downloaded in the system. BIDDER shall also supply 3 set of Documentation hard copy and 3 set of E-Doc CD for the complete system which shall cover all standard system documentation. The safety PLC shall be designed with total application cycle time less than the 1/4th of the process safety time, when it is fully loaded and running at pick load, including installed spare I/Os also. Total application cycle time is defined as the sum of all inputs (including installed spare I/Os) reading/polling time, application execution time, and time required to write all the outputs (including installed spare I/Os) and time required to do the system diagnostic in the whole system.

2.1 BIDDER’s responsibilities shall include, but are not limited to, the

following: a. System engineering including communication with DCS.

b. Supply of system hardware and software. ( including system cabinets, engg. station,

other PC's, all related hardware/software to complete the system integration)

c. System programming and configuration.

d. Implementing control strategies given by the Licensor/OWNER.

e. Implementing any advance level control strategies given by the Licensor / OWNER.

f. Configuration of various displays/views/FLDs. ( Engg. station )

g. Configuration of various Alarms for both the sections.

h. Generation of history database and reports. (in sequence of event recorder )

i. Generation of logging reports and other management information reports.

j. Factory acceptance testing.

k. Packing and forwarding.

l. Transport to site.

m. Material receipt at site-store, transportation from site-store to installation location

and erection / Installation at site.

n. Supply and termination of various interconnecting cables between marshalling racks

and between marshalling racks and system hardware cabinets, also between

auxiliary console terminal blocks and PLC marshalling cabinet.

o. Powering up, Loop checking, pre-commissioning and commissioning.

p. Providing assistance during commissioning like implementing control strategies,

tuning of loops etc.

q. Carrying out any amount of modifications/change/addition and deletion of extra

loops during commissioning as per OWNER’s requirement.

r. Providing documentation in required number of sets during engineering and also as-

built documents after commissioning. The same shall be supplied in editable soft

copies on the electronic media and Hard copy also..

s. Providing training for Owners’ operation & maintenance personnel in BIDDER’s works

and also at site.

t. Ensuring hardware support (supply of spare parts) and software support (including

supply of periodic updated software versions) for a minimum period of 15 years after

Commissioning.

u. Preparation of specifications, approval by OWNER, procurement, inspection, erection,

integration and commissioning of all bought out items included in BIDDER’s scope of

supply.

v. Providing certification for the systems specified by TŰV (AK6)/SIL-3 and limitation.

w. Supply, installation of Cable between PLC and DCS for communication will be in

BIDDER’s scope.

x. Developing operating and maintenance procedures, operator training procedures,

Factory acceptance test procedures, Site acceptance test procedures.

y. In addition to this BIDDER's responsibility shall include supply of filler panels,

wiring accessories like ferrules , anti-static strips , cable wrap coils , lugs etc, if

required.

3.1 STANDARDS AND SPECIFICATIONS The following standards and specifications apply for the design, fabrication,

implementation and installation of the PLC. - ASME/ANSI - ISO - API - NEC, NEMA - IEC - VDE, DIN (Germany), not for instrument fittings - TŰV - ISA 3.2 REQUIREMENT OF SYSTEM CONFIGURATION AND HARDWARE ESD SYSTEM The ESD system shall fulfil the protection requirements of the plant (AK6) with utmost

reliability and availability to improve on-stream hours. A minimum availability of more than 99.99% is required.

Electronic modules of the system shall be located in cabinets housed in the Central cabinet room in the close vicinity of control room/engineering room. The PLC system shall be triple modular redundant (TMR)/QMR type safety PLC, and 100% fault tolerant including processor, I/O modules shall be with redundant power supply and communication interface with redundant bus.

o Operating system and application software shall be stored in non-volatile memory.

o The system shall be provided with standard communication port to execute internal data

transmission with any other computer system.

o Failed modules within the system shall be automatically detected, identified and alarmed

via output contacts, diagnostic status and LED’s without interruption of normal processing

functions.

o On line replacement of any system module shall be possible without having to reconfigure

system or stopping the running plant.

o Software, system wiring or cabling or de-energise system power. 100% Redundancy shall

be provided for all I/O modules.

o For analog signals the system shall employ 1213-bit analog to digital conversion as a

minimum.

o As a minimum, associated power supplies for the main processors, communications and

I/O shall be redundant. Each node/segment shall be capable of accepting dual redundant

power supply, which will be fed to them from two diff. feeders from PDB.

o The system outputs shall be connected to the Motor Control Centre (MCC) and solenoid

valves/ lamps, etc. by hardwired connections with suitable interposing relays.

o Wherever this specification conflicts with bidder's current standard system, it shall be

clearly defined as an exception and highlighted in the bid.

o Under all circumstances, bidders are to use only their standard catalogued products.

Specially modified or unusual products should be proposed only with specific written

instructions from the buyer. Mixed mode configuration of fail safe and non-fail safe type,

redundant and non-redundant type configuration is not allowed. All module in individual

category shall be of the same make/model and type and interchangeable. The buyer is not

responsible for reviewing the standard documentation in manuals to determine what

exceptions may exist.

o Only necessary information shall be sent from PLC to DCS. All safety related inputs to PLC

shall be from independent switches / transmitters and field instruments.

o On replacing the defective CPU module, the database should be down loaded to it

automatically & without intervention of maintenance personnel. Following power failure,

system shall maintain integrity of database and on resumption of power, system should

resume its normal running status automatically, without any user intervention.

o The processing hardware shall provide for detailed fault diagnosis & should allow single

channel testing without the need to defeat either inputs or outputs.

o System memory capacity should be sufficient to implement the given logic at specified

scan rates with all installed I/O counts, including 20% installed spares. Bidders shall

elaborate how memory requirements are met & allocated in static and dynamic memories

to meet the requirements of this specification.

o The system shall be designed to ensure that no incorrect commands are given to the field

devices upon power on or power restore to the CPU or I/O modules.

o The programming shall be done on line / off line using PC interfaced with PLC using a

communication card without any TUV restrictions.

o System shall be offered with simulation software by default.

o RFI sources such as commercial hand held personal radio equipment operating at 5 watts

nominal output power, in the 150 to 170 and 450 to 470 MHz bands at a distance of 3

meters shall not cause a signal disturbance of more than 0.1% of range for analog signals

nor result in change of status for digital signals nor cause any system error for other

components, upon keying or transmitting.

o The system logic shall be fail safe, de-energise on alarm state. This implies that in the

normal condition, closed input sensor switches shall keep the logic outputs active

providing a closed circuit for supplying electrical power to remote devices such as

solenoid valves and relays. Opening of a contact, an open line or an equipment

malfunction in a particular circuit shall automatically initiate the designed control /

alarm function. The system shall be required to supply floating power to field input

devices in two wire technique and to external actuating devices such as solenoid valve

coils, relay coils in the interposing relay panel, etc. including interrogation voltage.

o All output signals shall be hardwired. Signal level shall be energised for normal and de-

energised for alarm and shutdown conditions.

o Crippled mode operation is a mandatory feature of failsafe system which must detect all

the faults in timely manner and upon detection of an input fault force the measured input

value to the safe state. In case of any fault at diff. level like I/O card single channel, I/O

card level, processor level, if the system shall degrade CRIPPLE MODE, it should provide

with an alarm. BIDDER shall provide information regarding time constraint for cripple

mode operation without degrading safety class and it should also clearly state whether

after termination of this time constraints the loop will automatically go in to fail safe

position. The system shall comeback to original state on replacement of failed module with

new one.

o BIDDER shall clearly highlight the philosophy followed for online repair and any extra

hardware required.

o BIDDER shall confirm the sequence of repair assuming fault indication for the Following

modules

1. Chassis power supply

2. CPU / Other central rack modules

3. Bus interface

4. I/O module with field termination

3.2.1 SYSTEM CPU/PROCESSOR The system operating program shall be resident on EEPROM / Flash ROM memory. The

central processing units should contain the application program in non-volatile memory. Each processor must maintain 40% spare memory after configuration to allow future expansion.

If the application program is kept in a battery backed up memory then:

A minimum 72 HOURS battery backup shall be provided.

It shall be possible to replace the battery while the system is operating without losing the

contents of the memory and without affecting the running plant.

Indication of low battery power shall be provided locally by LED and remotely on system

status display (DCS operator console) with alarm. The CPU shall continuously scan the

control program stored in memory, along with the status of all inputs and execute

specified commands to appropriate outputs and shall be capable of executing all

diagnostic / fault recording subroutines within the 1/4th of the total process safety time

period. This includes all installed spare I/Os also. ( i.e. if the process safety time is 1

second, the complete PLC application cycle time shall be less than or equal to 250 mili-

seconds or better, when it is running at full load, including installed spare I/Os also)

3.2.1.1 CPU HARDWARE SECURITY A key-lock mode-select switch on each CPU shall prevent memory modification from any

outside source. Software password & key-lock mode shall be used further at different levels in software.

3.2.1.2 CPU STATUS INDICATORS The CPU shall continuously monitor its own status and indicate both normal operation and

error conditions via LED status indicators on each CPU module faceplate in addition to various alarms on DCS operator console via redundant communication link. Fault conditions shall be annunciated both locally and remotely and logged on printer / history.

3.2.1.3 CPU PROTECTION Power line inputs to the CPU shall be protected against electrical transient EMI/RF pickup and

shall be minimized by standard wiring practices. ESD shall not have any RTD/ Thermocouple type input cards. The ESD system shall interface directly with the following devices, but not limited to: INPUTS: - Analogue transmitters (Both 2 wire, 4-20 ma dc input and 4 wire type Transmitter with 4-

20 ma dc inputs. The analog input card shall be capable of Supplying 24 V DC power supply to all 2 wire field transmitters. - Field switches (Dry contacts) - Dry contacts from Local panels DCS - Pushbuttons/key switches from field and control room consoles - Trip contacts from switchgear relay panels (Dry Contacts) - Dry-Potential free digital inputs

OUTPUTS: All the outputs shall be via 24 V DC, OMRON make, socket mounted Relays with 4 NO/NC

contacts. The contact rating of relay shall be min. 230 V AC/5 Amps - Solenoid valves operate on 110 VAC. - Local panels/ DCS system as Digital inputs - Motor Control Centre and switchgear devices - Man machine interface (i.e. operator station keyboard) - Unidirectional communication to DCS - Control room console lamps/ Local panel lamps, etc. All digital inputs/output cards shall be optically isolated and all analog cards shall be

galvanically isolated. The isolation shall be for individual channel and no group isolated cards shall be supplied.

As a minimum, PLC cards shall be with channel to channel and channel to field isolation. The system shall have the capability to monitor and test all sub-units comprising the ESD logic system, while in normal operation.

3.2.2 INPUT SUB-SYSTEM Inputs shall be physically configured to read a signal from an input device by three separate

input circuits in case of TMR system. The redundant circuits shall be physically mounted centrally. The TMR circuits shall transmit their data individually to each CPU via two or three separate I/O networks. Each CPU shall contain TMR I/O network interfaces to receive the input data from separate input circuits and corresponding I/O networks. Majority voting of the input data for TMR shall be performed by the CPU before use by the application program. All I/Os shall be capable of being mounted locally (central cabinet room).Optical isolation shall be provided for each input on the input module. Each card shall have channel to channel and channel to field isolation. No group isolated I/O cards are accepted. The input modules shall be removable without the need to disconnect field wiring or field wiring terminals. Each module shall be key locked to ensure its correct physical location. All modules shall be hot swappable. System should support online maintenance/replacement of faulty module out of redundant modules, without affecting running plant or without degrading the Safety Class of whole system.

Input bypass facility for each input whenever possible should be provided to allow calibration testing and maintenance

Besides, the input force facilities from ESD engineering station for individual input should be possible. They shall be enabled via dedicated displays on the engineering workstations (PLC). Activation of the said facilities shall be annunciated and logged at the engg. Workstations (PLC) and in the operator workstation (DCS) . This shall not bypass outputs to signalling devices, VDU alarms display, etc. Bypassing/forcing shall be password protected & TUV approved. BIDDER shall guarantee that each module operates properly without designed safety class degradation in presence of single fault and certain kinds of multiple faults. All input modules will be testable / supervised type to supervise the input cards channel wise and shall annunciate any input related fault to DCS & maintenance PC. This fault flag shall be for individual channel. The input voting (TMR) shall be performed at main processor level, which is the nearest end of system.

3.2.2.1 DIGITAL INPUTS Digital inputs to PLC shall be normally potential free contacts. All Digital Input modules shall

be supervised/fail safe type and TMR. Under normal conditions, the contact shall be closed and opens under abnormal conditions. The PLC system shall provide the voltage source to operate the system logic via field contacts. The interrogating voltage level shall be 24V DC floating. Individual channels shall be optically isolated from field as well as to other channels on the same cards.

The maximum channel density on a single card shall not be more than 16 inputs (16 channels) for a single Digital Input card.

The input voting (TMR) shall be performed at main processor level, which is the nearest end of system.

Input faults shall be logged in an easy to understand English language messages format with

date and time stamping for each fault. Any corresponding address (to determine location of faults) shall also be logged. Faults shall be logged in a chronological order. Diagnostic LED indication shall be viewable at each module. Also, each point in the module shall include an LED for indicating an on/off state in the circuit. Digital input diagnostics shall include but is not limited to the following:

Stuck on input circuit

Stuck off input circuit

Input-to-input short circuit

Input impedance high.

Input malfunction

Module failure

3.2.2.2 ANALOG INPUTS ( GALVANIC ISOLATION )

It shall be possible in PLC to realize 4-20 mA analog input signals from field instruments. All analog input modules shall be supervised/fail safe type QMR/TMR Type. All the analog input cards in the system shall have individual channel to field isolation as well as channel to channel isolation. Each channel shall be with galvanic isolation. Min. resolution of ADC of analog input card shall be 13 bit. Analog input card shall have 250ohm resistors in its front end circuit, so that it shall be possible to connect HART interface unit, on-line without disconnecting the analog input transmitters. Analog input shall be capable of powering 2 wires, 4-20 ma dc, and SMART transmitter with 24 V DC. Also, it should be capable of accepting 4-20 ma dc input from 4-wire transmitters.

The maximum channel density of a single analog input card shall not be more that 16 inputs.

(16- Channels). The input voting (TMR) shall be performed at main processor level, which is the nearest end

of system. Switching functions shall also be realized from High/High-High and Low/Low-Low Alarm/Trip

Flags (minimum four level of alarm with individual dead band / hysteresis. Shall be possible on each analog input channel) Input faults shall be logged in easy to understand English language message format with date and time stamping for each fault. Any corresponding address information (to determine the location of fault) shall also be logged. Diagnostic LED indicators shall be provided on each module.

Also, each point on the module shall include an LED for indicating the healthiness of the

same. All analog inputs shall be testable type. Analog input diagnostics shall include but is not

limited to the following:- • Input wiring error

• Input shorted

• Input open wire

• Input under range

• Input over range

• Input deviation (discrepancy)

• Module failure

• Drift

3.2.3.1 DIGITAL OUTPUTS The 24V DC sink type digital output module shall be capable of driving signal for interposing

relays • Solenoid valves / indicating lamps in field through 24V DC via interposing relays.

• Motor control trip contacts through 24V DC interposing relays. The relays shall be OMRON

make, 24 V DC, socket mount, with 4 NO/NC contacts and with 230 V AC/5 Amps contact

ratings. The coil shall be equipped with LED to indicate coil status.

• Contact for DCS – potential free.

• The 24V DC source type shall be capable of driving annunciator lamps / indicating lamps

in control room. The isolating relay shall not be used for multiplication of ESD system

inputs and outputs, unless they are specified to be essential for. The output signal shall

energize on healthy conditions and de-energize on abnormal process conditions.

The digital output card shall have optical isolation for channel isolation. Each channel shall

have channel to channel and channel to field isolation. The maximum number of channel shall not be more than 16 nos. for single digital output card in the system.

The output module shall be capable of testing its own output circuitry as well as line

monitoring for open circuit and short circuit of load so that in case of any hardware fault in the channel it should switch off the output channel to bring the plant to a safe shutdown. Output faults shall be logged in easy to understand English language message format with a date and time stamp for each fault. Any corresponding address (for location of fault) shall also be logged. Diagnostic LED indicator shall be provided on each module. Also, each point in the module shall include an LED indicating the off/on state of the outputs. All digital output cards shall be of hot swappable type, allowing them to replace on-line without affecting the running plant or without any degradation of designed safety class of complete system.

Output circuits shall be provided with protection against the switching of inductive loads (i.e.

solenoid valve coils) and protection against current overloads. The output voting (TMR) shall be performed at output card level, which is the farthest end of

the system. Digital output diagnostics shall include, but not limited to the following:- stuck on output circuit

stuck off output circuit

output to output short circuit

load shorted

output circuit overload

output circuit over temp.

output discrepancy

Module failure

OUTPUT SUB-SYSTEM All output modules shall be supervised/fail safe type and either QMR/TMR type . Output shall

be configured to send outputs to output devices via 24 V DC interposing relays (e.g. SOV, motor starter, lamps etc.) by either three separate output circuits in case of TMR system. The maximum channel density for Digital output card shall not be more that 16 channel per card. The separate output circuits shall be physically mounted centrally. Each module shall receive output data from each of the corresponding CPUs over separate I/O networks. All I/O shall be capable of being mounted locally in central cabinet room. Optical isolation shall be provided for each digital output in the output module. Each channel of digital output module shall have individually Channel to Field and Channel to Channel isolation. No group isolated cards shall be acceptable.

The output modules shall be removable without the need to disconnect field wiring or field

wiring terminals. Each module shall be key locked to ensure its correct physical location. All output modules shall be hot swappable type, capable of being replaced without affecting the running plant without affecting designed Safety class of the whole system. The output voting (TMR) shall be performed at output card level, which is the farthest end of system.

4.0 OPERATIONS AND FUNCTIONS 4.1 OVERVIEW The control room shall be made fully aware of the plant conditions on DCS console. In

addition, alarms & status of ESD system shall be available for the following conditions or their equivalents:

Forced Any I/O which is forced on or off Communications active / fault Communications status Processor run / fault Fault conditions with CPU

Remote I/O active / fault Status of remote I/O

Battery Status of battery backing up static Fan failure Status of cooling fan Trip bypass Status of bypass switches I/O interface or address faults & I/O module faults .

Operator Action to be Implemented so that if Operator takes any action which results in Tripping, Disturbance in operation due to change in set points, A/M changeover shall appear on that particular Operator Station.

4.2 SYSTEM STATUS (CPU, I/O cards, etc.)

System diagnostics shall be presented on the Engg. Workstation and DCS/ESD with flashing

points in alarm condition, turning to steady state upon alarm acknowledgement. 4.3 TRANSIT FAULT ALARM

Upon given shutdown order, transit fault alarm shall be given if, after a predefined time, a non-correct status shall be received from the field equipment. The transit fault time shall be defined for each output.

4.4 MANUAL RESET: In addition to the individual reset facilities from operator stations, the system shall be

provided with individual reset button for individual piece of interlock/logic, which shall light up when the reset is possible, i.e. the cause of the shut-down is cleared. When the pushbutton is pressed, the light in the button shall turn off and the related outputs could then be turned to normal status. Soft Reset is also to be provided.

4.5 SEQUENCE OF EVENT RECORDER: M/s ROCHESTER MAKE

It is a must that the sequence of event recorder (S.O.E.) facility with 1 mili-second time resolution in a chronological order, shall Independent system. The PC running this software shall be equipped with 22” TFT/LCD/LED Colour monitor and it shall be located in the central control room, along with other DCS operator stations. BIDDER to ensure the necessary hardware and software required shall be capable of recording the alarms and events with the resolution/time stamp of 1 mili second.

The total no of points will be to the full capacity of the system, which shall include all input/output and intermediate memory variable of ESD.

It shall be possible for the user to create a database of digital and analogue variables to

observe and specify the parameter for collecting the data. The system should start automatically for collecting data on trip (initiator) without human intervention and stoppage of SOE program should be programmable in case of plant shutdown/maintenance, to avoid collection of unwanted alarms.

The software shall record in chronological order on the hard disk of the dedicated PC. The

software shall store the data in the list for user specified time before and after trip. The software shall allow the user to create display and print out to help to evaluate the system behaviour.

The software should be able to give the reports in the below listed formats as Minimum: 1. Bar-chart

2. Trend line

3. Table

4. Static position and profile

5. Exporting events/alarms in Microsoft Excel Format, CSV file, Text File or DBF/MDB file for

database.

5.0 ESD SYSTEM SOFTWARE

5.1 SECURITY

Different levels of password shall prevent memory programs modification from any external source. Hardware protection key shall also be provided.

5.2 PROGRAMMING

Programming shall be kept simple through the use of common function blocks.

Programming and downloading to running ESD system shall be possible both on-line and

off-line.

5.2.1 PC based Programming Support

One engineering/programming workstation shall be provided to develop the control program, to diagnose system status, and, if necessary, to force points for loop check or maintenance of field sensors as per TŰV guidelines. Multiple application programming language capabilities shall be available as per IEC 1131 –3. BIDDER shall provide the details of the same. Methods for off-line debugging and program simulation in the development station shall be

possible.The programming environment of ESD shall be Object Oriented; Microsoft Windows based, with all GUI features. Native DOS, NTVDM application built for DOS environment and ported to Windows NT/XP platforms are not acceptable. The application must be built from scratch for the proposed platform.

Programming software, methodology and language supported shall conform to IEC1131 and shall be approved by TUV for designed safety class. As a minimum it should support Function Block Diagram method, structured text method and ladder logic method. Programming environment should support generic program and running of multiple instances of the same program with diff. set of input/outputs parameters. This engineering station shall be accommodated in the central engineering room, located in the close vicinity of Cabinet room. The interface between ESD main processor and programming station PC shall be via Ethernet with min. 100 MBPS speed.

ESD system application software shall allow incremental download to carry out online modifications, without affecting the running plant. There shall be facilities to monitor the running logic in FBD format in real time mode from engineering station. Also the engineering station of ESD shall allow forcing of any of the hardware input/output or intermediate local variables in complete system by software method.

5.3 SOFTWARE UTILITIES

The following software utilities/tools or equivalent functions shall be provided by BIDDER as a minimum:

Industry standard relay ladder logic,

Boolean operators with timing and voting functions,

High-level language like C, C++, VB, etc.

System diagnostic,

On-line data changes.

Cause-effect table

Print utility

Emulation Software, which can emulate complete ESD application without needing I/O

cards and without affecting I/O Cards status/running application.

Simulation test software and methods

Fault injection and diagnostic / clearance method

Offline engineers and database building package tools.

System software shall also include the software to configure the communication link

between DCS and ESD based on MODBUS or any other standard protocol.

Significant feature and characteristics of the interface shall include a. Availability of data in the interconnected ESD which will allow the DCS to integrate in

display Data from ESD and to centralise monitoring of ESD operating status in DCS,

including all ESD I/O, intermediate memory variable status, timers, counters, ESD health

status flags, in real time environment.

5.4 CONFIGURATION

BIDDER shall be required to develop application programs which perform the logic sequence and functionality as indicated on logic diagrams or cause and effect charts supplied by Owner. The application program shall be structured to keep similar programming features grouped together. ESD shall have facilities to communicate with proposed DCS and preferably it should sit on DCS network as one of the DCS node, so that seamless

integration of DCS with ESD could be achieved. These include the entire Digital input/output channel’s real time status, intermediate local/global ESD variables, timers, counters, all the analog input channels real time values in floats, etc. There shall not be any tag/parameter limits on DCS/ESD gateway communication and the update time of complete ESD parameter sets on DCS shall not take more than 1 second.

The following sequence of grouping is suggested: Common internal logics: if grouping of the same input contact status are used repeatedly

throughout the program, combine them into common internal logics for easy programming

and memory savings.

Data which are interfaced to external systems should be grouped together to facilitate

block transfer of data. Sufficient comments and descriptions shall be included throughout

all ladder logic networks to help operators and maintenance personnel.

5.5 DIAGNOSTICS

Each CPU shall incorporate self-diagnostic routines, I/O status checks ,loop back verification, STUCK ON/STUCK OFF status checks, memory bit pattern checks, CRC checks, watchdog timer to determine the health of each module within the ESD system.

If TMR system is offered, then comparison fault detection shall be performed using 2-out-of-3

voting for each module at each scan cycle. These routines shall automatically identify alarm, isolate and contain and automatically repair faults without compromising ESD system performance. If automatic repair is not possible in case of major fault, the complete system shall guarantee to bring the plant interlocks/logic to a fail-safe status.

Diagnostic routines shall run without interfering with application program scan or execution

time within the process safety time. On-line diagnostics shall include but not be limited to the following; memory testing ,

data and address line testing , processor testing , Interrupt testing , timer testing , memory battery testing, firmware CRC testing , Application program testing , data fault , I/O interface testing , Input discrepancy check ( digital & analog) & output discrepancy check .

The programmes should preferably be in firmware and the use of application software based

test programmes should be avoided. The BIDDER shall detail the basis of the design including a statement on how test software will be generated to match revised application logic.

BIDDER shall state the optimum frequency for the automatic self-test routine necessary to

maintain the requirements of system availability, reliability and safety. The result (healthy/fault) of the self-test shall be reported on the DCS at the CCR through

Communication bus and also on the engineering workstation (PLC ) . Should a fault be detected, and where there is redundancy of design, the system shall automatically adapt to maintain its ability to meet a demand.

The BIDDER shall identify in his bid all possible types of faults in his system and for

each type and describe the method of detection, the resulting system performance degradation, system status after the fault and the time required for detection of fault. This fault analysis has to be implemented by way of failure mode and effect analysis and severity of fault level must be reported in the diagnostic report to take corrective action immediately.

The BIDDER shall explicitly detail in his bid all types of faults which may not be

detected by the proposed / implemented diagnostics and self-tests and propose measures / procedures to overcome this problem and precaution to be taken to achieve class 6 protection as per TŰV.

6.0 CABINETS/ PANELS

6.1 INTERNAL WIRING

I/O and interconnecting wiring shall be tagged at each end with the identification tags. Ferruling shall be double cross ferruling with continuous sleeve. No discrete ferrules shall be accepted. There shall be uniform colour codes for ferrule sleeves various type of signals. All system cable/wire ferrules shall be of white colour with black fonts, whereas all other ferrule sleeve colour shall be yellow with black fonts.

6.2 POWER SUPPLY

Voltage : 115 VAC + 10 % Frequency : 50 HZ +3 % & -6%

6.2.1 INTERNAL DC POWER SUPPLIES

A dedicated redundant power supply unit, included in the scope of supply, shall be used to feed power to racks of the system.

Each power supply unit shall be sized to provide 130 % of required capacity for the specified

configuration of I/O cards, CPUs, including installed spare modules. Each power supply unit shall have built in diagnostic, circuitry to monitor out of range

voltages and over temperature conditions and diode O-ring circuits. Each power supply unit shall have its own internal fuse/circuit breaker protection on the

incoming line side. BIDDER shall carry out a fuse co-ordination study to ensure that in case of a short circuit only

the directly protecting fuse or circuit breaker interrupts the circuit and no higher level fuse melts or circuit breaker opens.

Any external power supply such as to drive 24V DC interposing relay , transmitters, and

interrogation voltage shall be TUV approved, fully redundant, modular with voltage, current indication and adjustable with cooling fans and potential free contacts for alarm.

If the BIDDER’s requirement requires dedicated grounds the proposal shall include sufficient

information to determine how these grounds are to be arranged. The BIDDER shall include heat dissipation requirement in his proposal so that air conditioning

system can be sized. The BIDDER is to include the power load requirements in the proposal that the battery

system can be sized. BIDDER shall provide complete Single Line Diagram of complete PDB systems including 115 V

AC and 24 V DC power supply distribution with proper fuse co-ordination calculation, heat dissipation data, etc.

.

7.0 SYSTEM AVAILABILITY

The ESD system (Emergency Shutdown system) availability shall be in the excess of

99.8% and the mean time between failures for all components in the ESD system should

be not less than 8 hours. The BIDDER should quote spares for the system so that the

mean time to repair the system should be below 8 hours.

a. Alarm handling.

b. Developing special programmes for plant control and their debugging (Restricted to

supervisory staff only).

c. Logging software.

8.0 INSPECTION 8.1 The system and all its 100 % associated components shall be inspected and tested

at the BIDDER’s works by OWNER & third party (if required). 8.2 OWNERs reserve the right to inspect any bought out items by the BIDDER at the

sub- BIDDER’s works. 8.3 Cost of inspecting/testing shall be borne by the BIDDER. FAT/SAT procedures to be

submitted with offer. 8.4 For final integrated inspection of the system, the BIDDER shall give a minimum

notice of 3 weeks to OWNER. Throughout the Factory acceptance test, BIDDER shall provide all necessary test equipment’s and consumables and shall make all necessary connection as many times required. OWNER shall carry out 100% functional checking of all hardware and software modules.

8.4.1 Acceptance testing BIDDER shall prepare test procedures for Owner’s approval. Level of testing: Beyond the mandatory test and inspections according to BIDDER's quality assurance program

during fabrication there shall be two testing described as follows: 1. Factory acceptance test (FAT) to be performed at the BIDDER's factory. 2. Site acceptance test to be performed on plant site. 8.4.2 FACTORY ACCEPTANCE TEST (FAT) The FAT shall be performed when the complete system, including all hardware and software

components, to be supplied by the BIDDER, has been assembled and prepared for operation in the factory.

The testing procedures shall be performed with the aid of adequate simulation hardware,

software And / or test programs. The objective of the testing procedures is to ensure that all hardware components and the related software modules (standard function blocks) are free from errors/defects when being tested individually and in the system configuration. The tests shall be performed with the aid of test programs permitting easy location of defective components and/or software modules.

During the factory acceptance test, the complete system must remain 100 % operational for

at least 100 consecutive hours with no hardware and/or software failures. The BIDDER shall provide test and simulation equipment, appropriate testing staff and any

service utilities to perform the test in an efficient and timely acceptable manner. The course and duration of the test procedure shall be specified by the BIDDER. Simulation equipment for simultaneous testing of 100 % of I/O-signals shall be kept available by the BIDDER/manufacturer (with multiple plug-in connectors).

The Owner and the BIDDER shall agree upon the start of the test. If any failures occur within

said 100 hours the test shall be restarted when the failure has been corrected and the system shall be re-tested for another 100 consecutive hours.

During FAT BIDDER shall prepare a report signed by the Owner and the BIDDER.

After the factory acceptance test has been successfully completed the system shall be ready for transportation to plant site.

Additionally the communication between ESD–system and DCS shall also be tested. The

procedure, e.g. simulation or test program has to be clarified between Owner and BIDDER. Boarding, Lodging and to & fro Fare will be in bidders scope till FAT Period.

8.4.3 SITE ACCEPTANCE TEST (SAT)

After transportation to plant site the BIDDER has to investigate and prove all system components and devices against transportation and erection damages.

This level of testing will take place on site after the system has been installed and certified as

operational by the BIDDER. The BIDDER shall have the responsibility to ensure that the installed hardware including the

software supplied is fully operational. The testing procedure shall include mechanical checks of the system including all system links

connected according to the BIDDER's specification. After this the software will be loaded and self-test routines of the ESD-system shall ensure

that all system components are in acceptable condition as well as the communication links are working properly.

The application software will be loaded. If the system shows no deviation to the normal

operation, the system will be ready for loop checks. When the system operates normally for continuously 30 days, after completion of the loop

checks and all simulation tests, the ESD-system shall be considered as accepted by the Owner.

All guarantee performance data which are specified (CPU spare capacity, spare capacity of

hardware, scanning time of process variables etc.) will be proven by BIDDER. A certificate of acceptance shall be signed by the representatives of the Owner and BIDDER. 8.5 The inspection shall briefly envisage the following: 8.5.1 HARDWARE INSPECTION a. Checks on general workmanship like fabrication quality, paint quality, whether paint shade

identical to all cabinets etc. b. Dimensional inspection for base frame, height, depth, gland plates etc.

c. Power supply, wiring checks for fans, tube lights etc.

d. Supply/signal wiring checks including colour code checking, checking of ferrules, correctness

of wiring, size of wires, proper segregation of wires etc.

e. Provision of terminals of correct size and type.

f. Operations of various lamps, push buttons, MCBs, annunciators, relays, ammeters and

other instruments mounted on the consoles or within the cabinets.

g. Megger test for power distribution cabinets.

h. Provision of earthing bus bars for safety earth/intrinsic safety earth.

i. If a group of panels/consoles is to be mounted and bolted together in the final layout frozen

the same shall be offered for inspection exactly in the same fashion to check inter panel

wiring, mechanical alignment etc. All system modules shall be checked for their correct

mountings in respective slots as per configuration frozen.

j. Redundancy and failsafe features wherever specified shall be checked for:

i. Power supply. ii. I/O cards. iii. CPU/CPUS.

iv. Communication (between nodes as well as within a node).

k. Scan times as specified shall be checked for all inputs/outputs, including installed spare I/Os

in the system.

l. Individual modules wherever possible shall be checked for their performance with

redundancy and fault tolerance checking.

m. All volatile memory shall be checked for battery backup by tripping power for the duration

given in the BIDDER’s specifications.

n. Generating the trip signals and checking the performance of SOE.

8.5.2 SOFTWARE CHECKS These shall include, but not limited to, the following: a. 100% check on the generated data base. This includes checks on: i. Correctness of tag number and description. ii. Measuring range. iii. Input type, input conditioning. iv. Algorithms to be executed. v. Output type and conditioning if any. vi. Logic. vii. Other details if required. b. Logging operation shall be checked in sequential Event recorder

c. Communication with external device to be checked including DCS.

d. S.O.E. history and interface software checks.

9.0 INSTALLATION, PRE-COMMISSIONING AND COMMISSIONING. BIDDER shall depute a team of experienced engineers, technicians and other staff for the

purpose of installation, pre-commissioning and commissioning of the system at site. Following activities are included in the BIDDER’s scope: a. Receipt of system hardware and software at site store and transportation of system from

site stores to cabinet room. b. Unpacking the system and inspection of the same for any damages. c. Erection of system in control room/cabinet room; including welding of channel

supports in false floors. d. Inter cabinet wiring/cabling for all signal, power supply and system cables. e. System and Safety earthing of all panels from a bus bar given at one point in console/cabinet

room. f. Intrinsic safe earthing of all panels from a separate bus bar given at one point in

console/cabinet room. g. Mounting of all hardwired instruments like signal distributors in various cabinets; calibration

& programming of these instruments for ranges, set points etc. h. Mounting, wiring and termination of all free issue instruments given by the OWNERs and

listed in Part-II of project specification.

i. Powering up the system, loading the system configuration and carrying out internal loop checks for correctness of wiring is in BIDDER’s scope. This shall be carried out from marshalling cabinets up to system cabinets. It also includes checking of the software by hardware simulation. The completion of this activity marks the “mechanical completion” of the system and the protocol to this effect shall be jointly signed by the OWNERs/OWNER and the BIDDER.

j. Coordination with OWNERs/OWNER/site erection contractor during complete loop/interlock checking of the plant. This shall be done at least at 4 points in instrument range and with printer online.

k. Consolidate all loop-checking reports with OWNERs/OWNER. l. Correction of all drawings to make them “as built”. m. Provide commissioning assistance to OWNERs/Licensor in the form of implementing

configuration and interlock changes etc. required during commissioning of the plant. o. BIDDER will arrange all necessary tools and equipment's like welding machine etc. for

erection of system cabinets / consoles and cable laying, glanding and termination. 10.0 FINAL ACCEPTANCE & WARRANTY OWNER shall take over the system from BIDDER after site acceptance test. The integrated

system shall run uninterruptedly for four weeks from date of commissioning of the whole plant. Any loss of time due to reasons like power failures, forced shutdowns etc. which are due to no fault of the BIDDER shall also be counted as run time. However, if any major software/hardware failure of the system occurs due to which the system or a part thereof has to be shutdown the test shall be conducted afresh on the whole system.

The warranty period shall be 12 months from final acceptance of the system.

During warranty period BIDDER shall make good all failed components of any part of the system and depute his service engineer to site if required free of cost.

11.0 DOCUMENTATION / DRAWINGS

Documents / drawings shall be supplied as per requirement given below each for

Ammonia-II and UREA-II:

S.No. Item With Quotation

For approval after P.O.

After approval for information

Final As-built

a. Architecture (one line diagram) of the quoted system. 2 1 2 1 2 1 5 copies each

b. Detailed bill of material up to module level & including all bought out auxiliary items.

2 1 2 1 2 1 5 copies each

c. Bill of material, make/model number, with catalogues for all bought out items.

2 1 2 1 2 1 5 copies each

d. Proposed organisation chart for job execution. 2 - 2 1 - - 5 copies each

e. Detailed schedule of job execution. 2 - 2 1 2 1 5 copies each f. A copy of unfilled standard

engineering formats which shall be filled in by OWNERs/OWNER during engineering.

2 - 2 1 2 1

5 copies each

g. Standard dimensional drawings for:

5 copies each

1. System cabinets/ marshalling cabinets/ power distribution cabinets with cabinet Arrangement duty.

2 - 2 1 2 1

5 copies each

2. Peripherals like printers. 2 2 2 2 1

5 copies each

3. Recommended spare parts list for 2 years operation after FAT. 2 2 2 2 - - 5 copies each

h. Final layout drawings including internal hardware mounting details. 2 2 2 2 1

5 copies each

i. Calculation of total power requirement. 2 2 2 2 - - 5 copies each

j. Expected heat dissipation. 2 2 2 2 - - 5 copies each k. Schematic drawings for: 2 5 copies each i) Safety ground. - - 2 1 5 copies each ii) Intrinsic safe / shield / reference

ground. - - 2 1 5 copies each

l. Typical loop schematic for: 2 5 copies each i) Analog closed loops. 2 - - 2 1 5 copies each ii) Analog open loops. 2 - - 2 1 5 copies each iii) Digital inputs. 2 - - 2 1 5 copies each iv) Digital outputs. 2 - - 2 1 5 copies each m. Final loop wiring diagrams with

termination details for all loops. 2 - - 2 1 5 copies each

n. Loop configuration drawings. - - 2 1 3 o. Assembly and interconnection

wiring diagram 2 2 2 1 3

p. Interface details between subsystems 2 2 2 1 3

q. Power distribution block diagram 2 2 2 1 -

r. Nest loading and Tag assignments.

2 2 2 1 6

s. Copy of different log formats available. 2 2 2 1 3

t. Logic/Ladder drawings. 2 2 2 1 3 u. Printouts of all higher language

programmes. 2 2 2 1 3

v. Software loading calculations for various system nodes with spare margins available.

2 2 2 2 2 1 3

w. Factory acceptance test (FAT) plan. 2 2 2 2 2 1 -

x. Standard system documentation available for all system nodes like:

i) Instruction manuals. 2 2 - - ii) Software reference manuals. 2 1 - - - iii) Installation instructions. 2 1 - - - iv) Algorithm library. 2 1 - - - v) Standard symbol library.

2 1 - - -

vi) Safety and test Certificate 2 2 - - - - y. Graphic display detail 2 1 2 2 3

z. Test requirements 2 2 2 1 - - - i. Index of system database

including tag names, description names and set points.

2 1 2 2 3

ii. Sequence of event recorder, hardware and software testing. 2 1 2 1 - - -

iii. Drawing and document index. - 2 1 2 2 3 iv. List of sub-BIDDERs and

datasheet 2 1 2 1 2 2 -

v. TUV Restriction 2 2 vi. Inspection procedure 2 2 vii. Maintenance procedure 2 2 Note: As a final documentation one set shall be provided in Hard Disk in editable software

format in MS-OFFICE and / or AUTOCAD only.

12 AS-BUILT DRAWINGS BIDDERs’ site representative shall mark up all engineering modifications done at site on

THREE master copies to be maintained by him at site. One of the copies shall be in custody of Owner’s site representative and one shall be handed over to the OWNERs.

BIDDER shall incorporate all the changes made at site in his “master copy” and submit as-

built documentation to OWNER as per requirements given above. The BIDDER shall indemnify the OWNER against any damage or loss suffered by OWNER, as

a result of any defect in BIDDER's documents attributed to BIDDER. In the event that any defect in BIDDER's documents attributable to BIDDER results in correction of construction and erection work of the equipment, performed or to be performed by OWNER, the additional cost associated with such correction shall be borne by BIDDER.

13.0 INFORMATION REQUIRED WITH THE BID 13.1 CLARIFICATIONS/CONFIRMATIONS BIDDER is required to confirm point by point whether requirements of specification are met

partly or fully and needs to sign and stamp each of the pages of this enquiry specification document. Any deviations from the specifications are to be highlighted by the BIDDER in his offer. Silence on the part of BIDDER shall be deemed as a deviation from specifications and the same shall reflect in the technical comparison. Similarly if the BIDDER is above to offer some extra useful features over and above the specification the same should be highlighted by him in the offer which shall help in bid evaluation.

Following Additional Confirmations Are Required: 13.1.1 BIDDER shall highlight any special or non-standard hardware/software quoted. 13.1.2 BIDDER shall indicate whether any advanced software versions of the offered systems are

being introduced by him or his principals in India/abroad. Also in case a completely new version of the system (of the same clone or otherwise) is to be introduced into the market in the next 6-12 months, the same shall be Identified by the BIDDER.

13.1.3 A copy of various displays available for operation/maintenance shall be given by the BIDDER. 13.1.4 For “Interlocking system” BIDDER shall state trade-off between scan time (considering

installed spare I/Os in the system) and number of logic/sequence blocks with documentary proof. If the quoted/committed and agreed scan time between OWENER and BIDDER is not achievable practically with implemented system I/O and interlocks, it shall be BIDDER’s responsibility to provide another system in parallel to the offered system to meet/fulfil these enquiry specifications document. Also it shall be BIDDER’s responsibility to build application software/interlocks/logic as per OWNER’s requirement for complete ESD

system including all installed spare I/O counts, if required by OWNER, without any cost implications.

13.1.5 BIDDER shall indicate the communication error detection methods used for: a. Bus communication to external device (MODBUS). b. Internal I/O communication bus. 13.1.6 BIDDER shall indicate the maximum number of nodes possible on main data highway,

maximum number of I/O modules possible on one I/O communication bus & the distance limitations for each.

13.1.7 BIDDER shall indicate the maximum permissible distance between a node and a Peripheral devices like printer. 13.1.9 BIDDER should provide the safety manual with the quotation and give the restriction of the

system as per TŰV for (AK6)/SIL-3 Class application.

PART-II INDEX

CLAUSE

NO.

ITEM

1.0 SPECIFIC PROJECT REQUIREMENT

2.0 SCAN TIMES

3.0 INTER CONNECTION CABLES

4.0 FURNITURES

5.0 BOM

6.0 DEVIATION

1.0 SPECIFIC PROJECT REQUIREMENTS 1.1 This section deals with requirements of ESD system specific to the project under

consideration.

2.0 SCAN TIME

a. Analog Inputs * 50ms 100ms b. Digital Inputs *50ms 100ms c. Digital Inputs * 50ms 100ms

d. CPU Cycle time * 50ms 100ms e. Sequence of Event * 1ms

3.0 INTERCONNECTING CABLES These shall be used for interconnection between various cabinets only when cabinets are

located apart (not bolted together). Following specifications shall hold:

S.N. CABLE TYPE SPECIFICATION

a. Signal cables for analogue I/Os, digital inputs, temperature inputs. 12 pair only

0.75 mm2, multi stranded standard tinned copper conductor, PVC insulated, twisted into pair, overall screened with aluminium backed Mylar tape, PVC sheathed, White/Black colour

b. T/C extension cables. 6 pair, 12 pair

Conductors same as T/C.

PVC insulated, twisted 1 Pair or 12 Pair only, individual/overall screened, PVC sheathed., armoured, if laid below false flooring

c. Power supply cables. 2C multi stranded solid copper conductor, PVC insulated, PVC sheathed. Size of conductor as required. Colour codes shall be as specified above

.

4.0 FURNITURES

S.No. DESCRIPTION MAKE MODEL QUANTITY REMARKS

a. Engineers' chairs

Godrej Make * 1 per PC

b.

Computer Table

Godrej Make * 1 per PC

c Printer Table Godrej Make * 1per Printer

5.0 BOM 5.1 BOM OF CABLES, JUNCTION BOXES, CABLE TRAYS

ITEM QTY 12P x 0.75 mm2 70,000 MR 1P X 1.5 mm2 Signal Cable 8,000 MR 12 triad x 1.5mm2 15,000MR T/C Ext. cable 1P x 20swg K TYPE 4,000 MR

T/C Ext. cable 12P x 20swg K TYPE 32,000 MR 3C x 1.5mm2 Power Cable 5,000 MR 3C x 2.5mm2 Power Cable 2,000 MR JUNCTION BOXES for 24 pair entry 65 Nos. JUNCTION BOXES for 12 pair entry 20 Nos. PERFORATED CABLE TRAY 400MM 4,000MR PERFORATED CABLE TRAY 300MM 1,000MR PERFORATED CABLE TRAY 200 MM 2,000MR PERFORATED CABLE TRAY 100 MM 2,000 MR PERFORATED CABLE TRAY 50 MM 2,000 MR

Above given items & their quantities are minimum estimated quantities, however BIDDER shall visit owner site for actual estimate total requirement of above items. Bidder to note that procurement of BOM will be in Bidders scope.

Note:1 Procurement of all the Hardware material (like Angle, channel, joints, clamps, nut bolts) and Structural material (for installation of JB and cable trays etc.) will be in vender’s scope. Note:2 Bidders to submit the technical specifications of the item under BOM for OWNER approval shall be taken before purchasing.

5.0 Bidder to clearly mention any Deviation from ITB. BIDDER is required to confirm point by point whether requirements of specification are met

partly or fully and needs to sign and stamp each of the pages of this enquiry specification document. Any deviations from the specifications are to be highlighted by the BIDDER in his offer. Silence on the part of BIDDER shall be deemed as a deviation from specifications and the same shall reflect in the technical comparison. Similarly if the BIDDER is above to offer some extra useful features over and above the specification the same should be highlighted by him in the offer which shall help in bid evaluation.

SECTION-IV SPECIFICATION OF MARSHALLING CABINET

a. Dimensions 1200 mm (W) 800 mm(D) 2100 mm(H) (Rittal make only with RAL7035 colour shed) with 100 mm Black powder coated base frame.

b. Colour RITTAL RAL7035 c. Cable entry Bottom d. Lifting eyebolts Required e. Various bus bars Copper Ni/Chromium Plated f. Removable hinged doors (

Lockable ) Required

g. Magnetic latches for doors Required h. Material of labels Rear engraved acrylic, white letters on black

background All labels to be fixed in the cabinet with screws and

not pasted with glue i. Panel illumination 2 Nos. CFL, one in front, one in rear.

Rating 110Vac, 20W each.

j. Ventilation fans 4 Nos.(Two in front, Two in rear) to be provided in:-

i. All marshalling racks ii. Cabinets for mounting free issue

instruments. k. Wiring i. 0.75 mm2multistranded, tinned copper,

PVC insulated wire. White (+) / Black (-) for analog signal.

1.0 mm2multistranded, tinned copper, PVC insulated wire. Grey(+) / Grey(-) for Digital Inputs

1.5 mm2multistranded, tinned copper, PVC insulated wire. RED(+) / Blue(-) for Digital Output to drive relays

l. Colour Coding Of Wires - Power supply Red(P),Black(N)(AC grounded)

Red(P),Black(N) / Green (E) (AC grounded) Sizing as per requirement

- Earthing Green - Analog IS signals White(+) , Black(-) - Analog non-IS signals White(+) , Black(-) - Digital IS signals Grey, Grey - Digital non-IS signals Black m. Terminals - Make WAGO/PHOENIX

All TB shall be WAGO/PHOENIX make, screw less, side/side entry type suitable for 0.5 sq.mm to 4.0 sq.mm. Other size as per requirement. Colour shall be diff. for diff. type of I/O Signals Qty. Shall be 20% extra in each category.

- Type Fused 2.5 mm2 with LED indication

WAGO/PHOENIX Make, Screw Less, Side/Side entry only, DIN Rail mounted. No double Decker permissible. Colour shall be diff. for diff. type of I/O Signals

Qty. Shall be 20% extra in each category.

n. Power Supply Distribution - Utility power One switch 5A rating, black colour, decorative type,

each for 2 tube lights and 2 fans. 1No. 5 pin socket with switch, 5A rating, black

colour, decorative type. Common incoming fuse for all above. Door limit switches required. - Main power Incoming 2 pole Rotary Switch with MCB for each

type of supply. - Earthing Bus bars Each panel shall include 2 nos. of insulated bus bar

for system ground, 2 nos. of non-insulated bus bar for safety earth. 1 type of each on either side.

O Active barriers P&F. Specific Requirements for marshalling cabinets Different cabinet shall be used for diff. category of signals. This is as mentioned below a. Analog input and Analog output b. Digital Inputs c. Digital Output/Relays d. Electrical /Instrument Interface Analog cabinet e. Electrical / Instrument Interface Digital Cabinet (For DI from MCC and DO to MCC and

corresponding relays of DO cards for MCC outputs) There shall be min. 20% spare space in each marshalling cabinet after full implementation of

the project. 1.0 SYSTEM HARDWARE CABINETS

i. These shall be used to mount the system hardware. ii. All the specifications shall be strictly same as those of marshalling cabinets. However there

are two options available in dimensions, viz. 1200mm(W) x 800mm(D) x 2100mm(H) or 800mm(W) x 800mm(D) x 2100mm(H), based on system architecture. However, BIDDER to ensure that all other specifications shall remain same as specified above in marshalling panel details.

iii. These shall be provided with a separate system earth bus bar insulated from ground and a separate safety earth bus bar connected with panel body. There shall be min. two nos. of bus bar (1 of each type) on both side of panels.

iv. The qty. of system panels shall be based on total I/O cards, system hardware modules, 20% spare loading space for future margin on both side and with proper type of Common/Central System hardware as well diff. type of I/O cards segregation and as per OWNER’s requirement, as specified in above section. In main system hardware panel, which will accommodate central ESD parts, will not accommodate any other type of I/O cards/ marshalling inputs/outputs. Also, there shall be diff. / separate cabinet for diff. type of input/output cards.

1.1 COMMON SPECIFICATIONS

a. Dimensions : 1200 mm (W) 800mm(D) 2100 mm(H)

OR

600 mm (W) 800mm(D) 2100 mm(H)

Only Two standard sizes are to be used, based

on system hardware requirement.

(Rittal make only with RAL7032 colour shed)

with 100 mm Black powder coated base frame.

b. Color : RAL 7035 only

c. Cable entry : Bottom Top

d. Lifting eyebolts : Required Not-required

e. All bus bars : Copper Ni/Chromium plated

f. Removable hinged doors (lockable ) : Required Not-required

g. Magnetic latches for doors : Required Not-required

h. Material of labels : Rear engraved acrylic, white letters on black background fixed to the cabinet with screws.

i. Panel illumination Fans

: :

As per BIDDER’s standard requirements Required

j. Wiring/colour coding : As per BIDDER’s standard requirements

k. Terminals

: As per BIDDER’s standard requirements

l. Power Supply Distribution

- Utility power : Same as for marshalling racks

- Main power : As per BIDDER’s standard. 2 main incoming HRC to be provided for isolation. These shall be wired from PDB from two diff. 110 V AC UPS feeders to maintain redundancy Each load shall be capable of accepting dual redundant 110 V AC input.

Empty Slots in system shall be plugged by blind plates & Louvers for each door with 5 micron filter required at the bottom

All other specification, guide lines for installation, earthing bus bar, accessories, colour codes or wiring, etc. shall be exactly same as that of marshalling panels’ specification.

System hardware panels shall provide 10% spare space for future expansion, including system card slots in I/O racks. This is excluding 20% installed spares.

1.2 POWER DISTRIBUTION CABINETS a. These shall be used to mount the hardware required to distribute power at various voltage

levels and types to the system. The total number of HRC fuses required shall accommodate extra 50 points on each side (Total 100 points). The distribution shall be on front and back side. No components/fuses/feeders shall be installed / terminated on both sides of adjacent panels.

b. These shall be exactly same in all specifications as mentioned in marshalling and system

hardware panels, except the dimensions. For all type of PDB, the panel size shall will be 1200mm (W) x 800mm (D) x 2100mm (H). These shall be self-standing type with front and rear doors.

c. Other specifications remain identical to those of marshalling cabinets. d. Vendor shall provide required no. of 115 V AC, 50 Hz main supply feeders up to PDB main

isolation switches. PDB shall be equipped with double pole, rotary isolation switches with mains HRC fuses with suitable terminators. OWNER shall provide power at incomers of rotary switch only. Further wiring/distribution, sub-distribution shall be carried out by BIDDER. MCB

shall not be used at any location. Main feeder and sub feeders shall be provided with HRC fuses/sockets for individual load.

e. BIDDER to provide fuse co-ordination details, calculations for internal distribution for above

all PDB. f. If system requires a separate 24 V DC power supply, BIDDER shall provide 100% redundant

24 V DC bulk power supply in these PDB panels with all mounting hardware, diode paralleling unit and other accessories. The individual 24 V DC bulk power supply unit in a pair or redundant units shall be designed with 130% load carrying capacity. This is required to ensure the catering of complete from single bulk power supply from a redundant pair, in case of failure of any one of the power supply. The complete system shall be designed with 50% spare future margin.

g. The qty. of PDB panels shall be based on total sub feeder requirement, diff. type of voltage

levels, 20% spare loading space for future margin on 110 V AC side and 50% spare future margin on 24 V DC bulk power supply side as per OWNER’s requirement.

h. All the PDB shall have min. 3 receptacles for 230 V AC/5 Amp distributions inside panel.

4.1.3 COMMON SPECIFICATIOS

Separate cabinets are required in general for different voltage levels. .

a. Dimensions : 1200 mm (W) 800mm(D) 2100 mm(H) (

Rittal make only with RAL7035 colour shed) with

100 mm Black powder coated base frame.

b. Colour : RITTAL RAL7035 ONLY

c. Cable entry : Bottom Top

d. Lifting eyebolts : Required Not-required

e. All bus bars : Copper Ni/Chromium plated

f. Removable hinged doors (Lockable ) : Required Not-required

g. Magnetic latches for doors : Required Not-required

h. Material of labels : Rear engraved acrylic, white letters on black background fixed to the cabinet with screws

i. Panel illumination/fans Louvers

: 2 Nos. Tubelights. One each in front and rear. Rating: 110V ac 20W each required.

j. Ventilation fans : 2 Nos. required in each panel.

k. Incoming isolation : MCCB Isolator with fuse

l. Voltmeter (Digital) : Required Not-required

Type (Panel door mounted, visible from the outside)

: 96 mm x 96 mm with fuse. Range as per single line diagram.

m. Ammeter Type : Required Not-required

: Direct CT Operated

: 96 mm x 96 mm with fuse. Range as per single line diagram.

n. Power on indication lamp : Required, with series resistor.

o. Wiring : Outlet of incomer shall be wired to a bus bar from which individual circuits shall be tapped.

No looping of any type shall be permitted.

i. Wire type & size : Solid copper, PVC insulated 600V grade. Size as per current rating of each feeder. Ref. SLD for the same.

ii. Isolation for each feeder : Rotary switch 2 pole with HRC fuses. OWNER shall provide 110 V AC UPS feeders in required qty up to first termination point on rotary switch. Further sub distribution via HRC fuse links shall be by BIDDER There shall be 50 point spare provision per PDB panel for 110 V AC sub feeders

p. Terminals

- Material : PVC Melamine Backlit

- Make : WAGO, Screw less , Size based on wiring size,

Entry Side/Side

Colour, as per Vendor standard.

- Type & Size : DIN rail mounted. All open type terminals to be separated with phase barriers. For size ref. SLD

1.4 INTER CONNECTION CABLES All cables inside the cabinet (e.g. power supply, internal bus etc.) as well as any cable

from cabinet to cabinet , shall be labelled properly with the cable number on both ends . The labelling shall include also the destination of each cable end. Different cables running between various panels inside the cabinet room, below the false floor shall armoured type. These shall be laid in perforated aluminium cable trays below the false flooring, in different trays, with proper segregation like 110 V AC power supply, 24 V DC power supply, signal cables, communication cables, etc. All communication cables shall run thru’ Flexible PVC conduits only, within the panel and between the panels.

1.5 INTERCONNECTION CABLES SPECIFICATION These shall be used for interconnection between various cabinets only when cabinets are

located apart (not bolted together). Following specifications shall hold:

S.NO. CABLE TYPE SPECIFICATION

a. Signal cables for analogue I/Os, digital inputs, temperature inputs.

For Analog Input/Outputs: - 0.75 mm2, multistrand, ATC conductor,

PVC insulated, twisted into pair, Single or 12 Pairs, Individually and overall screened with aluminium backed Mylar tape, PVC sheathed, armoured, if laid below false flooring

- Colour codes shall be White(+)/Black(-) For Digital Inputs - 1.0 sq mm, multi strand, ATC conductor,

PVC insulated, 2 core or 24 core only, PVC sheathed, shielded, armoured, if laid below false flooring,

- Colour codes shall be RED(+)/Blue(-)

For Digital Output – 24 V DC - 1.5 sq mm, multi strand, ATC conductor,

PVC insulated, Single pair or 12 pair only, PVC sheathed, shielded individually/overall armoured, if laid below false flooring,

- Colour codes shall be RED(+)/Blue(-) For Digital Output – 110 V AC for SOV - 1.5 sq mm, multi strand, ATC conductor,

PVC insulated, 1 pair or 12 pair only, PVC sheathed, armoured, if laid below false flooring,

- Colour codes shall be RED(+)/Black(-) For RTD: - 1.0 mm2, multistrand, ATC conductor,

PVC insulated, 1 Triad or 8 Triad only, PVC sheathed, shielded individually/overall armoured, if laid below false flooring

- Colour codes shall be Red(+)/ White(-) / Black(-)

b. T/C extension cables.

6 pair, 12 pair Conductors same as T/C.

PVC insulated, twisted 1 Pair or 12 Pair only, individual/overall screened, PVC sheathed., armoured, if laid below false flooring

c. Power supply cables. 110 V AC/230 V AC

- 3Cx RED/Black/Green, multi strand copper conductor, PVC insulated, PVC sheathed, Armoured, if laid below false flooring. Size of conductor as required. ( minimum 2.5 mm2 )

1.6 VENTILATION Cabinets shall be provided with an internal ventilation system, in order to extract the heat

produced by electronic circuits assuring that all devices properly work in the specified temperature range. Each cabinet shall be provided with 4 ventilation louvers (one on each door, two on front side, two on back side at bottom) of 5-micron size with wire mesh to prevent dust & rodent at bottom only.

A temperature measuring system shall also be provided to generate a potential free digital

alarm signal in case the temperature exceeds the set value for each panel.

Fans shall be suitable for continuous operation and mounted on self-lubricated bearings. All the fans shall run on 115 V AC UPS power supply.

1.7 WIRE TERMINATION

All the terminals for connecting field cables shall be WAGO make, screw less, side-side entry type suitable for 0.5 sq.mm to 4 sqmm cables. No looping of common terminals shall be done on the terminals. All outputs for solenoid valves shall be provided with WAGO make screw less, side-side entry type, fused terminals with LED indication. Wiring shall be PVC insulated 600-volt grade with copper conductor. Power cable shall be 600 / 1100 volt grade.

Conductor shall be multi strand type and size shall be as mentioned below.

For analog inputs :- 2.5 sq mm, multi strand 12 pair or single pair individual/overall shielded with white (+) / Black (-) colour codes.

For Digital Inputs :- 2.5 sq mm, multi strand, flexible, 12 pair or single pair individual/overall shielded with Grey (+) / Grey(-) colour

For Digital Outputs :- 2.5 sq mm multi strand, flexible, 12 pair or single pair individual/overall shielded with Red (+)/Blue (-) colour

For 110 V AC power cable :- 3 Core, multi strand, flexible, RED(P) / BLACK (N) /GREEN (E), Sizing shall be based on load, however min. size shall be 2.5 sq.mm.

For 24 V DC power cable :- 2 core, multi strand, flexible, RED (+)/ Blue (-), sizing shall be based on load, however min. size shall be 2.5 sq.mm.

Adequate segregation of terminals and accordingly marshalling panels and wiring shall be maintained to allow quick identification of wires. The broad segregation is provided below:

Discrete inputs

Discrete outputs thru Relays for Solenoid valves

Discrete outputs thru Relays for Solenoid valves

Analog inputs

Output to Annunciator / Lamp

Output to MCC

Output to DCS

Power supply

The system cables used between the marshaling cabinets and the system cabinets shall be supplied by the BIDDER in a prefabricated form and pre-connected at the ESD BIDDER factory to the respective cabinets.

Termination boards shall be provided with suitable input/output connectors for quick interconnection. It shall be BIDDER’s responsibility to select proper type of terminal assembly for each cards of system.

No more than two wires shall be connected to a single terminal block connection. The second wire, if necessary, shall be a jumper wire to another terminal.

Spare terminal shall be provided for the future use as per PART –II.

1.8 INTERNAL WIRING

I/O and interconnecting wiring shall be tagged at each end with the identification tags. Ferruling shall be double cross ferruling with continuous sleeve. No discrete ferrules shall be accepted. There shall be uniform colour codes for ferrule sleeves various type of signals. All system cable/wire ferrules shall be of white colour with black fonts, whereas all other ferrule sleeve colour shall be yellow with black fonts. System shall withstand transient voltage spikes of 140% for a period of 10 ms . System shall withstand momentary loss of complete power for 20 milli seconds.

1.9 INTERNAL DC POWER SUPPLIES

A dedicated redundant power supply unit, included in the scope of supply, shall be used to feed power to racks of the system.

Each power supply unit shall be sized to provide 130 % of required capacity for the specified configuration of I/O cards, CPUs, including installed spare modules.

Each power supply unit shall have built in diagnostic, circuitry to monitor out of range voltages and over temperature conditions and diode O-ring circuits.

Each power supply unit shall have its own internal fuse/circuit breaker protection on the incoming line side.

BIDDER shall carry out a fuse co-ordination study to ensure that in case of a short circuit only the directly protecting fuse or circuit breaker interrupts the circuit and no higher level fuse melts or circuit breaker opens. Any external power supply such as to drive 24V DC interposing relay , transmitters, and interrogation voltage shall be TUV approved, fully redundant, modular with voltage, current indication and adjustable with cooling fans and potential free contacts for alarm.

If the BIDDER’s requirement requires dedicated grounds the proposal shall include sufficient information to determine how these grounds are to be arranged.

The BIDDER shall include heat dissipation requirement in his proposal so that air conditioning system can be sized.

The BIDDER is to include the power load requirements in the proposal that the battery system can be sized.

BIDDER shall provide complete Single Line Diagram of complete PDB systems including 110 V AC and 24 V DC power supply distribution with proper fuse co-ordination calculation, heat dissipation data, etc.

1.10 POWER SYSTEM INDICATORS

Power supply unit status shall be indicated on the faceplate of PDB panel doors from outside with the help of Digital Voltmeters and shall be remotely communicated via alarm contacts and software. This will be wired to DCS and annunciated in DCS operating station.

1.11 GROUNDING/ EARTHING There shall be 2 type Earthing points, one shall be insulated system earth bus bar and

the other shall be safety earth bus bar. There shall be total 4 nos. of such Earth bus bar provided in the each cabinet (two on either side). The looping of the Earthing points should be in such a way that a break in one circuit will not affect complete earthing . Both the earthing points will be provided at a single point. Inside the cabinet this shall be done by the BIDDER. A ground fault detection circuitry shall monitor grounded electrical circuits in field wiring via an alarm indicator, when resistance to earth fails for all types of I/O. BIDDER to specify total numbers of earthpits. All inter panel and system component grounding/earthing shall be carried out by BIDDER inside cabinet room, with 100% redundant looping. OWNER shall provide two separate earth bus bar in cabinet room at one location. BIDDER to lay all earthing/grounding cable up to this point.

1.12 Name and Tag Plates

Each instrument, equipment, cabinet, panel included in BIDDER’s scope of supply shall have its individual name and tag plate which matches with thedocuments submitted.

All name and tag plates, or plates for brevity, shall be designed and supplied by the BIDDER

which will be made of black Acrylic sheet and screwed with SS screw to the panel. Tag numbers shall be engraved or embossed in white colour only. The naming philosophy shall be as per OWNER requirement.

SECTION-V

BASIC SPECIFICATIONS OF INSTRUMENTS 1.0 Broad Specifications for Various type of Instruments power/signal and control

cables:

In addition to various cable manufacturing standards like IS1554, BS/ IS5831 and IS694-Part-I & II standards, the following basic design criteria as per Owner’s standard shall be followed as a minimum. All cables, color codes shall be strictly as follows. This philosophy applies to package unit instruments also.

a. Single pair signal cable: ATC, Multi strand (Max 7 strands), 1 Pair, twisted pair, shielded,

1.5sq. mm, Blue-Black colour armoured/ FRLS cable, Outer Jacket colour code: Blue. This shall be used for all 4-20 m ampere analog inputs/outputs signals.

b. Multi pair signal cable: ATC, Multi strand (Max 7 strands), 12 Pair, twisted pair shielded, 0.75

sq. mm, Blue-black colour, individual and overall armoured/ FRLS cable, Outer Jacket colour code: Light Blue.. 6 pair multi pair cable shall not be used. This shall be used for all 4-20 m amps. analog inputs/outputs signals.

c. Power cable: - ATC, Multi strand (Max 7 strands), 1.5 sq. mm for 115 V AC, 3 cores- Red / Black / Green,) armoured/FRLS, Outer jacket colour code: Black. This shall be used for 115V AC power supply to field instruments, solenoid valves, etc. This shall be used for 115AC power supply as a minimum size. BIDDER to ensure correct size (cross section area) for various requirements.

d. Power cable: - ATC, Multi strand (Max 7 strands), 2.5 sq. mm for 24 V DC, (2 core- Red-

Black) armoured/FRLS, Outer jacket colour code: Black. This shall be used for 24 V DC power supply as a minimum size. BIDDER to ensure correct size (cross section area) for various requirements.

e. Control Cable for DI - Multi pair:- ATC, Multi strand(Max 7 strands), 1.5 sq. mm, 2Cx12Pair, individual/overall screened, Red/Blue colour, armoured/FRLS cable, Outer Jacket Colour code: Black. 6 pair multi pair cable shall not be used. These shall be used for all 24 V DC Digital inputs.

f. Single Triad RTD cable ATC, Multi strand (Max 7 strands), 1 Triad, 1.3 sq. mm, red/white/black colour, armoured/ FRLS cable, Outer Jacket colour code: Blue. This shall be used for all RTD input signals.

g. Multi Triad RTD cable ATC, Multi strand (Max 7 strands), 12 Triad, 1.5 Triad, 1.3 sq. mm, red/white/black colour, individual/overall armoured/ FRLS cable, Outer Jacket colour code: Blue. This shall be used for all RTD input signals.

h. Thermocouple Extension single pair: 1 P x 18 AWG (Single) or 20 AWG (Duplex) as per IEC

60584-3, Special compensating cable for particular type of thermocouple. MOC of the conductor shall be same as the thermocouple type except ISA type R,S& B thermocouple.

i. Thermocouple ExtensionMulti pairCable: 12 P x 18 (Single) or 20 AWG (Duplex) individual/overall shielded as per IEC 60584-3, Special compensating cable for particular type of thermocouple. MOC of the conductor shall be same as the thermocouple type except ISA type R,S& B thermocouple.

2.0 Broad Specifications for various Field Junction box and Cables:

The following basic design criteria is to be followed for all type of junction boxes, throughout the specifications, including those being supplied by package unit vendors.

a. Irrespective of plant’s hazardous classification, all the supplied junction boxes shall be of Flame proof type approved for Ex-d IIC/T4 as per CENELEC.

b. All the field junction box shall be made of die-cast aluminium. c. Fasteners of all the Junctions boxes will be of SS material. d. There shall be diff. junction box for diff. type of I/O signals as well as dif. Destination like

DCS and ESD systems. As a minimum the following segregation shall be maintained

Signal Category wise segregation

a. Analog Input and Analog output b. 24 V DC Digital Input / NAMUR sensors c. 24 V DC Digital Output used for lamps, etc. d. 115 V AC/ DC Digital output signals for Solenoid valves e. 115 AC power cables for field instrument power

Destination Based Segregation

A. DCS Junction Boxes B. ESD Junction Boxes C. Other systems

e. The naming philosophy for junction box shall be adopted in such a way that from the tag

number of the particular junction box, it shall be evident to decide type of signal and destination

f. All junction box MOC shall be die-cast aluminium and it shall be epoxy painted. Based on requirement, there shall be diff. insulated shield and earth bus bars are to be provided in the junction box. The individual branch cable shall be brought to central cabinet room panel instrument shield bus bar via insulated shield bus bars and multi pair shields from junction boxes.

g. All junction boxes shall have branch and multi pair cable entries from bottom only. h. All junction boxes shall be weather proof to IP67 as a minimum. Generally 12 branch entries

of ¾” ET and 1 no. of main multi pair cable entry type junction boxes shall be used in the total project.

i. Each Junction box shall have suitable screw less, side entry for wire, WAGO make terminals inside them. These shall be DIN rail mounted. The colour code shall be based on type of signals. The qty. shall be as required.

j. Each junction box shall have engraved/embossed SS tag plate with tag number. This tag plate shall be screwed on the junction box the naming philosophy for junction box shall be adopted in such a way that from the tag number of the particular junction box, it shall be evident to decide type of signal and destination.

SPECIFICATIONS FOR SIGNAL CABLE 1 PAIR X 1.5 SQ.MM

GENERAL Cable Type Signal Cable No. Of Cores/Pair 1 Pair Voltage Grade 600 V

CONDUCTOR

Conductor Material Annealed Tinned Copper No. Of Strands 7 Dia of Each Strand 0.53 mm Cross Section Area 1.5 mm2

INSULATION

Insulation Material Type C HR PVC Compound Insulation Type Extruded Insulation Thickness 0.9 mm min. Temperature Limit 85 Degc

FORMATION

Element Formation Laid UP Cable Formation Pair Twisted No. of Twists/Meter 13-15 nos. Core/Pair Number At 100 mm Interval Communication Pair NA

INDV. PAIR SHIELD

Shield Material Al-myler Min. Thickness(mm) 0.05 Overlap/Coverage 30% /100 % Drain wire Cu. 7 strand/ 0.5 mm2 Insulator/Binder Polypropylene/Polyester

OVERALL SHIELD

Shield Material NA Min. Thickness(mm) NA Overlap/Coverage NA Drain wire NA Insulator/Binder NA

INNER SHEATH

Sheath Material HR PVC ST-2 Thickness (min) 0.5 mm Color Black

ARMOURING Armoring Material Hot Dipped Galvanized Steel Round wire Wire Dia/ Thickness(mm) 0.9 mm/-

OUTER

Outer Sheath Material FRLS, ST2 PVC Outer Sheath Thickness(mm) 1.4 mm Temperature Limit 90 Deg C Cable Length Marking At every meter, drum rolling to start from 0

meter

COLOR Each Pair Color Code Black, Blue Outer Sheath Color Blue

MECH. & ELECTRICAL

Conductor Resistance at 20 Deg.c. 12.3 ohm/km Drain Wire Resistance at 20 Deg.c. 30 ohm/km Capacitance Adj. Cores 250 PF/m Capacitance Core and Shield 400 PF/m Mutual Inductance 0.65 MH/km

L/R Ratio 40 micro/km Insulation Resistance at 40 Degc 25 M ohm/ km Over/Under Armour Dia 9.8/ 7.8 mm Overall DIA 13 mm Bending Radius 10 X OD Net Wt. Of Cable( Kg/Km) 330 Kg/km Drum Length 1 KM

SPECIFICATIONS FOR SIGNAL CABLE 12 PAIR X 1.5 SQ.MM

GENERAL Cable Type Signal Cable No. Of Cores/Pair 12 Pair Voltage Grade 600 V

CONDUCTOR

Conductor Material Annealed bare Electrolytic grade stranded Copper as per IS-8130

No. Of Strands 7 Dia of Each Strand 0.3 mm Cross Section Area 0.75 mm2

INSULATION

Insulation Material Type C HR PVC Compound Insulation Type Extruded Insulation Thickness 0.6 mm min. Temperature Limit 85 Degc

FORMATION

Element Formation Laid UP Cable Formation Pair Twisted No. of Twists/Meter 13-15 nos. Core/Pair Number At 300 mm Interval Communication Pair NA

INDV. PAIR SHIELD

Shield Material Al-Myler Min. Thickness(mm) 0.05 Overlap/Coverage 30% /100 % Drain wire Cu. 7 strand/ 0.5 mm2 Insulator/Binder Polypropylene/Polyester

OVERALL SHIELD

Shield Material Al-Myler Min. Thickness(mm) 0.05 Overlap/Coverage 30% Drain wire Cu. 7 strand/ 0.5 mm2 Insulator/Binder Polypropylene/Polyester

INNER SHEATH ARMOURING

Sheath Material Extruded type ST-2 PVC Thickness (min) 0.6 mm Color Black Stranded Confirming to IS-5831,1984 Armoring Material Hot Dipped Galvanized Steel Round wire

OUTER

Wire Dia/ Thickness(mm) 1.6 mm/- Outer Sheath Material Extruded type ST-2 PVC ,with FRLS

Stranded Confirming to IS-5831,1984

COLOR

Outer Sheath Thickness(mm) 1.4 mm Temperature Limit 90 Deg C Cable Length Marking At every meter, drum rolling to start

from 0 meter Each Pair Color Code Black, Blue Outer Sheath Color Blue

MECH. & ELECTRICAL

Conductor Resistance at 20 Deg.C. 39.7 ohm/km Drain Wire Resistance at 20 Deg.c. 30 ohm/km

Capacitance Adj. Cores 250 PF/m Capacitance Core and Shield 400 PF/m Mutual Inductance 0.65 MH/km L/R Ratio 25 micro/km Insulation Resistance at 40 Degc 25 M ohm/ km Over/Under Armour Dia 24.9/ 21.5 mm Overall DIA 27.9 mm Bending Radius 10 X OD Net Wt. Of Cable( Kg/Km) 1362.3 Kg/km Drum Length 1 KM Drum Length 1 KM

SPECIFICATIONS FOR T/C EXTENSION CABLE K-TYPE 12 PAIR

GENERAL

Cable Type T/C Extension cable ( K type) No. Of Cores/Pair 12P X 20 AWG Voltage Grade 500 V Thermal EMF Conform to ANSI MC 96.1 Limit of Error +/- 2.22 deg C

CONDUCTOR

Conductor Material Chromel-Alumel No. Of Strands Solid(0.813 mm) Dia of Each Strand 20 AWG Cross Section Area 0.5 mm2

INSULATION

Insulation Material Type C HR PVC Compound Insulation Type Extruded Insulation Thickness 0.6 mm min. Temperature Limit 85 Degc

FORMATION

Element Formation Pair Twisted 13-15 twist/Meter Cable Formation Twisted Pair & Laided Core/Pair Number At 100 mm Interval Communication Pair Cu. 7 strand/ 0.5 mm2

INDV. PAIR SHIELD

Shield Material Al-myler Min. Thickness(mm) 0.05 Overlap/Coverage 30% /100 % Drain wire Cu. 7 strand/ 0.5 mm2 Insulator/Binder Polypropylene/polyester

OVERALL SHIELD

Shield Material Al-myler Min. Thickness(mm) 0.1 Overlap/Coverage 30% /100 % Drain wire Cu. 7 strand/ 0.5 mm2 Insulator/Binder Polypropylene/polyester

INNER SHEATH Sheath Material Extruded ST2 PVC Thickness (min) 0.6 mm Color Black

ARMOURING Armoring Material Hot Dipped Galvanized Steel Round wire Wire Dia/ Thickness(mm) 1.6 mm

OUTER

Outer Sheath Material FRLS, ST2 PVC Outer Sheath Thickness(mm) 1.4 mm Temperature Limit 90 Deg C Cable Length Marking At every meter, drum rolling to start from 0

meter

COLOR Each Pair Color Code Yellow(+ve)/Red(-ve) Outer Sheath Color Yellow with blue line

MECH. & ELECTRICAL

Conductor Resistance at 20 Degc 1921 ohm/km Mutual Capacitance 250 pf/m Capacitance Core& Shield 400 pf/m Mutual Inductance 0.65mH/km L/R Ratio NA Insulation Resistance at 40 Degc 25 M ohm/ km Over/Under ArmorDia 24.9/ 21.5 mm Overall DIA 28.5 mm Bending Radius 10 X OD Net Wt. Of Cable( Kg/Km) 1700 Kg/km Drum Length 1 KM

SPECIFICATIONS FOR 3 CORE POWER CABLE

GENERAL Cable Type Power Cable No. Of Cores/Pair 3 Core Voltage Grade 1100 V

CONDUCTOR

Conductor Material Annealed Bare Electrolytic Grade Stranded Copper

No. Of Strands 7 Dia of Each Strand 0.53 mm Cross Section Area 1.5 mm2

INSULATION

Insulation Material Type C HR PVC Compound Insulation Type Extruded Insulation Thickness 0.9 mm min. Temperature Limit 85 Degc

FORMATION

Element Formation Laid UP Cable Formation Note1 Core/Pair Number At 100 mm Interval Communication Pair NA

INDV. PAIR SHIELD

Shield Material NA Thickness NA Overlap/Coverage NA Drain wire NA Insulator/Binder NA

OVERALL SHIELD

Shield Material NA Min. Thickness NA Overlap/Coverage NA Drain wire NA Insulator/Binder NA

INNER SHEATH Sheath Material Extruded ST2 PVC Thickness (min) 0.7 mm Color Black

ARMOURING Armoring Material Hot Dipped Galvanized Steel Round wire Wire Dia/ Thickness(mm) 0.9 mm/-

OUTER

Outer Sheath Material FRLS, Extruded ST2 PVC Outer Sheath Thickness(mm) 1.4 mm Temperature Limit 90 Deg C Cable Length Marking At every meter, drum rolling to start from 0

meter

COLOR Each Pair Color Code Red , Yellow , Blue Outer Sheath Color Black

MECH. & ELECTRICAL

Conductor Resistance at 20 Degc 12.3 ohm/km Mutual Capacitance 0.65 mH/km Capacitance Core to core (max) 250 pf/m Mutual Inductance - L/R Ratio - Insulation Resistance at 40 Degc >25 M ohm/ km Over/Under Armor Dia 10.4/ 8.4 mm Overall DIA 13.4 mm Bending Radius 10 X OD Net Wt. Of Cable( Kg/Km) 375 Kg/km Drum Length 2 Km

SPECIFICATION OF JUNCTION BOX

1 Type: Weather proof junction boxes suitable for installation on

Hazardous area

2 Door: Single Door, hinged at left hand side and bolted with lock washers/ clips.

3 Enclosure: IP 66 4 Explosion proof Classification: E Ex d IIC T6 5 Sealing: Neoprene gasket 6 Type of sealing gasket: Endless molded 7 Size: 415 X 330 X 150 mm 8 Material of Construction: Cast Aluminum Alloy 9 Mounting: Four bracket on corner 10 Paint: Light blue synthetic or better 11 Earthing: Two no. screws (one no external and one no internal) 12 Cable Entry: 24 nos. 2 no 1/1/4" NPT (F) Bottom Entry and 12 nos. 1/2" NPT (F)

each side Entry 12 nos. 2 no 1/1/4" NPT (F) Bottom Entry and 06 nos. 1/2" NPT (F) each side Entry

13 Accessories: (i) 2 no’s copper bar mounted parallel with terminal rail (upper and bottom) with 50 mm gap.

(ii) One number terminal rail with 2.5 size, 50 no’s terminal with both side numbering.

14 Type of Terminal: WAGO make screw less on DIN rail. 15 Type of Cable glands: Double Compression type 16 Material of cable glands: SS 17 Size of cable glands: Suitable for (i) 1 no 1.5 X 24 core multi stand cable (ii) 12 no’s 2.5 X 3 core multi stand cable

18 Tag Plate: Junction boxes shall have name plate fixed on front cover through SS screw

19 Cover bolt: S.S.

NOTE: 1) Other required dimensions shall be taken. 2) Offer shall be made with complete drawing and catalogue.

3) Deviation if any may be indicated separately. 4) All cable entries shall be blinded with SS male plug. 5) Party shall submit GA/Dimensional drawing for JB/Canopy. 6) JB with Canopy will be required. 7) JB mounting shall be in Vendor scope.

SECTION-VI

1.0 GENERAL GUIDELINES FOR CABLE LAYING, TRAY LAYING, LOOP

CHECKING

I. All potential free/dry contacts for pump / motor running indications, etc. from MCC/SWB or VSD panels from electrical shall be wired to IRC and by Electrical, including design, procurement and installation/laying of various cables between MCC panels to IRC.

II. All Digital output commands from I&C DCS/ESD systems for various purpose like Motor

Trip/Auto-Manual Command( if used), Emergency Stop, etc. shall be wired from respective DSC/ESD panels to IRC via interposing relays by I & C.

III. All Digital output commands from interposing relays meant for Electrical MCC panels, etc.

from IRC shall be wired from IRC panel to MCC panel by Electrical. All cables shall be designed, procured and laid by Electrical.

IV. All IRC/IFC panels shall be of standard RITTAL make panels with 1200mm (W) x 800mm (D) x 2100 mm (H) size, with RAL7032 color and shall be located at central cabinet room within the premises of I & C. It is the responsibility of I & C

V. All cabling between the IRC/IFC and MCC or other electrical control panels, field Motors, etc.

is the responsibility of Electrical. VI. The measurement of power factor, frequency, power consumption and other typical electrical

signals to be processed / handled in instrumentation systems is the responsibility of the Electrical discipline. I&CS will be responsible for incorporation of these measurements into their system(s) from the interface point (IFC) to respective ESD/DCS panel. Measurements shall preferably be presented by Electrical as isolated analogue signals of 4-20 mA DC.

VII. The monitoring and alarms annunciating associated with motors, switchgear, transformers

and any other electrical equipment, which are to be, annunciated on instrument panels and/or in I&CS are the responsibility of Electrical. I&CS will be responsible for incorporation of these alarms into their system(s) from the interface point (IRC).

VIII. I&CS will be responsible for the detailed control, alarm, safeguarding requirements as shown

on the P&ID's and passing all signals required for electrical control to the interface point as detailed for each project.

IX. I&CS shall include the tag number on the interface document.

X. Instrument Loop Diagram shall show the complete loop inclusive a reference drawing

number with respect to the electrical wiring up to the point of interface, i.e. IRC/IFC. XI. For all pumps/motors, emergency stop command, I&C shall use a Mushroom Push Button

with key lock, installed on Operator console. This buttons shall operate a 24 V DC interposing relay located in IRC. The potential free contact from these relays shall be wired to relevant MCC/SWB/Motors at Electrical Substation by Electrical for stopping those motors. The other spare contact of such relay from IRC shall be wired by I&C as a feed back to DCS as digital inputs to their system for registration of pressing of push buttons with alarms on DCS graphics.

XII. This emergency push buttons shall be in addition to any Trip/Auto stop contact generated

from ESD/DCS interlock from I&C System. In this case the two contacts shall be wired to MCC/SWB/Motors by Electrical in their protection circuitry in series.

XIII. In general, remote start from Operator Console from Central Control room is not envisaged

for any Motor/Equipment’s. These shall not be provided.

2.0 LAYING OF CABLES

The scope includes but not limited to the - Transportation of the cable drums from the place of storage to the place of work - Cutting the cable to required length as per cable and drum schedules - Laying and termination at both the ends. - The scope shall include the installation, glanding and termination of cables using cable glands

at both the ends for all single and multi-pair cables. - Grounding of junction boxes & cable -glands - Supply of bootlace lugs, continuous ferrule sleeves, insulation tapes, Teflon tapes, etc. - Laying of cables on trays, dressing, clamping, supporting, continuity checking, meager

testing and all related activities. - IEC will supply all the consumable items & accessories for the grounding of junction boxes &

cable glands and other items shall also be includes in the scope of supply of IEC like insulation tape, Teflon tape, Teflon paste, silicon rubber paste, bootlace ferrules, lugs, earthing/shielding cable sleeves, of all types/size, etc.

3.0 INSTRUMENT CABLE INSTALLATION a. The IEC must ensure that whenever an electrical specification is issued the appropriate

sections shall be read in conjunction with these specifications and any omission or ambiguities should be resolved with the engineer-in-charge.

b. The cable installation drawings and documentations provided by the engineer will normally

specify or incorporate regulations for the electrical noise pick up. However following general rules apply,

c. Parallel runs of the instrument cables and power cables should be avoided where parallel

runs must be made cable spacing specified in the documentation must be maintained. d. Where instrument and power cable cross in close proximity the cross shall be made at right

angle. e. Multi core / multi pair cables shall be cut after the exact site measurements are taken

between ends the cable drum schedule shall be followed before cutting the length to avoid any wastage. Drum schedule shall be provided by Owner during execution.

f. Joints shall only be made at terminals in instruments or approved equipment. No

intermediate joints shall be made on cable tray or in conduit. Cables must be run in accordance with the purchaser’s documentation.

g. All cables shall be terminated at junction boxes and instruments by proper glanding, using

proper size crimping lugs of approved design and with appropriate crimping tools. h. Qualified electrician who is well experienced in this type of work shall do the junction box or

instrument wiring connections in an approved manner. i. Where conduit terminates at cabinets, terminal box trunking or ducting, it shall be secured

with a lock nut, brushed and ferruled in an approved manner. Sharp edges shall be removed and conduit not otherwise connected shall be terminated in smooth brushes.

j. Cables shall properly be laid in perforated trays of suitable size aluminum MOC. k. All cable shall be tagged with permanently punched strip of aluminum and identified as given

in cable schedule. The cable tag shall be on instrument side, junction box side, & control room panel. The aluminum strips shall be securely fastened to cables using SS wires. Cable identification tags shall be provided as following :

i. At an interval of 10 mtrs for cable laid above ground. at an interval of 5 mtrs. For cable laid

underground. l. Shield, drain wire, terminated in junction boxes or earthling strips shall be provided with PVC

sleeve cover. This shall be supplied by IEC. m. Yellow color continuous Ferrules sleeve (with black font) of proper size shall be provided for

each terminated wire as per termination drawing. Double cross ferruling philosophy shall be used at all locations, which indicates sour/destination side detail at each end.

n. Spare wires shall also be ferruled / tagged and neatly dressed. o. Cables shall not be bent to radius less than the manufacturer’s recommendations (i.e. 10

times the cable O.D). p. All copper cables shall be terminated at junction boxes and instruments by proper glanding

with PVC hood covering. q. Clips and saddles securing to steelwork or tray shall be of aluminum. These clips shall be

spaced at 0.5-meter intervals. r. The cable laid on the cable tray shall be properly dressed in such a manner that the crossing

of cables shall be minimized. The cable on the cable tray shall be clamped with SS strip at every 0.5 mtrs in vertical tray & 2 mtrs in the horizontal cable tray.

s. No cable laying cables in the cable trench or to be buried in concrete trench 3.1 INSTALLATION OF CABLE TRAYS/DUCTS

The scope shall include, but not limited to the - Transportation of the trays from the place of storage to the place of work, - Lifting to the place of work - Proper alignment and fixing/ clamping (SS clamp). - The cable duct/trays shall be of MS or Aluminum (perforated or ladder type) as specified in

the detailed MTO. The cable trays shall be supplied in standard straight lengths of approx. 2500 mm.

- Any bends, elbows, risers, tees etc. as required for cable trays as per site conditions shall be

fabricated by the IEC from the straight run only. The coupler plates shall be used to join the two trays.

- Cable trays / ducts for multi core cables from control room to JB is considered as main trays.

Rest all trays shall be considered as sub trays. Prefabricated perforated Aluminum sub trays/ branch trays shall be used to run individual pneumatic signal / sample tubing/ electrical (signals not to be mixed up) and shall be mounted on steel structure.

- The scope of work shall include fabrication, welding and installation of trays including supports from structural and laying of various sizes sub trays in position.

- Sub trays shall be bolted to the supports. The scope work is also inclusive of the supply and fabrication of all tray fittings such as bends, offsets, corners and crossings etc., as per requirements.

- Minor civil works like grouting, providing inserts, chipping the concrete, bricks etc. shall be

included under the IEC’s scope of work. - The sub trays shall be properly finished and laid to give neat appearance. - All supports, clamps and other fixtures shall be painted with min. two coats of Red oxide and

two paint coats of epoxy paints as per OWNER’s standard color codes. Welding of cable trays joints is permitted. However aluminum paint to be applied before

cable/ tube laying. Support trays shall be run with the breadth of the tray in a vertical plane. Where the engineer agrees that the breadth horizontal the tray must be provided with additional support prevent sagging

4. LOOP CHECKING a. Loop test shall be performed after calibration of all instruments and leak test of signal lines.

Loop test are conducted to check the functional performance of all element comprising the loop, thereby ensuring proper conditions and operations. All the control room equipment namely DCS, PLC, and other peripherals are supplied, installed and commissioned by DCS supplier/OWNER. Instrument installation contractor should bring all the field cable and terminate in the termination cabinet in the rack room. The loop testing shall be done by IEC with complete co-ordination with DCS/PLC supplier and OWNER in presence of OWNER Engineers / Technicians.

b. Loop testing for all control loop shall be generally by simulation of process condition and shall

fix points namely 0%, 25%, 50%, 75%, 100% of full scale inputs. Detailed procedure shall be submitted to Engineer in charge for approval before proceeding with the loop testing.

c. In case of shutdown system field / receiver pressure switches are stimulated for abnormality by disconnecting the wires at terminal and function of all associated system are checked.

d. After the loop testing is completed, the contractor shall connect back any terminations and connections removed for loop test./ marking shall be done on “loop checked” instruments.

e. A loop shall be considered as handed over only after all the tests are over in that particular loop are completed and certified by Engineer in charge, in addition to loop sheets being duly filled in all respects and approved and accepted by Engineer in charge. Proposed loop test format is enclosed with this enquiry at appendix-X.

f. In case of loop, in which certain instruments of the loops are calibrated by other agency, the loop testing shall be performed in coordination with agency involved. If any defect in the calibration of the instruments in contractor’s scope is observed, it shall be rectified to the satisfaction of the engineer in charge. However, defect in calibration in the instruments in the scope of other agency; it shall be rectified by other agency involved. After the calibration has been rechecked by other agency, the loop checking would be performed to the satisfaction of Engineer in charge, and this part is covered under the scope of the contract.

g. Final certified loop sheet should be submitted in two copies to OWNER and two copies to consultant.

SECTION-VII

SPECIAL TERMS & CONDITIONS FOR ERECTION AND COMMISSIONING 1. As this is an up-gradation to existing DCS & ESD control systems of Ammonia-II & Urea-II

Plants, for exact assessment bidder have to visit the NFL Vijaipur site to see the site conditions in respect of field instrumentation, cabling, control rooms, installation space, existing documentation etc. at vendor’s cost and NFL will not entertain any claim on this account.

2. After opening the un-priced bids a series of technical review meeting are envisaged, which shall be held at NFL Vijaipur and vendors have to come prepared for discussion / clarifications as per comments and observations already conveyed on their bids. All expenses for the same shall be to vendor’s account and NFL will not entertain any claim on this account.

3. Vendor shall submit the detailed schedule of different activities for completion in respect of detailed engineering, supply, erection & commissioning and successful handing over of the Control system for approval from Owner, within 15 days from the date of LOI/FOI and simultaneously shall arrange kick-off meeting.

4. As per schedule given by the vendor, all related engineering documents shall be issued to vendor for detailed engineering.

5. After placement of Purchase Order / Work Order vendor shall submit all engineering documents for approval preferably through courier or in person to reduce transit time.

6. Stage wise progress shall also be submitted fortnightly to the Owner. The Owner may visit vendor works to see stage wise progress.

7. Vendor shall inform in advance regarding the requirement of battery limit conditions to be provided by Owner and other scope of work to be undertaken by the Owner e.g. system power requirement, system earthing pit requirement etc.

8. After awarding of contract successful vendor shall send all engineering documents in three hard copies to owner for approval and soft copies through e-mail.

9. Site Mobilization: a) As the total supply and Erection & commissioning is in vendors scope, the vendor has to

mobilize the site for safe storage of material and office for day to day work during erection and commissioning.

b) The contractor shall inform the owner within 15 days of placement of LOI, his space requirements for storage and office. Depending on availability and requirement, space shall be allotted to the contractor but he will not be permitted to use any other space without the sanction of the owner. The use of this space shall strictly be made for execution of this contract only.

c) The security of the contractors’ equipments and material is his own responsibility. The owner accepts no liability for loss or damage to contractors’ materials.

d) No free issue material shall be issued to contractor for site erection, commissioning activity. In very emergent cases, if any material issued to contractor shall be on chargeable basis if available, as per the rates available in Owner’s book of accounts or at the prevailing rates available in the market plus 25% overheads.

e) All construction material shall be neatly stacked in an orderly manner at site.

f) The contractor shall maintain all the drawings carefully and well protected from ravages of termites and other insects.

g) The contractor shall not permit entry to the site of any person without prior written permission of the owner.

h) The contractor shall submit a list of tools, tackles, etc, which he will use to perform the work. The contractor shall submit a list in duplicate of all materials, tools, tackles, etc, brought

inside the plant duly signed by owner's security staff as per rules laid by owner at site. These tools shall not be removed from the site till the completion of the job.

i) The contractor shall submit list of employees deployed at NFL Vijaipur site with full Bio-data.

j) All employees of the contractor shall conform to all rules of conduct, etc. established by owners. Failure to do so will be sufficient cause for removal of such person from the site.

k) The contractor will be responsible for providing all material, tools & tackles and consumables, etc. required for execution of work as per the best Engineering practices.

l) The receipt, offloading, movement and storage of material and tools at site shall be contractor’s responsibility.

m) Electricity: The contractor shall inform the owner within 15 days of placement of LOI his electrical power requirements for storage, site office and erection & commissioning. The same shall be provided at one point by the owner and further distribution shall be in contractor’s scope. The electrical power shall be provided free of cost to the contractor.

n) Messing & Accommodation: The contractor will make his own arrangement for messing and accommodation of contractor’s personnel. However, accommodation may be provided by owner on chargeable basis subject to availability.

o) First Aid: The contractor may have access to the owner’s first aid post if available in case of accident.

10. Supervision of work:

a) Erection and commissioning teams including site engineers shall be deputed by the contractor for erection and commissioning of supplied control system.

b) Entire work is to be completed as per the time schedule already submitted and approved by the owner. The contractor shall conform to the targets set forth in the time schedule.

11. Inspection: The work of the contractor is subject to the inspection by the owner time to time. The suggestion of owner engineers shall be honoured by the contractor for the jobs to be carried out at site as per best engineering practices. Minor changes shall not attract any price implication.

12. Employment of Labour:

a) The contractor will employ only his regular skilled/ semi skilled/ unskilled employees with experience in erection & commissioning of supplied control system. No person below the age of 18 years shall be employed. The contractor shall pay to his employees/workers the minimum wages as per, MP State Government notification issued from time to time.

b) Normal working hours at site shall be 8 hours from Monday to Saturday. However, as per exigency of work erection and commissioning activities shall be continued beyond 8 hours and even on weekly off days to meet the time schedule of completion. All such overstay charges if any, for contractors labour shall be the responsibility of the contractor.

c) All notices and instructions issued by the Owner must be strictly adhered to by the Contractor and his employees.

d) Contractor shall arrange labour license, if required, as per rules from State authorities at his own cost and shall submit a copy to the owner.

e) Contractor will take umbrella insurance cover for all his employees for all purposes of claims under Workman's Compensation Act during stay at Owner site and shall submit a copy of the same to the owner. The expenditure incurred for insurance shall be to the contractors account.

f) In case the Owner becomes liable to pay any dues to the labour of the contractor or to any Government Agency or any other agency under any of the provision of the Minimum wages Act, Workmen compensation Act or any other law due to act of omission of the contractor, the owner shall recover the same from the Contractor’s bills.

g) The contractor shall submit documentary evidence of Employees Provident Fund under Act, 1952 for his employees working at site.

13. Reporting: The contractor shall submit weekly report of following information to the owner:

i. Number of employees working under him

ii. Progress achieved as per schedule of completion

iii. Expected dates of completion of work

iv. Any actual or potential delay in schedule caused and reasons thereof.

14. Site Clearance: Before finally leaving site, Contractor shall handover the storage and office building in clean and tidy condition.

15. Short supply/Insurance claim for damages: On receipt of material at site, Contractor shall promptly check each item for any transit damage or any shortage of material as per the details of consignment. The contractor shall inform to owner in writing and shall take necessary action for arranging the short supply material by him at the earliest at site to avoid any delay in erection and commissioning. However complete supply shall be ensured by the contractor within stipulated time. Any insurance claim lodging and getting reimbursement from insurance agency against short supply / damage material shall be the responsibility of the contractor.

16. Working and Safety Regulations:

a) The contractor shall fulfill all statutory and legal requirements enforced by Central, State Governments and local authorities applying to the work as well as safety requirements for the same.

b) Particular attention is drawn to the following: -

i. The contractor shall strictly follow regulations laid down by owner, Factory Inspector, Government and state authorities in all respects.

ii. Compliance with all electricity regulations.

c) Explosive material/equipment prone to explosion shall not be allowed inside the owner premises. The contractor shall make his own arrangement for fire extinguishers and other safety equipment for his office and storage.

17. Electrical Safety Regulations:

All safety regulations shall be applicable for electrical jobs. Contractor shall request to Owner for Safety Work Permit before starting of the work and owner shall arrange the same for safe execution of job. On completion of working hours the contractor shall surrender the Safety Work Permit to the owner.

18. After erection & commissioning and handing over of the systems to the owner, contractor shall leave the site only after getting the completion certificate from the owner. The owner shall issue certificate on completion of total package in all respects.

*****

National Fertilizers Limited (A Government of India Undertaking)

Vijaipur – 473 111, Dist: Guna (MP), India (An ISO 9001, 14001 & OHSAS 18001 Unit)

CIN No. L74899DL1974GOI007417

Annexure-D

E-Tender ID - 1990

NIT No. NFV/PUR/BIU160645V Dated: 16-11-2017

Online Template for confirmation on Techno-Commercial Points

S.No. Description NFL Requirement as per NIT Vendor’s Comments

1 Item Description Design, Engineering, Supply, Supervision and Erection &Commissioning of Distributed Control System (DCS) & Emergency Shutdown System (ESD) System along with Spares for Ammonia-II and Urea-II Plants in NFL, Vijaipur as per Technical Annexure attached.

2 Quantity Required One No. Complete System.

3 Earnest Money Deposit EMD of Rs. 1,00,000/- (Rupees One Lakh only) or equivalent amount in USD (as per prevailing exchange rate at the time of submission of bid), to be furnished in the manner as explained in Clause No. 15.00 of Terms and Conditions of NIT (Annexure-B). Bidders shall indicate the details of DD/BG here. (Scanned copy of DD/BG to be uploaded).

4 Security Deposit cum Performance Bank Guarantee (SD-cum-PBG)

Successful Tenderer will have to furnish SD-cum-PBG equivalent to 10% of Order Value for the faithful and proper fulfillment of the contract as per Clause No. 16.00 of Terms and Conditions of NIT (Annexure-B). Tenderers shall confirm their acceptance for the same.

5 Final Acceptance & Warranty

The warranty period shall be 12 months from final acceptance of the system as per Clause No. 8.0 of Section-II of Annexure-II. Warranty Certificate shall be submitted along with despatch documents.

6

Offer Validity Offers should be valid for 120 Days from bid opening date. Vendors confirm their acceptance

7 Price Basis for Indian Bidders

Vendors shall indicate the basis of prices quoted by them i.e. Ex-Works/Godown or FOR/FOT (Name of Despatching Station) / FOR – Destination as per Price Bid Format (Annexure-E & G)

8 Price Basis for Overseas Bidders

Overseas bidders shall quote the prices on FCA, International Airport of the country concerned basis as per INCOTERMS 2010® (Please indicate the name of Airport/) as per enclosed Price Bid format (Annexure-F & H). The FCA Price basis shall be inclusive of all costs up to the point of Aircraft. The consignment shall be handed over to our Consolidation-cum-Freight Forwarding Agent located in the country of participating bidder after clearance of all formalities related to export of goods and all charges paid up to Aircraft which shall be to Seller’s account (Name and other details of our Freight Forwarding Agent will be intimated at the time of Order).

9 Indian Agency Commission (For Overseas Bidders)

Percentage of Agency Commission, if any, included in quoted prices and payable to your Indian Agents in Indian Currency must be clearly indicated by the Foreign Bidders. Agency Commission, if applicable will be paid after satisfactory receipt and acceptance of material at our site. Please indicate the Name and Address of your Indian Agent

10 Enhancement of Rates after submission of Quotation not allowed

No enhancement of rates will be allowed once the quotation is submitted/accepted and the order is placed. Withdrawal of the quotation after its acceptance will entail forfeiture of earnest money, if any, and/or risk purchase without prejudice to our rights of legal remedies.

11 GST (For Indian Bidders)

The rate (%) of GST quoted & considered in Total Price to be mentioned by Vendor

12 GST Identification Number (For Indian Bidders)

Tenderers shall invariably mention the GST Identification Number allotted to them

13 HSN Code Tenderers shall invariably mention the HSN Code of the offered item

14 Freight (For Indian Bidders)

If prices tendered are for delivery FOR – Despatching Station, then freight charges should be clearly mentioned in the Price Bid

15 Transit Insurance (For Indian Bidders)

The rates should be exclusive of transit insurance from Despatch Station to our warehouse. The goods shall be covered under NFL’s Open Marine Policy/NFL Open policy

16 Transit Insurance (For Overseas Bidders)

NFL shall be responsible for the arrangement of transit insurance from the Port of Embarkation to NFL, Vijaipur Stores. The goods shall be covered under NFL’s Open Marine Policy. The rates quoted shall be exclusive of transit insurance.

17 Payment Term for Indian Bidders

(a) Supply Portion: “70% of Purchase Order value towards supply portion plus 100% taxes towards supply portion within 30 days after Receipt & Acceptance of Material at our site through RTGS.”. (b) Installation/Erection & Commissioning: 100% payment including taxes towards Installation & Commissioning along with balance payment of supply potion (i.e. 30%) within 30 days after successful installation & commissioning of supplied material at our site through RTGS.

18 Payment Term for Overseas Bidders

(a) Supply Portion: “70% of supply portion through Irrevocable Letter of Credit. LC shall be opened through a reputed Indian Bank in your country. Please confirm your acceptance. Please note that your Banker’s charges including confirmation charges of LC shall have to be borne by you. However, Bank Charges in India shall be borne by NFL. Also in case of an Order, if validity of Letter of Credit is required to be got extended for reasons for which NFL is not responsible, then the Bank Commission for such extensions of LC shall be borne by you. (b) Installation/Erection & Commissioning: 100% payment including taxes towards Installation & Commissioning along with balance payment of supply potion (i.e. 30%) within 30 days after successful installation & commissioning of supplied material at our site through Wire Transfer.

19 Delivery Period (For Indian Bidders)

To be indicated by the Bidder

20 Delivery Period (For Overseas Bidders)

Minimum delivery period on FCA International Airport basis to be indicated by the Bidder

21 Price Firmness Vendors to confirm that the quoted prices will remain firm till execution of the PO except variations in statutory duties/taxes

22 Liquidated Damages for Delay in Supply

It shall be obligatory on the part of suppliers to adhere strictly to the deliveries quoted and accepted by us in our orders. In case of delay in supplies, unless extension of delivery has been granted by us on application by the suppliers, we may at our option either: (i) recover liquidated damages from supplier at a sum equal to ½% per week or part thereof of the value of stores not delivered subject to a maximum of 5% of the value of the order, or (ii) purchase elsewhere on account and at the risk and cost of the suppliers the stores not delivered or (iii) cancel the contract without prejudice to our rights under (i) & (ii) above. (Ref. Clause 25.00 of General Terms and Conditions of Notice Inviting Tender (Annexure-B)

23 Packing Shall be securely packed before dispatch so as to avoid any damage during transit. Please mention Net Weight/Gross Weight/Dimensions and Size of Packages etc. of the item being offered

24 Mode of Despatch (For Indian Bidders)

By road preferably through TCI/ETO

25 Mode of Despatch (For Overseas Bidders)

By Air to IGI Airport, New Delhi or By sea to Mumbai Seaport, India

26 PAN Number (For Indian Bidders)

Vendors to indicate the PAN Number allotted to their firm/company and upload the scan of the PAN Card

27 TIN Number (For Indian Bidders)

Vendors to indicate the TIN Number allotted to their firm/company and upload the scan of letter/Certificate issued by concerned authorities

28 Phytosanitary Certificate

Foreign Bidders may please confirm acceptance of submission of Phytosanitary Certificate as per details given in tender documents

29 HS Code Overseas Bidders shall mention the HS Classification Code 30 MSMED Registration

(For Indian Bidders) See Clause No. 14.00 of General Terms and Conditions of Notice Inviting Tender (Annexure-B) for details. In case no information is given by you, it will be presumed that you are not covered by the MSMED Act and consequently not eligible to the benefits admissible under the Act.

31 Clear Understanding When a tenderer submits his tender in response to this tender document, he will be deemed to have understood fully about requirements terms and conditions. No claim from tenderer shall be entertained whatsoever on the plea that the tenderer did not have a clear idea on any particular point and/or a clause of the tender.

32.1 Relationship It shall be certified by the Tenderers that none of NFL employee is related to Owners/ Directors of their Company/Firm (In case any relative is working in NFL, furnish details separately)

32.2 * It shall be certified by the Tenderers that none of NFL’s ex-employee is employed in their Company/Firm (In case any ex-employee of NFL is employed, furnish details separately)

32.3 * It shall be certified by the Tenderer that none of blood relation of the Owners/Directors is participating in this tender in the name of other firm

33 Debarment of Tenderers

If a tenderer resorts to any frivolous, malicious or baseless complaints/allegations with an intent to hamper or delay the tendering process or resorts to canvassing/rigging/influencing the tendering process, NFL reserves the right to debar such tenderer from participation in the present/future tenders up to a period of two (2) years.

34 Blacklisting/Delisting of Bidders previously

It shall be certified by the Tenderers that they have not been delisted/blacklisted by any Institutional Agency/Govt. Department/Public Sector Undertakings for participation in the Tenders and no other Firm/Sister Concern/ Associate belongs to the same group is participating/submitting the tender against this E-Tender

35 Award of Contract Award of contract will be made at the sole and absolute discretion of National Fertilizers Limited, which shall not be disputed. Purchase Order issued on the basis of this tender will be called ‘CONTRACT’. The terms and conditions as embodies in the Purchase Order shall be final and shall supersede any other terms and conditions that might have been indicated in the Tender submitted by the Tenderers.

36 Secrecy Any information delivered or otherwise communicated by NFL to supplier in connection with the contract shall be regarded as secret and confidential and shall not without the written consent of NFL be published or disclosed to any third party or made use of by the supplier except for the purpose of implementing the contract.

37 Compliance to statutory requirements/laws (for Indian Bidders)

The seller shall comply with all Central/State Laws as well as the rules, regulations, by-laws as may be in force, from time to time. Any failure on their count on the part of the seller and the consequence thereof shall be solely on account of the seller. Liability, if any, under this head shall be solely borne and paid for by the seller.

38 Laws governing Purchase Order

The purchase order shall be governed by the Laws of Union of India for the time being in force.

39 Subletting of Contract Not allowed

The successful tenderer shall not sublet or assign the contract or any part of it without obtaining the written permission of NFL in advance. In the event of the successful tenderer subletting or assigning the contract or any part thereof without such permission, NFL shall be entitled to cancel the contract and to purchase the goods elsewhere and successful tenderer shall be liable to the National Fertilizers Ltd for any loss or damage which NFL may sustain in consequence or arising out of such purchases. Even in case subletting is permitted, NFL shall not recognize any contractual obligation with the person or party to whom subletting is permitted and shall look to the successful tenderer for satisfactory and due and proper fulfillment of the contract.

40 Disputes In all cases of disputes, the decision of National Fertilizers Limited shall be final. Failing this, the matter will be referred to the Arbitration in accordance with the Indian Arbitration Act and amendments thereof (Applicable for Indian Bidders) and in accordance with Rules of ICC (for Overseas Bidders).

41 Force Majeure Shall be as per Clause No. 45.00 of Terms and Conditions of Notice Inviting Tender

42 Arbitration Arbitration Procedures shall be as per Clause 47.00 of Terms and Conditions of Notice Inviting Tender

43 Jurisdiction All actions at law or suits arising out of or in connection with this contract or the subject matter thereof will be instituted in the Courts located at Guna in the Guna district of Madhya Pradesh State

44 Uploading of Unpriced Format

Bidders will upload a copy of Unpriced Format of Price Bid (with Unit Price Blank and details of other columns) with Techno-Commercial Bid

45 Acceptance of NIT Terms and Conditions and uploading of complete Set of Tender Enquiry

Vendors will confirm their acceptance to the Terms and Conditions of the NIT without any deviation and upload a complete set of Tender Enquiry duly signed and stamped on each and every page as token of acceptance of terms and conditions

46 Uploading of Other documents

Vendors may upload any other document (if required) and indicate the same

47 Any Other Comment / Information /Remarks

No Deviation to the Terms & Conditions of NIT is allowed. Offers with any condition/deviation are liable to be rejected at Sole option of NFL. However Vendor may offer comment, if any.

48 Signing of Integrity Pact

Confirm that you have signed and submitted the Integrity Pact as per enclosed Annexure-K, failing which you will stand disqualified from the tendering process and your bid would be rejected.

49 Erection & Commissioning

The erection & commissioning of the systems shall be in bidder’s scope.

50 Annual Maintenance Contract (AMC) for Ammonia-II & Urea-II

Comprehensive AMC (without resident engineer) for five years after expiry of the warranty period with minimum five visits (including emergency & periodic visits) of the service engineer per year. The AMC shall include supply, replacement / repairs of all the system modules / cards etc. including all IT products (HMI consoles, printers, switches etc.). Any Software modifications and Software patches released by vendor shall be included in vendor’s scope. Vendors to indicate yearly breakup of comprehensive AMC.

51 Bidder’s comments on Annexure-II

You will be required to give your comments/confirmation on all the points mentioned in Technical Specifications Annexure-II of our NIT, in your offer.

Upload Digitally Signed Tender Document We hereby declare that we have read, understood and accepted all terms & conditions of NIT without any deviation. As a token of same, we are uploading herewith digitally signed Tender Document Upload duly digitally signed Tender Document; else your Bid will be rejected

Annexure-E E-Tender ID – 1990

NIT No. NFV/PUR/BIU160645-V Dated: 16-11-2017

PRICE BID FORMAT FOR INDIAN BIDDERS (Supply Portion)

Sl. No.

Item Description

Unit

of M

easu

rem

ent

Qua

ntity

HSN Code

Unit Price (in Rs.)

Total Basic Cost (Rs.)

P&F Charges (if applicable) (in % of 7)

Freight Charges (from Despatching Station to NFL, Vijaipur (in % on 7)

Other Charges (if any)

IGST @ __ (in % of 7+8+9+10)

CGST @__ (in % of 7+8+9+10)

SGST @___ (in of 7+8+9+10)

Total – FOR – Delivered Price (Rs) (7+8+9+10+ 11+ 12+13)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 01 Supply of Distributed Control

System (DCS) for Ammonia-II plant.

NO

1

02 Supply of Emergency Shutdown System (ESD) for Ammonia-II plant.

NO

1

03 Supply of Distributed Control System (DCS) for Urea-II plant.

NO

1

04 Supply of Emergency Shutdown System (ESD) for Urea-II plant.

NO

1

05 Spares required for 2 years operation of system after final acceptance. As per Clause No. 10.2 of Section-II.

LOT

1

06 12P x 0.75 mm2 MR 70000 07 1P X 1.5 mm2 Signal Cable MR 8000 08 12 triad x 1.5mm2 MR 15000

09 T/C Ext. Cable 1P x 20swg K TYPE

MR 4000

10 T/C Ext. Cable 12P x 20swg K TYPE

MR 32000

11 3C x 1.5mm2 Power Cable MR 5000

12 3C x 2.5mm2 Power Cable MR 2000 13 Junction Boxes for 24 pair

entry NO 65

14 Junction Boxes for 12 pair entry

NO 20

15 Perforated Cable Tray 400mm MR 4000 16 Perforated Cable Tray 300mm MR 1000 17 Perforated Cable Tray 200 mm MR 2000 18 Perforated Cable Tray 100 mm MR 2000 19 Perforated Cable Tray 50 mm MR 2000

Note:

1. Goods and Service Tax, Freight etc. shall be paid extra at actuals against submission of documentary evidence subject to maximum of those quoted above. 2. Price basis should be clearly indicated in the offer and break-up of the rates should be given accordingly.

I/We have read all the terms and conditions of the NIT and the Annexure(s) thereto and agree to accept and abide by the same in toto. The above quotation has been prepared after taking into account all the terms and conditions of the NIT. Dated: Signature of Tenderer or their Authorized Representative ______ Name & Address of Tenderer______________________________ Place: Phone Number _________________________________________ Fax No. _______________________________________________ Email ID ______________________________________________

Annexure-F E-Tender ID - 1990

NIT No. NFV/PUR/BIU160645-V Dated: 16-11-2017

PRICE BID FORMAT FOR OVERSEAS BIDDERS (Supply Portion)

Sl. No.

Item Description

Unit

of

Mea

sure

men

t

Qua

ntity

Curr

ency

(Te

xt)

Basic Unit Price in quoted currency

Total Basic Price

Packing and Forwarding Charges (if applicable) (Absolute Value)

FCA/FOB Charges, if any (including Inland Freight from your Works to Port of Embarkation) in accordance with INCOTERMS 2010

Other Charges (if any)

Total Price on FOB/FCA International Airport basis

1 Supply of Distributed Control System (DCS) for Ammonia-II plant.

NO

1

2 Supply of Emergency Shutdown System (ESD) for Ammonia-II plant.

NO

1

3 Supply of Distributed Control System (DCS) for Urea-II plant.

NO

1

4 Supply of Emergency Shutdown System (ESD) for Urea-II plant.

NO

1

5 Spares required for 2 years operation of system after final acceptance. As per Clause No. 10.2 of Section-II.

LOT

1

6 12P x 0.75 mm2 MR 70000 7 1P X 1.5 mm2 Signal Cable MR 8000

8 12 triad x 1.5mm2 MR 15000

9 T/C Ext. Cable 1P x 20swg K TYPE

MR 4000

10 T/C Ext. Cable 12P x 20swg K TYPE

MR 32000

11 3C x 1.5mm2 Power Cable MR 5000

12 3C x 2.5mm2 Power Cable MR 2000 13 Junction Boxes for 24 pair

entry NO 65

14 Junction Boxes for 12 pair entry

NO 20

15 Perforated Cable Tray 400mm

MR 4000

16 Perforated Cable Tray 300mm

MR 1000

17 Perforated Cable Tray 200 mm

MR 2000

18 Perforated Cable Tray 100 mm

MR 2000

19 Perforated Cable Tray 50 mm

MR 2000

Note: 1. NFL shall be responsible for arrangement of transit insurance from Sea-port/Airport of embarkation to our stores. The rates shall be exclusive of transit insurance. 2. The price basis F.C.A. (International Air Port) Incoterm 2010 shall be inclusive of all charges up to air craft in seller’s account. In case of placement of order the consignment shall be handed over after all necessary export clearance of the same and all charges paid upto aircraft will be in seller’s account. I/We have read all the terms and conditions of the NIT and the Annexure(s) thereto and agree to accept and abide by the same in toto. The above quotation has been prepared after taking into account all the terms and conditions of the NIT. Dated: Signature of Tenderer or their Authorized Representative ______ Name & Address of Tenderer______________________________ Place: Phone Number _________________________________________ Fax No. _______________________________________________ Email ID ______________________________________________

Annexure-G

E-Tender ID - 1990

NIT No. NFV/PUR/BIU160645-V Dated: 16-11-2017

PRICE BID FORMAT FOR INDIAN BIDDERS (Services)

Sl. No.

Item Description

Uni

t of

M

easu

rem

ent

Q

uant

ity

SAC Code

Basic Price per Unit (in Rs.)

Total Basic Price (in Rs.)

GST Rate Applicable if any (in % of 7)

8

Total (Rs) (7+8)

1 2 3 4 5 6 7 CGST SGST IGST 9 01 Erection & Commissioning charges for Erection &

Commissioning of DCS & ESD System of Ammonia-II plant, at our site.

Lot

1

02 Erection & Commissioning charges for Erection & Commissioning of DCS & ESD System of Urea-II plant, at our site.

Lot

1

03 Design and Engineering Charges, if any. Lot 1 04 Factory Acceptance Test (FAT)/Site Acceptance Test (SAT)

charges, if any. Lot 1

05 Supplied System Operational training to Owner operation Engineers at owner’s site.

Lot 1

06 Other Charges, if any. 07 Comprehensive Annual Maintenance Contract (AMC) for five

years after expiry of warranty period. Year -

7.1 1st Year - 1 7.2 2nd Year - 1

7.3 3rd Year - 1 7.4 4th Year - 1 7.5 5th Year - 1

I/We have read all the terms and conditions of the NIT and the Annexure(s) thereto and agree to accept and abide by the same in toto. The above quotation has been prepared after taking into account all the terms and conditions of the NIT. Dated: Signature of Tenderer or their Authorized Representative ______ Name & Address of Tenderer______________________________ Place: Phone Number _____________Fax No. __________________Email ID _______________________________

Annexure-H

E-Tender ID - 1990

NIT No. NFV/PUR/BIU160645-V Dated: 16-11-2017

PRICE BID FORMAT FOR OVERSEAS BIDDERS (Services)

Sl. No.

Item Description

Unit

of

Mea

sure

men

t Q

uant

ity

SAC Code

CURRENCY (Please mention the name of Currency)

Basic Price per Unit (Amount)

Total Basic Price (Amount)

GST Rate Applicable, if any (in % of 7) 8

Total Price (Amount) (7+8)

1 2 3 4 5 6 7 CGST SGST IGST 9 01 Erection & Commissioning charges for Erection &

Commissioning of DCS & ESD System of Ammonia-II plant, at our site.

Lot

1

02 Erection & Commissioning charges for Erection & Commissioning of DCS & ESD System of Urea-II plant, at our site.

Lot

1

03 Design and Engineering Charges, if any. Lot 1 04 Factory Acceptance Test (FAT)/Site Acceptance Test

(SAT) charges, if any. Lot 1

05 Supplied System Operational training to Owner operation Engineers at owner’s site.

Lot 1

06 Other Charges, if any. 07 Comprehensive Annual Maintenance Contract (AMC) for

five years after expiry of warranty period. Year -

7.1 1st Year - 1 7.2 2nd Year - 1 7.3 3rd Year - 1 7.4 4th Year - 1 7.5 5th Year - 1 I/We have read all the terms and conditions of the NIT and the Annexure(s) thereto and agree to accept and abide by the same in toto. The above quotation has been prepared after taking into account all the terms and conditions of the NIT. Dated: Signature of Tenderer or their Authorized Representative ______ Name & Address of Tenderer______________________________ Place: Phone Number _____________Fax No. __________________Email ID _______________________________

National Fertilizers Limited (A Government of India Undertaking)

Vijaipur – 473 111, Dist: Guna (MP), India (An ISO 9001, 14001 & OHSAS 18001 Unit)

CIN No. L74899DL1974GOI007417

Annexure-J E-Tender ID - 1990

NIT No. NFV/PUR/ NFV/PUR/BIU160645-V Dated: 16-11-2017

LOADING CRITERIA The bidders must accept the terms and conditions stipulated in the NIT, failing which the bid

is likely to be rejected at the sole discretion of NFL. However, NFL may at its sole discretion, accept bids having deviation to NIT terms and Conditions by adopting the following loading Criteria, wherever applicable. i. Offers received without EMD:-

EMD amount (absolute value), as required in the NIT shall be loaded on landed cost of total offer value.

ii. a. Non-submission of Security Deposit

The loading shall be adopted for shortfall in the bank guarantee agreed by the bidder. For example, NIT calls for bank guarantee for 10%, then loading shall be done as under:-

Bank guarantee for Security Deposit

Loading Criteria

Less than 10%. (10%-Quoted Percentage) of basic price @ Prime Lending Rate {SBI PLR} + 1% on shortfall in Bank Guarantee value agreed by the Bidder for delivery period with additional one month period

b. Non-submission of Performance Bank Guarantee

The loading shall be adopted for shortfall in the bank guarantee agreed by the bidder. For example, NIT calls for bank guarantee for 10%, then loading shall be done as under:-

PBG Quoted Loading Criteria Less than 10%. 10% - Quoted Percentage of CIF/Ex-Works Prices

c. Loading on account of discrepancy in the Warranty/Guarantee Period

Wherever Bidders quote reduced Warranty/Guarantee Period, following loading criteria shall be adopted:

[10% of CIF/Ex-Works Price x (No. of Months as per NIT – No. of Months quoted]

No. of Months as per NIT NOTE:

If the sum of (b) and (c) above is more than 10% of CIF/ Ex-Works Prices, then the loading shall be limited to 10%.

iii. Payment Terms

NFL will not make any advance/progressive payments. NFL’s standard payment term is “100% within 30 days of receipt and acceptance of material at site.” The deviation in differential payment terms with respect to NIT Clause shall be loaded as under for interest @Prime Lending Rate (SBI MCLR) + 1% for the period: 1 Against Payment for dispatch of

material/ through Bank

1a Foreign Bidders Three Months

:2: Loading Criteria (Contd..)

1b Indian Bidders Depending on Delivery Conditions viz.

Ex-Works – One and a Half Month FOR Destination – One Month

2 100% within 30 days of the receipt and acceptance of material at NFL Stores

Nil

iv. Packing & Forwarding

Wherever Bidders have not indicated P&F Charges, but mentioned that ‘P&F Charges extra at actual’, their Prices shall be loaded @2% of Ex-Works Prices or the maximum amount as quoted by another bidder whichever is higher. NFL’s maximum liability to pay P&F Charges shall be limited to the amount loaded for evaluation purpose.

v. Liquidated damages due to delay in supplies:-

If deviation is noted in the quoted liquidated damages, the proportionate loading for shortfall shall be adopted. For example, NIT calls for 0.5% per week subject to maximum of 5% of the total order value, loading criteria shall be as under:-

Quoted Liquidated Damages Loading criteria a) 0.5% per week subject to a ceiling of 05% of total order

value (Ex-Works/CIF Value) No loading.

b) 0.5% per week subject to a ceiling of 2.5% of total order value.

2.5% loading.

c) Liquidated Damages accepted on undelivered value instead of total order value.

2.5% loading.

d) Non-acceptance of liquidated damages. 5% loading.

vi. Loading of Freight [Inland Transportation Charges] in percentage terms as under:

a. In case weights and distances are known for all suppliers: i. FOR SMALLS : Inland transportation charges shall be calculated @ Rs.5.00 per KM/MT. ii) FOR TRUCK LOADS : @ Rs. 4.00 per KM/MT

b) While undertaking item-wise evaluation where item wise weights are not available,

the following procedure shall be adopted for calculating transportation charges up to NFL site: i. Transportation from the vendors situated- 1% of CIF/Ex-works Prices

within a distance of 400 KMS. ii. Transportation from the vendors situated- 2% of CIF/Ex-works Prices

within a distance of 401 to 800 KMS. iii. Transportation from the vendors situated- 3% of CIF/Ex-works Prices

at a distance of more than 800 KMS. All Indian parties are required to quote ex-works Price and freight charges up to NFL Site, compulsorily. If all the parties have given freight charges up to site the same shall be considered for evaluation. However, if only some parties have given freight charges, NFL reserves the right to load for such parties who have not quoted freight charges with freight charges as above. NFL’s decision on this regard shall be final and binding on these Bidders.

viii. Loading of Ocean/Air Freight (Foreign Bidders): Offers of Foreign Bidders shall be loaded for Ocean/Air Freight as under:-

a. Ocean Freight - @3% of FOB Value b. Air Freight - @5% of FCA Value

National Fertilizers Limited, Vijaipur

Annexure-K

NIT No. NFV/PUR/ NFV/PUR/BIU160645-V Dated: 16-11-2017

INTEGRITY PACT (To be executed on plain paper and submitted along with Technical Bid/Tender.

To be signed by the Bidder and NFL.)

National Fertilizers Limited (NFL) hereinafter referred to as “The Principal” AND

____________________________hereinafter referred to as “The Bidder/Contractor”

PREAMBLE The Principal intends to award, under laid down organizational procedures, contract/s for ___________________________. The Principal values full compliance with all relevant laws of the land, rules, regulations, economic use of and of fairness/ transparency in its relations with its Bidder(s) and/or Contractor(s). In order to achieve these goals, the Principal will appoint an Independent External Monitor (IEM), who will monitor the tender process and the execution of the contract for compliance with the principles mentioned above. Action 1 – Commitments of the Principal. 1. The Principal commits itself to take all measures necessary to prevent corruption and to

observe the following principles :-

a) No employee of the Principal, personally or through family members, will in connection with the tender for, or the execution of a contract, demand, take a promise for or accept, for self or third person, any material or immaterial benefit which the personal is not legally entitled.

b) The Principal will during the tender process treat all Bidder(s) with equity and reason.

The Principal will in particular, before and during the tender process, provide to all Bidder(s) the same information and will not provide to any Bidder(s) confidential/additional information through which the Bidder(s) could obtain an advantage in relation to the process or the contract execution.

c) The Principal will exclude from the process all known prejudiced persons.

2. If the Principal obtains information on the conduct of any of its employees which is a criminal

offence under the IPC/PC Act, or if there be a substantive suspicion in this regard, the Principal will inform the Chief Vigilance Officer and in addition can initiate disciplinary actions.

Section 2 – Commitments of the Bidder(s)/Contractor(s) 1. The Bidder(s)/Contractor(s) commit himself to take all measures necessary to prevent

corruption. He commits himself to observe the following principles during his participation in the tender process and during the contract execution.

a. The Bidder(s)/contractor(s) will not, directly or through any other persons or firm,

offer promise or give to any of the Principal’s employees involved in the tender process or the execution of the contract or to any third person any material or other benefit which he/she is not legally entitled to, in order to obtain in exchange any advantage or during the execution of the contract.

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b. The Bidder(s)/Contractor(s) will not enter with other Bidders into any undisclosed agreement or understanding, whether formal or informal. This applies in particular to prices, specifications, certifications, subsidiary contracts, submission or non-submission of bids or any other actions to restrict competitiveness or to introduce cartelization in the bidding process.

c. The Bidder(s)/Contractor(s) will not commit any offence under the relevant IPC/PC

Act; further the Bidder(s)/Contractors will not use improperly, for purposes of competition or personal gain, or pass on to others, any information or documents provided by the Principal as part of the business relationship, regarding plans, technical proposals and business details, including information contained or transmitted electronically.

d. The Bidder(s)/Contractor(s) of foreign origin shall disclose the name and address of

the Agents/representatives in India, if any. Similarly, the bidder(s)/contractor(s) of Indian Nationality shall furnish the name and address of the foreign principals, if any. All the payments made to the India agent/representative have to be in Indian Rupees only.

e. The Bidder(s)/Contractor(s) will, when presenting his bid, disclose any and all

payments he has made, is committed to or intends to make to agents, brokers or any other intermediaries in connection with the award of the contract.

2. The Bidder(s)/Contractor(s) will not instigate third persons to commit offences outlined above

or be an accessory to such offences. Section 3: Disqualification from tender process and exclusion from future contract If the Bidder(s)/Contractor(s), before award or during execution has committed a transgression through a violation of Section 2 above or in any other form such as to put his reliability or credibility in question, the Principal is entitled to disqualify the Bidder(s)/Contractor(s) from the tender process or to terminate the contract, if already signed, for such reasons. Section 4 : Compensation for Damages 1. If the Principal has disqualified the Bidder(s) from the tender process prior to the award

according to Section 3, the Principal is entitled to demand and recover the damages equivalent to Earnest Money Deposit/Bid Security.

2. If the Principal has terminated the contract according to Section3, or if the Principal is entitled

to terminate the contract according to Section3, The Principal shall be entitled to demand and recover from the Contractor liquidated damages of the Contract value or the amount equivalent to Performance Bank Guarantee.

Section 5 : Previous Transgression 1. The Bidder declares that no previous transgressions occurred in the last three years with any

other company in any country conforming to the TII’s anti-corruption approach or with any other public sector enterprise in India that could justify his exclusion from the tender process.

2. If the bidder makes incorrect statement on this subject, he can be disqualified from the

tender process and appropriate action can be taken including termination of the contract, if already awarded, for such reason.

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Section 6 : Equal treatment of all Bidders/Contractors/Subcontractors. 1. The Principal will enter into agreements with the identical conditions as this one with all

bidders, contractors and sub-contractors. 2. The Principal will disqualify from the tender process all bidders who do not sign this Pact or

violate its provisions. Section 7: Criminal charges against violation Bidder(s)/Contractor(s)/Sub-contractors(s). If the Principal obtains knowledge of conduct of a Bidder(s)/ Contractor(s) which constitutes corruption, or if the Principal has substantive suspicion in this regard, the Principal will inform the same to the Chief Vigilance Officer. Section 8 : Independent External Monitor/Monitors 1. The Principal appoints competent and credible Independent External Monitor for this Pact.

The task of the Monitor is to review independently and objectively, whether and to what extent the parties comply with the obligations under this agreement.

2. The Monitor is not subject to instructions by the representatives of the parties and performs

his functions neutrally and independently. It will be obligatory for him to treat the information and documents of bidders /contractors as confidential. He reports to the Chairman & Managing Director, NFL.

3. The Bidder(s)/Contractor(s) accepts that the Monitor has the right to access without

restriction to all project documentation of the Principal including that provided by the Contractor. The Contractor will also grant the Monitor, upon his request and demonstration of a valid interest, unrestricted and unconditional access to his project documentation. The same is applicable to Subcontractors. The Monitor is under contractual obligation to treat the information and documents of the Bidder(s)/Contractor(s)/Subcontractor(s) with confidentiality.

4. The Principal will provide to the Monitor sufficient information about all meetings among the

parties related to the Project provided such meetings could have an impact on the contractual relations between the Principal and the Contractor. The parties offer to the Monitor the option to participate in such meetings.

5. As soon as the Monitor notices, or believes to notice, a violation of this agreement, he will so

inform the Management of the Principal and request the Management to discontinue or take corrective action, or to take other relevant action. The monitor can in this regard submit non-binding recommendations. Beyond this, the Monitor has no right to demand from the parties that they act in a specific manner, refrain from action or tolerate action.

6. The Monitor will submit a written report to the Chairman & Managing Director,, NFL within 8

to 10 weeks from the date of reference or intimation to him by the Principal and, should be occasion arise, submit proposals for correcting problematic situations.

7. Monitor shall be entitled to compensation on the same terms as being extended to/provided

to Independent Directors on BFL Board.

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8. If the Monitor has reported to the Chairman & Managing Director, National Fertilizers Limited, a substantiated suspicion of an offence under relevant IPC/PC Act, and the Chairman & Managing Director, NFL has not, within the reasonable time taken visible action to proceed against such offence or reported it to the Chief Vigilance Officer, the Monitor may also transmit this information directly to the Central Vigilance Commissioner.

9. The word “Monitor” word include both singular and plural. Section 9 : Pact Duration This pact begins when both parties have legally signed it. It expires for the Contractor 12 months after the last payment under the contract, and for all other Bidder 6 months after the contract has been awarded. If any claim is made/lodged during this time, the same shall be binding and continue to be valid despite the lapse of this pact as specified above, unless it is discharged/determined by Chairman & Managing Director of NFL. Section 10 : Other Provisions • This agreement is subject to Indian Law. Place of performance and jurisdiction is the

Registered Office of the Principal i.e. New Delhi. • Changes and supplements as well as termination notices need to be made in writing. Side

agreements have not been made. • If the contractor is a partnership or a consortium, this agreement must be signed by all

partners or consortium members. • Should one or several provisions of this agreement turn out to be invalid, the remainder of

this agreement remains valid. In this case, the parties will strive to come to an agreement to their original intentions.

(For & on behalf of the Principal) (For & on behalf of Bidder/Contractor) (Office Seal) (Office Seal) Place_________________ Date_________________ Witness 1 : Witness 1 : (Name & Address) (Name & Address) _____________________________ _____________________________ ______________________________ _____________________________ ______________________________ _____________________________ ______________________________ _____________________________ Witness 2 : Witness 2 : (Name & Address) (Name & Address) _____________________________ _____________________________ ______________________________ _____________________________ ______________________________ _____________________________ ______________________________ _____________________________

Annexure - L

BID SECURITY FORM

Draft of Bank Guarantee for Bid Security Deposit (i.e. Earnest Money Deposit) (To be prepared on Stamp paper issued in the name of Bank)

In consideration of National Fertilizers Limited (NFL), having its Registered Office at SCOPE

Complex, Core-III, 7, Institutional Area, Lodhi Road, New Delhi-110 003 (hereinafter called as ‘NFL’ which expression shall unless repugnant to the subject or context includes its successors and assigns) having agreed to exempt ____________________________ (hereinafter called the, ‘the said tenderer(s)’ which expression shall unless repugnant to the subject or context includes his successors and assigns) from the demand under the terms and conditions of tender No___________________ for ___________________ hereinafter called “the said tenderer’ of such Bid Security Deposit for the due fulfillment by the said tenderer(s) of the terms and conditions contained in the said tender _______________ for ____________ on production of Bank Guarantee for Rs. ___________ (Rupees ___________________ only). 1. We ___________________, the bank, hereinafter referred to as ‘the bank’ do hereby

undertake to pay to NFL an amount not exceeding Rs.____________ (Rupees___________________ only) against any loss or damage caused to or suffered by ‘NFL’ reason of any breach by the said tenderer(s) of any of the terms and conditions contained in the said tender (the decision of the company as to any such breach having been committed and loss suffered shall be binding on us).

2. We _________________, the bank do hereby undertake to pay the amounts due and payable

under this guarantee without any demur merely or a demand from ‘NFL' stating that the amount claimed is due by way of loss or damage caused to or would cause to or suffered by ‘NFL’ by reason of any breach by the said tenderer(s) of any of the terms or conditions contained in the said tender or by reason of the said tenderer’s failure to keep the tender open. Any such demand made on the bank shall be conclusive as regards the amount due and payable by the bank under this guarantee. However, our liability under this guarantee shall be restricted to an amount not exceeding Rs. ________________ (Rs_____________________only).

3. We ____________________, the bank, further agree that the guarantee herein contained

shall remain in full force and effect during the period that would be taken for the finalisation of the said tender and that it shall continue to be enforceable till the said tender is finally decided and order placed on the successful tenderer and/ or till all the dues of NFL under/or by virtue of the said tender have been fully paid and its claims satisfied or discharged or till a duly authorised officer of NFL certified that the terms and conditions of the said tender have been fully and properly carried out by the said tenderer(s) and accordingly discharges the guarantee. Unless a demand or claim under this guarantee is made on us in writing on or before the _____________ to include three months claim over and above the period mentioned in the paragraph for the validity of the bank guarantee in the tender we shall be discharged from all liability under this guarantee thereafter.

4. We ______________________________, the bank, lastly undertake not to revoke this

guarantee during its currency except with the previous consent of ‘NFL’ in writing. Dated ________________ day of ______________________2017 Corporate seal for Bank

Annexure-M

SECURITY DEPOSIT-CUM-PERFORMANCE BANK GUARANTEE FORMAT (To be prepared on Stamp paper issued in the name of Bank)

This BANK GUARANTEE No. _____________________________ made this day of ____________________________ between_______________________________ ______________________ a bank incorporated and having its registered office at ______________________________ (hereinafter called BANK) which expression shall unless repugnant to the context or contrary to the meaning thereof includeits successors and assigns on the one part and NATIONAL FERTILIZERS LIMITED, a Company registered in India under Companies Act, 1956 and having its registered office at Core - III, Scope Complex, 7,Institutional Area, Lodhi Road, New Delhi - 110 003, India to the context or contrary to the meaning thereof include its successors and assigns on the other part. WHEREAS in pursuance to the agreement dated ____________________(hereinafter called CONTRACT) entered into between National Fertilizers Limited (hereinafter called OWNER and_______________________a Company incorporated in_______________________ (hereinafter called CONTRACTOR) which expression shall unless repugnant to the context or contrary to the meaning thereof include its successors and assigns, for supply of_________________________as envisaged in the Contract, Contractor has to submit a Security Deposit-cum-Performance Bank Guarantee for Rs._________. CONTRACTOR accordingly agrees to furnish the Security cum performance Bank Guarantee as hereinafter contained towards fulfillment of all of its obligations under the contract. NOW THIS DEED WITNESSES AS FOLLOWS: 1. In pursuance of the Contract, the Bank hereby guarantees as a direct responsibility to OWNER that the BANK is holding the amount of Rs.___________________at Owner's disposal and hereby promises and shall be bound to pay to OWNER, forthwith at Owner's written notice stating that the contractor has failed to fulfill its obligations under the contract for reasons for which contractor is liable and without any protest or demur and without recourse to contractor and without asking for any reasons as to whether the amount if lawfully asked for by Owner or not, the entire amount or the portion thereof as mentioned by Owner in the notice. The decision of the Owner as to whether the terms and conditions of this Security Deposit cum Performance Bank Guarantee have been observed or not shall be final and binding on the BANK. In any case, however the Bank's responsibility under this Security Deposit-cum-Performance Bank Guarantee is limited to Rs._____________. 2. This Security Deposit-cum-Performance Bank Guarantee shall be valid for an initial period of___________Months from the date of this Bank Guarantee No.___________________ dated ______________ given by the Bank to Owner become effective. Upon issuance of Commissioning / Erection / Completion certificate according to terms of contract on expiry of _________________ months after the issuance of the above mentioned certificate of commissioning / erection / completion certificate, the Security Deposit-cum-Performance Bank Guarantee shall become null and void. 3. This Security Deposit-cum-Performance Bank Guarantee shall be in addition to and shall not affect or be affected by any other security now or hereafter held by Owner on account of money hereby intended to secure and Owner at its discretion and without any further consent from the Bank, and without affecting its rights against the Bank, may compound with, give time or other indulgence to or make any other arrangement with Contractor and nothing done or omitted to be done by Owner in pursuance of any authority or permission contained in this guarantee, shall effect discharge of the liability of the Bank. 4. UNLESS PREVIOUSLY CANCELLED BY THE OWNER, this Security Deposit-cum- Performance Bank Guarantee will remain in force initially up to __________________months from the effective date of Bank Guarantee No. ________________ dated ____________ given by the Bank to the Owner and subject to provisions of paragraph 2above will stand automatically cancelled on the expiry of the said period. Unless demand or claim under this Bank Guarantee is made on Bank in writing within three

months from the date of expiry of this Bank Guarantee, all the rights of Owner against the Bank shall be forfeited and Bank shall be relieved and discharged from all the liabilities hereunder. 5. Any notice by way of request, demand or otherwise hereunder may be sent by post to the Bank, addressed as aforesaid, and if sent by post, it shall be deemed to have been given at the time when it would be delivered in due course of post, and in proving such notice, when given by post, it shall be sufficient to prove that the envelope containing the notice was posted and a certificate, signed by an officer of the owners, to the effect that the envelope was so posted, shall be conclusive. 6. The Security Deposit-cum-Performance Bank Guarantee is to be returned to the Bank after its expiry in terms of Paragraph 4 above. 7. The Bank declares that it has the power to issue this guarantee and the undersigned have full power to do so. Dated _______________ this __________________ day of ___________

(Indicate the name of the Bank with stamp)