A. DCS-PLC ADD-ON AT DHDS and PH1A UNIT

Transcription

1 A. DCS-PLC ADD-ON AT DHDS and PH1A UNIT 1.0 INTRODUCTION: BPCL Mumbai Refinery, Mahul intends to implement the new process I/O s related to a new Dry Gas Seal System to the existing C300_2 controller in existing Experion DCS of DHDS Unit. This document specifies the requirements for the design, selection, testing, shipping, installation, integration with existing system, commissioning, site acceptance test and documentation for the add-on jobs on the existing system within the control room at DHDS. 2.0 GENERAL REQUIREMENT: 2.1 The additional job mainly includes supply of hardware and configuration of all Dry Gas Seal Process I/O s and related logic to be added to the existing C300_2 controller in existing Experion DCS. 2.2 The logic and I/O s related to Interlocks of Dry Gas Seal shall be added to FSC-1 controller. The existing HMI stations of DHDS shall be utilized for adding the Dry Gas Seal Process graphics, trends, etc. 2.3 Vendor to consider the following I/O counts for the additional I/O s configuration and Analog Input Modules, Digital Input & Output Modules, FTA and Barriers / Relays shall be Supplied by the vendor. Sr No DCS IO Type IO Count (Nos) Cards Barrier/Relay 1 Analog Input (AI) 15 New card & FTA 32 Barriers 2 Analog Output (AO) 1 Existing Card 16 Barriers 3 Digital Input (DI) 7 Existing Card 16 Barriers 16 Relays 4 Digital Output (DO) 2 Existing Card 32 Relays Sr No PLC IO Type IO Count (Nos) Cards Barrier/Relay 1 Analog Input (AI) 11 New card & FTA 16 Barriers 2 Digital Output (DO) 2 New card & FTA 8 Relays 2.4 Configuration of, newly supplied I/O cards in the existing DCS & PLC system, modification of existing interlock / logic to incorporate the new logic / interlocks. Creation of new graphic pages in existing system for operator interface / viewing purpose. 2.5 New I/O cards if required shall be installed in the existing system cabinet only. 2.6 All the I/O cards shall be Redundant / non-redundant in-line with existing system configuration. 2.7 Provision of system / application software (like SCADA points) license for the additional I/O counts is not required. Existing license shall be utilized. Page 1 of 6

2 2.8 Existing Bulk Power Supply shall be utilized for the new IO signals of Dry Gas Seal system and existing Power distribution philosophy shall be followed. 2.9 All the spares shall be installed and fully wired up to field terminals All the wiring shall have cross reference ferrules. 3.0 SCOPE OF WORK: 3.1 INCLUSION: Design, selection, testing, shipping, installation, integration with existing system, commissioning, site acceptance test and documentation for the add-on jobs within the control room on the existing system at DHDS Unit Supply of all necessary accessories and necessary hardwares, softwares, FTA cables for the add-on jobs as per the tender requirement Transportation of all the supplied materials from BPCL ware-house/ issue point to DHDS Control Room Installation of new I/O cards if required in the existing system cabinet Laying of all the necessary FTA cables from existing system cabinet to existing marshalling cabinet. Cable protection to be included Configuration of new additional hardware, tags, graphics and integration the same with existing system Existing logic / interlock modification to integrate the new logic as per new safety requirement Loop checking assistance for the add-on jobs Commissioning of the system Incorporation of the new add-on jobs in the existing documents and preparation & submission of new as-built document Site acceptance test of the system. 3.2 EXCLUSION: Supply & laying of any type of field cables Supply & laying of power supply cable from existing PDB / system cabinet to Existing marshalling cabinet if required Any kind of Civil/ Mechanical work/physical work Scope. Page 2 of 6

3 B. MODBUS RS485 COMMUNICATION OF SM PLC AT P/H 1A 4.0 INTRODUCTION: BPCL Mumbai Refinery, Mahul intends to implement the modbus communication of all existing I/O s of SM PLC system at PH1A to establish two way communication with Emerson DCS and also provide an additional Experion station for extension of Operator console in new Control Room This document specifies the requirements for the design, selection, testing, shipping, installation, integration with Emerson Delta V DCS system, commissioning, site acceptance test and documentation for the same within the control room at Ph-1a. 5.0 SCOPE OF WORK: The scope shall include installing Serial communication card in existing SM PLC panel at PH-1a for establishing a serial communication with the Emerson Delta V DCS system. An experion station shall be supplied and installed in new control room. 5.1 INCLUSION: Installation of new communication Module in the existing Cabinet located inside Ph-1a Installation of new experion station in new control room Configuration of new hardware in the Emerson Delta V DCS system. Upgradation of license for the new station Implementation of New Logics, control loops and programs related to COM addition as per system requirement Necessary mapping for establishing serial connectivity at SM PLC end Supply of all necessary accessories and necessary hardwares, softwares for communication job as per the tender requirement Supply of all necessary fibre accessories like patch cord, LIU, converters, etc Connection of the fibre cables Transportation of all the supplied materials from BPCL ware-house/ issue point to DHDS Control Room Loop checking assistance for the add-on jobs Commissioning of the system Incorporation of the new tags, loops in the existing documents and preparation for submission of new as-built document as per the tender requirement Site acceptance test of the system. Page 3 of 6

4 5.2 EXCLUSION: Supply & laying of any type of field cables and fibre cables Supply & laying of power supply cable from existing PDB / system cabinet to Existing marshalling cabinet if required Any kind of Civil/ Mechanical work/physical work Scope Supply of Metallic Operator console. 6.0 GENERAL TERMS & CONDITION: BID DOCUMENT: Vendor to attach following as minimum with the bid, Signed & Stamped copy of tender specification Final Bill of Material indicating make & model no inline with SOR format attached as Annexure-II Back-up literature and catalogues for the offered components models with model decoding details Vendor shall provide unit price against each type equipments / components as per SOR. The price shall include all the associated accessories, inspection, testing, applicable statutory certificate requirements Bpcl intends to reduce repeated technical clarifications. Hence, vendor s offer shall be clear and unambiguous In general no deviation is acceptable. In case of any unavoidable deviation, vendor shall list out the deviations along with technical reasons If at any stage, till the completion of order, the offered instruments and accessories are found unsuitable for the specified application or in operating conditions, vendor shall replace the same with suitable make/model no. to meet the specifications without any time & cost implications The technical catalogues shall be in English language. Any offer without technical catalogue & model de-codification sheet shall be considered as incomplete and is liable for rejection. INSPECTION AND TESTING Vendor shall be fully responsible for completing all the in-house testing and test reports & same shall be ready before inspection by BPCL Site acceptance test shall be carried out after successfully installation and commissioning of the instruments. Vendor shall be fully responsible to carry out the SAT with user s fullest satisfaction. Page 4 of 6

5 DELIVERY PERIOD: Material shall be delivered at Mumbai Refinery warehouse along with packing slip and relevant documents The delivery period for the material supply shall be 6 weeks from the date of purchase order placement All necessary precautions shall be taken for adequate protection of the cards, FTA cables, Marshalling cabinets including accessories, during shipment and outdoor storage at their destination All the consignment shall have the clear packing slip with identification number & material description The delivery period for the installation & commissioning shall be 15 days after writing intimation from BPCL Engineer In-Charge for each location. 6.4 PAYMENT TERMS: Two separate purchase order shall be placed after technical and commercial evaluation by BPCL For Material Supply: - 100% within 30days from the date of supply and acceptance of Material at BPCL warehouse against 10 % performance bank guarantee of the PO value as per BPCL format For Installation & Commissioning: - 100% after completion of successful installation & commissioning against 10 % performance bank guarantee of the PO value as per BPCL format. PERFORMANCE TEST AND GUARANTEE: Vendor shall guarantee the equipment supplied for satisfactory performance for a period of 12 months from the date of commissioning or 18 months from the date of supply whichever is earlier. Any deficiency observed during this period shall be set right by the vendor without any further price implication. All the new supplied hardware shall be considered under the existing AMC. COMMISSIONING & CONSUMBALE SPARES: All spare items required for commissioning shall be supplied by vendor as a part of offer. Page 5 of 6

6 DOCUMENTATION: The following minimum documents in hard copy (3 sets) as well as soft copy in CD (2 nos) shall be provided along with the materials as as-shipped document: a. Internal inspection & test report. b. Warranty Certificate. c. Engineering document. d. All the component part/model no. with model de-codification sheet. e. Loop wiring diagram. 6.8 ANNEXURES: Following annexures are attached along with the tender specification: a. Annexure I: SOR Format. 7.0 APPROVED VENDOR LIST: Vendor shall supply material as per below mentioned approved vendor list. Sr Item Description Vendor list No 1 Terminal Board Phoenix (Germany), Wago 2 Relay Omron (Japan Made) or equivalent 3 Barrier P&F or MTL Page 6 of 6