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Table of Contents
Document Number Rev. Document Title Page
Number
A133-000-YE-MR- C Distributed Control System 4
1500
A133-000-16-51-SP- A Preamble 11
1501
A133-000-16-51-SP- A List of Documents (Section-II) 14
1502
44NC-4600- 0 Standard Specification for Distributed Control System 16
0000/J.SS/0102/A4
44NC-4600- 0 Standard Specification for Programmable Logic Controllers 55
0000/J.SS/0103/A4
6-78-0001 0 Specification for Quality Mgt. System Requirements from Bidders 74
6-78-0003 0 Specification for Documentation Requirement from Suppliers 83
A133-00-6-82-0001 1 Spec For HSE 95
REV 1
7-51-0332 2 Safety measures for electrical installations during construction 196
A133-000-16-51-SP- B Specific Project Requirement 198
1503
A133-000-16-51-ED- B Logistic Support Formats (Section-III, Annexure-I) 202
01
A133-000-16-51-ED- B Responsibility Chart (Section-III, Annexure-II) 206
02
A133-000-16-51-ED- B Power Consumption & UPS Requirements (Section-III, Annexure- 213
03 III)
A133-000-16-51-ED- A Ventilation & Air-conditioning Requirements (Section-III, Annexure- 218
04 IV)
A133-000-16-51-ED- A Air Quality Requirements (Section-III, Annexure-V) 225
05
A133-000-16-51-ED- A Proven Track Record Format (Section-III, Annexure-VI) 227
06
A133-000-16-51-SP- B Table of Contents 232
1504
A133-000-16-51-SP- A Project Information 234
1507
A133-000-16-51-SIV- B Special Instructions to Vendor 238
1500
A133-000-16-51-OD- A Additional Requirements of DCS / PLC System (Section-IV, 263
01 Annexure-A)
A133-000-16-51-OD- B Specification for F&G System (Section-IV, Annexure-B) 285
02
A133-000-16-51-OD- A Tagging Philosophy for Junction Boxes, Panels & Cables (Section- 297
03 IV, Annexure-C)
A133-000-16-51-OD- A Cables & Junction Box Requirements (Section-IV, Annexure-D) 304
04
44NC-4600- 0 PMC Job Specifications (Instrumentation) 307
0000/J.02/0101
44NC-4600- 0 Instrument Cable Duct Fabrication Drawing 339
0000/JSD/0004
A133-000-16-51- A Scope of Works 359
SOW-1500
A133-000-16-51-OD- C I/O Summary and Sizing Consideration (Section-V, Annexure-VII) 364
05
A133-000-16-51-MD- 0 System Configuration Diagram (Part-A) 373
008
A133-000-16-51-SK- 0 110V AC UPS Power Distribution Diagram 376
3101
A133-000-16-51-OD- A 110V AC UPS Non DCS Power Supply Distribution List (Section- 377
06 V, Annexure-VIII)

Page 1 of 564
Table of Contents
Document Number Rev. Document Title Page
Number
A133-000-16-51-SK- 0 230V AC Power Supply Distribution Diagram 380
3102
A133-000-16-51-OD- A 24V DC Non UPS Power Supply Distribution List (Section-V, 381
07 Annexure-IX)
A133-000-16-51-SK- A Control Room Layout 383
1101
A133-000-16-51-SK- 0 Control Room Ground & Basement Floor Plan 384
0009
A133-000-16-51-SK- 0 Control Room-Terrace Floor Plan, Section 385
0010
A133-000-16-51-SK- 0 Control Room Elevations, Sections 386
0011
44NC-4600-0000/L- B Overall Plot Plan 387
01/0001/A1
A133-000-16-51- 0 VENDOR DATA REQUIREMENT 388
VDR-1500
A133-000-16-51-OD- A Fieldbus Design and Implementation Criteria (Section-V, 392
08 Annexure-X)
A133-000-16-51-OD- B1 Vendor List (Section-V, Annexure-XI) 407
09
A133-000-16-51-OD- B Mandatory Spare Parts List (Section-V, Annexure-XII) 412
10
A133-000-16-51-SP- A Vendor's Proposal Outline 415
1506
A133-000-16-50-SP- A JOB SPECIFICATION 421
1500
A133-000-16-50-DS- A DATA SHEET 430
1500
44NC4600ESS025 0 STATIC UNINTERRUPTIBLE POWER SUPPLY UNIT (UPS) 433
44NC4600ESS026 0 ELECTRICAL INSTALLATION 453
44NC4600ESS008 0 MEDIUM AND HIGH VOLTAGE HEAVY DUTY CABLES 486
7-51-0335 2 Typ. installation details of electrical panels on false flooring 494
A133-000-16-50-VL- 4 VENDOR LIST 495
1500
A133-000-16-50-VR- A VENDOR DATA REQUIREMENTS 508
1500
44NC-4600-0000- 0 DRAWING 511
E.01-0007-A4
44NC4600ITP025 1 ITP FOR UPS SYSTEM 512
A133-000-16-51- B Scope of Works (Part-C) 514
SOW-1501
A133-000-16-51-ED- A Responsibility Definition (Part-C, Annexure-A) 519
07
A133-000-16-51-ED- A Distance Table (Part-C, Annexure-B) 523
08
A133-000-16-51-ED- A Proven Track Record 525
09
A133-000-16-51-ED- A Logistics Suppor Format (Part-C, Annexure-D) 528
10
A133-000-16-51-ED- A Compliane Statement (Part-C, Annexure-E) 530
11
A133-000-51-16-DS- B CCTV Datasheet 532
5001
A133-000-16-51-SIV- B Special Instructions to Vendor 534
1501
44NC-4600- 0 Standard Specification for Instrumentation Works 540
0000/J.SS/0101
A133-000-16-51- A VENDOR DATA REQUIREMENT 562
VDR-1501

Page 2 of 564
Table of Contents
Document Number Rev. Document Title Page
Number
A133-000-16-51-MD- 2 System Configuration Diagram (CCTV) 564
08D

Page 3 of 564
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned and on the borrower's express agreement that they will not be reproduced,
MATERIAL REQUISITION (TOP SHEET)
ITEM DESCRIPTION: Distributed Control System
GROUP ITEM CODE 16EA DESTINATION : As per Commercial Document
ITEM CATEGORY II DELIVERY PERIOD :

DOCUMENT NUMBER
(Always quote the Document Number given below as reference)

A133 000 YE MR 1500 C 13/03/2014 16 51


copied, exhibited or used, except in limited way permitted by a written consent given by the lender to the borrower for the indended use. EIL-1641-515 Rev.1 A4-210x297

JOB NO UNIT/ MAIN DOC. SR.NO. REV DIVN. DEPT.


COST CODE DATE
ORIGINATOR

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

REV DATE BY CHK APPD DETAILS


A 17/01/2014 RK ZH AR Issued for Bids

B 03/02/2014 RK ZH AR Issued for Bids

C 13/03/2014 RK ZH AR Revised & Issued for Bids

This is a system generated approved document and does not require signature.

Project : RESID UPGRADATION PROJE


ENGINEERS INDIA LIMITED
Client : M/S CPCL Sheet 1 Of 5
NEW DELHI
Page 4 of 564
S.NO TAG NO . DESCRIPTION QUANTITY
/ ITEM CODE
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned and on the borrower's express agreement that they will not be reproduced,

1 Design ,engineering,manufacture,procurement of materials and


bought out items/components, assembly at shop, system engineering,
internal testing, integration, inspection, Factory testing and
acceptance at manufacturer's works, packing, delivery of the
following consumables, commissioning spares, special tools and
tackles, consumables, erection materials and documentation as per the
enclosed specifications, instructions to vendors, job specification, data
sheets etc and other codes and standards attached or referred in the
MR.
copied, exhibited or used, except in limited way permitted by a written consent given by the lender to the borrower for the indended use. EIL-1641-515 Rev.1 A4-210x297

1.01 000-DCSSYS-00 Complete DCS System including CCTV and UPS systems 1 Lot
1.01.01 [000-DCS-01] Complete DCS System 1 Lot
1.01.01.01 [01-CDAS-100] Controller and Data Acquisition Subsystems 1 Lot
1.01.01.02 [02-OIS-100] Operator Interface Subsystems 1 Lot
1.01.01.03 [03-ENGS-100] Engineering Interface Subsystems 1 Lot
1.01.01.04 [04-PLC-100] Programmable Logic Controllers Subsystems 1 Lot
1.01.01.05 [05-FDI-100] Dedicated Foreign Device Interface Subsystems 1 Lot
1.01.01.06 [06-CAB-100] Cabinets, Panels and Racks 1 Lot
1.01.01.07 [07-HWC-100] Hardwired and other Consoles 1 Lot
1.01.01.08 [08-HWI-100] Hardwired Instruments,Barriers,Relays,Power Supplies,Fieldbus 1 Lot
accessories,Interconnectin cabling etc
1.01.01.09 [09-IAMS-100] Instrument Asset Management System 1 Lot
1.01.01.10 [10-OPC-100] Open System Connectivity including OPC server 1 Lot
1.01.01.11 [11-AIMS-100] Alarm Information Management System 1 Lot
1.01.01.12 [12-GTS-100] Giant Screens along with connectivity to DCS and CCTV 1 Lot
1.01.01.13 [13-MCT-100] MCT frames and Blocks 1 Lot
1.01.01.14 [14-FJB-100] Fieldbus Junction Boxes complete with all Fieldbus accessories 1 Lot
1.01.01.15 [15-CIVIL-100] Base Frames, trays, ducts 1 Lot
1.01.01.16 [16-DON-100] Documentation Node with CD retrieval and storage system 1 Lot
1.01.01.17 [17-OTR-100] All system cables including all interconnecting cables & FO cables with 1 Lot
necessary connectors
1.01.01.18 [18-TRKIT-100] Training Kit for DCS & PLC 1 Lot
1.01.01.19 [19-UPS-100] Complete UPS system as per Part B 1 Lot
1.01.01.20 [20-CCTV-100] Complete CCTV system as per Part C 1 Lot
2 Unloading, handling at site, transportation to site store and from store
to work site, storage at site, assembly at site, installation, testing, pre-
commissioning, loop checking, system commissioning, site acceptance
test, handing over to client and associated site works including
residual civil / structural works for the following as per the enclosed
standard specifications, instructions to vendor, job specification, data
sheets etc. of the MR.
2.01 {2}000-DCSSYS-00 For Item 1.01 1 Lot
3 Transportation from Vendor's shop to site for the following as per
enclosed standard specifications, special instructions to vendors,job
specification,data sheet etc. of MR.
3.01 {3}000-DCSSYS-00 For Item 1.01 1 Lot
4 Supply of Mandatory Spares for Item 1.01.
5 Supply of two years operation and Maintenance Spares,as per

Project : RESID UPGRADATION PROJE REQUISITION No. REV


ENGINEERS INDIA LIMITED
A133-000-YE-MR-1500 C
NEW DELHI Client : M/S CPCL
Page 5 of 564 Sheet 2 Of 5
S.NO TAG NO . DESCRIPTION QUANTITY
/ ITEM CODE
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned and on the borrower's express agreement that they will not be reproduced,

specification and special instructions to vendor.


6 Unit Rates for addition/deletion purpose.
6.001 Unit Rates of each DCS & its constituents/PLC/CCTV/UPS/sub systems 1 Lot
hardware and software items, as per enclosed special instruction to vendor
/ MR.
7 Training for Owner Personnel as per MR:
copied, exhibited or used, except in limited way permitted by a written consent given by the lender to the borrower for the indended use. EIL-1641-515 Rev.1 A4-210x297

7A At Manufacturer's Work
7B At Site
8 Five Years Post Warranty Annual Maintenance Contract as per MR.

Vendors shall quote prices against these items in their price schedule
Vendor to note that the numbers given in square '[]' and curly '{}' brackets are not for their use and
meant for store purpose only.Items shall be tagged as per equipment Tag No. only.

Project : RESID UPGRADATION PROJE REQUISITION No. REV


ENGINEERS INDIA LIMITED
A133-000-YE-MR-1500 C
NEW DELHI Client : M/S CPCL
Page 6 of 564 Sheet 3 Of 5
This document, drawing, and the design/ details given in this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrowers express agreement that they will not be
LIST OF ATTACHMENTS
REV
S. NO. DOCUMENT TITLE DOCUMENT NO. SHEETS
DATE
PART-A (DISTRIBUTED CONTROL SYSTEM)
reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.EIL-1641-507. A4-210 x 297.

SECTION-I A
1 A133-000-16-51-SP-1501 3
(Preamble) 17-01-2014
SECTION-II
2 - - -
(Standard Specifications)
a. A
List of Documents A133-000-16-51-SP-1502 2
17-01-2014
b. Standard Specification for Distributed Control 44NC-4600- 0
39
System 0000/J.SS/0102/A4 12-03-2010
c. Standard Specification for Programmable 44NC-4600- 0
19
Logic Controllers 0000/J.SS/0103/A4 12-03-2010
d. Specification for Quality Management System 0
6-78-0001 9
Requirements from Bidders 04-06-2009
e. Specification for Documentation 0
6-78-0003 12
Requirements from Suppliers 04-06-2009
f. Specification for Health, Safety & 1
Environment (HSE) Management at DCU, A133-00-6-82-0001 101
30-12-13
CPCL, Chennai
g. Safety Measures for Electrical Installation 2
7-51-0332 2
during construction 02-03-2013
SECTION-III B
3 A133-000-16-51-SP-1503 4
(Specific Project Requirement) 11-03-2014
a. A133-000-16-51-ED-01 B
Logistic Support Formats 4
(Annexure-I) 11-03-2014
b. A133-000-16-51-ED-02 B
Responsibility Chart 7
(Annexure-II) 11-03-2014
c. A133-000-16-51-ED-03 B
Power Consumption & UPS Requirement 5
(Annexure-III) 11-03-2014
d. A133-000-16-51-ED-04 A
Ventilation & Air-conditioning Requirements 7
(Annexure-IV) 17-01-2014
e. A133-000-16-51-ED-05 A
Air Quality Requirements 2
(Annexure-V) 17-01-2014
f. A133-000-16-51-ED-06 A
Proven Track Record Format 5
(Annexure-VI) 17-01-2014
SECTION-IV -
4 - -
(PROJECT SPECIFICATION)
a. B
Table of Content A133-000-16-51-SP-1504 2
11-03-2014
b. A
Project Information A133-000-16-51-SP-1507 4
17-01-2014
c. B
Special Instructions to Vendor A133-000-16-51-SIV-1500 25
11-03-2014
A133-000-16-51-OD-01 A
d. Additional requirements of DCS/PLC system 22
(Annexure-A) 17-01-2014
A133-000-16-51-OD-02 B
e. Specification for F&G system 12
(Annexure-B) 11-03-2014
Tagging Philosophy for Junction Boxes, A133-000-16-51-OD-03 A
f. 7
Panels & Cables (Annexure-C) 17-01-2014
A133-000-16-51-OD-04 A
g. Cables & Junction Box Requirements 3
(Annexure-D) 17-01-2014

PROJECT : RESID UPGRADATION


SPECIFICATION NO. REV
ENGINEER INDIA LIMITED
NEW DELHI
PROJECT, LSTK-01 A133-000-YE-MR-1500 C
CLIENT : CPCL, CHENNAILTD

Page 7 of 564
This document, drawing, and the design/ details given in this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrowers express agreement that they will not be
LIST OF ATTACHMENTS

REV
S. NO. DOCUMENT TITLE DOCUMENT NO. SHEETS
DATE
h. 44NC-4600- 0
PMC job specifications (Instrumentation) 32
0000/J.02/0101/A4 19-07-2010
reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.EIL-1641-507. A4-210 x 297.

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

NEW DELHI
PROJECT, LSTK-01 A133-000-YE-MR-1500 C
CLIENT : CPCL, CHENNAILTD

Page 8 of 564
This document, drawing, and the design/ details given in this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrowers express agreement that they will not be
LIST OF ATTACHMENTS

REV
S. NO. DOCUMENT TITLE DOCUMENT NO. SHEETS
DATE
d. Standard Specification for Medium & High 0 8
44NC-4600: ESS008
Voltage Heavy Duty cables 03-05-2010
reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.EIL-1641-507. A4-210 x 297.

e. Typical Installation details of Electrical panels 2


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

PART-C (CCTV SYSTEM)


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

PROJECT : RESID UPGRADATION


SPECIFICATION NO. REV
ENGINEER INDIA LIMITED
NEW DELHI
PROJECT, LSTK-01 A133-000-YE-MR-1500 C
CLIENT : CPCL, CHENNAILTD

Page 9 of 564
Engineers India Limited Vendor Drawing/ Document Submission Schedule
Client/ Project:M/S CPCL/ RESID Vendor's Name : Contact Person (Name/ Tel/ Fax/ email) : Status Date:
UPGRADATION PROJECT

Item Description:Distributed PR No.: Review Status Code:


Control System 1. No Comments
Date of LOI:
2. Proceed with manufacture/ fabrication as per commented document.
PO No.: Revised document required.
3. Document does not conform to basic requirements as marked.

Page 10 of 564
Date of PO: Resubmit for Review. R: Retained for Reference V: Void
EIL Originating Department :Instrumentation Contact Person(EIL):

Anticipated (Ant) Date of submission by vendor


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

SECTION-I
(PREAMBLE)

A 17.01.2014 Issued with MR PR AB AR


Prepared Checked Approved
Rev. No Date Purpose
by by by

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved


Page 11 of 564
Part A - Section: I
PREAMBLE A133-000-16-51-SP-1501 Rev. A
RESID UPGRADATION PROJECT
CPCL,CHENNAI Page 2 of 3

1.0 General:
1.1 Chennai Petroleum Corporation Limited (CPCL), formerly known as Madras Refineries Limited
(MRL) was formed as a joint venture in 1965 between the Government of India (GOI), AMOCO and
national Iranian Oil Company (NIOC). In 1985, AMOCO disinvested in favour of GOI. As a part of
restructuring steps taken by the Government of India, Indian Oil Corporation Limited (IOCL) acquired
equity from GOI in 2000-01. In view CPCL becomes subsidiary of IOCL in 2001, presently the equity
of CPCL is held amongst Indian Oil Corporation, Naftiran Intertrade Company and
Public/FI/FII/NRIs/Others.
1.2 CPCL intends to execute Coker Block consisting of Delayed Coker and LPG CFC Treating Unit on
Lump Sum Turn Key (LSTK) Basis. CPCL has appointed Engineers India Ltd (EIL) to do
Engineering, Procurement, Construction and Commissioning (LSTK route), for Coker Block.
1.3 The process unit shall be shall be monitored and controlled using Distributed Control System (DCS)/
Programmable Logic Controller (PLC), which shall be located in Main Control Room (MCR).
1.4 This Material Requisition (MR) defines the functional requirements of Distributed Control System,
Programmable Logic Controller (PLC) and UPS system to be supplied for Resid Upgration project
located at Manali, in the state of Tamil Nadu, India.
1.5 This MR consists of the following parts and sections:-
PART A: - Distributed Control System ( DCS)
a. Section-I (Preamble)
b. Section-II (Standard Specifications)
c. Section-III (Specific Project Requirement)
d. Section-IV (Project Specification)
e. Section-V (Specific Requirement for DCS/PLC)
f. Section-VI (Vendors Proposal Outline)

PART B: - UPS

PART C: - CCTV System

1.6 Bidder shall prepare their technical proposal as per Section-VI (Vendors Proposal Outline) and the
item summary of this MR. Bidder shall categorically state whether their proposal meets all the
technical specifications listed in the standard and project specification enclosed with this MR.
1.7 Bidder to note that one lump-sum cost must be submitted for all the control system together including
UPS and CCTV system
1.8 Bidder shall sign and stamp each and every sheet of the following documents indicating deviations
wherever applicable and filling the necessary information wherever asked for:-
a. Project Specification
Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved
Page 12 of 564
Part A - Section: I
PREAMBLE A133-000-16-51-SP-1501 Rev. A
RESID UPGRADATION PROJECT
CPCL,CHENNAI Page 3 of 3

b. Standard Specification
c. Special Instruction to Vendor
d. Specific Project Requirements
1.9 The proposal shall be evaluated, as received. Bidders are required to quote strictly as per the
requirements of this MR. Purchaser reserve the right to reject any or all alternatives, if proposed by the
Bidder, without assigning any reason thereof.
1.10 Bidder to note that they should desist from making comment or observations or explanation on any of
the clauses in the specifications. Only the deviations from the specifications should be listed in the
deviation chapter of the proposal (refer clause 1.11 of this section)
1.11 Generally, deviations will not be accepted and the Owner/ EIL reserve the right to reject any proposal
without seeking any further clarifications from the Bidder.
Deviations with proper technical reasons shall only be listed under SectionVI of the proposal.
Deviations mentioned elsewhere in the proposal shall not be considered. Bidder shall not contractually
refer to any of the comments or observations except deviations those listed in Section-VI in all or any
future correspondence.
Any comment or explanation in the deviation section of any point or requirement without highlighting
deviation shall be construed as non-compliance to the specification leading to the rejection of their
offer without assigning any reason and referring the same to the Bidder.
1.12 Bidder shall provide written guarantee for the availability of back-up engineering, maintenance
support and spare parts for a period of ten (10) years as per the format enclosed.

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved


Page 13 of 564
STANDARD SPECIFICATIONS Part A - Section: II
DISTRIBUTED CONTROL SYSTEM A133-000-16-51-SP-1502 Rev. A
RESID UPGRATION PROJECT
CPCL, CHENNAI Page 1 of 2

SECTION-II
(LIST OF STANDARD SPECIFICATIONS)

A 17-01-2014 Issued with MR RK NZ AR


Rev. Prepared Checked Approved
Date Purpose
No by by by

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved


Page 14 of 564
STANDARD SPECIFICATIONS Part A - Section: II
DISTRIBUTED CONTROL SYSTEM A133-000-16-51-SP-1502 Rev. A
RESID UPGRATION PROJECT
CPCL, CHENNAI Page 2 of 2

LIST OF STANDARD SPECIFICATIONS

S. No. Document title Document no. No. of sheets

1. Standard Specification for Distributed Control 44NC-4600- 39


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

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved


Page 15 of 564
Page 1 of 39

SPECIFICATION NO: 44NC-4600-0000/J.SS/0102/A4

TITLE: STANDARD SPECIFICATION FOR DISTRIBUTED


CONTROL SYSTEM

PROJECT REFERENCE:

- Project No: 44NC-4600

- Project Location: Manali, Chennai

- Project Title: RESID UPGRADATION PROJECT

- Client: Chennai Petroleum Corporation Limited

- Project Manager Authorization: B.B. DARAK Date:

- Client Authorization: Date:

APPROVALS
Rev. Issue Pages Revision Description By Check Approve
No. Date

0 12- Mar-10 39 Issued For Feed ADM MSD BSP


 Entire Specification SPECIFICATION ISSUED FOR:
Issued this Revision  In-house Review  Purchase
 Revised Pages Only  Client Approval  Construction
Issued this Revision  Enquiry  Engineering

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CONTENTS

1.0 PURPOSE

2.0 GENERAL

2.1 SCOPE
2.2 BIDS
2.3 DEFINITIONS
2.4 SYSTEM AVAILABILITY

3.0 DESIGN AND CONSTRUCTION

3.1 GENERAL
3.2 SPARES PHILOSOPHY
3.3 SYSTEM COMPONENT / INSTRUMENT ENCLOSURES
3.4 POWER SUPPLIES AND DISTRIBUTION
3.5 TRANSIENT, STATIC AND EMI / RFI PROTECTION
3.6 SYSTEM SIZING / LOADING CRITERIA
3.7 UPS SIZING CRITERIA
3.8 HEAT LOAD CALCULATIONS
3.9 SYSTEM FURNITURE

4.0 SYSTEM CONFIGURATION & FUNCTIONAL SPECIFICATIONS

4.1 SYSTEM COMPONENTS


4.2 FUNCTIONAL REQUIREMENTS
4.3 PROCESSOR SYSTEM
4.4 I/O SYSTEM
4.5 OPERATOR INTERFACE SYSTEM
4.6 ENGINEERS INTERFACE SYSTEM
4.7 COMMUNICATION SYSTEM
4.8 PLC INTERFACE WITH DCS
4.9 THIRD PARTY INTERFACE
4.10 OPEN SYSTEM CONNECTIVITY
4.11 INTERFACE WITH SMART TRANSMITTERS
4.12 DOCUMENTATION NODE (DN)
4.13 HARDWIRED INSTRUMENTATION
4.14 ALARM AND ANNUNCIATOR SYSTEM
4.15 CABINETS
4.16 CABLING
4.17 EARTHING

5.0 TESTING AND ACCEPTANCE

5.1 GENERAL
5.2 FACTORY ACCEPTANCE TEST (FAT)

6.0 INSTALLATION, TESTING AND COMMISSIONING

7.0 PROJECT MANAGEMENT

8.0 TRAINING
9.0 DOCUMENTATION

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10.0 WARRANTY

11.0 MAINTENANCE CONTRACT

12.0 SHIPPING

13.0 REJECTION

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1.0 PURPOSE

The purpose of this specification is to define the minimum requirements of a Distributed


Control System (DCS) designed for reliable, effective and optimum control and
monitoring of a process plant.

2.0 GENERAL

2.1 SCOPE

2.1.1 This specification defines the minimum requirements of system design including
hardware & software, configuration, manufacture, engineering, programming, inspection
and testing, documentation, installation, commissioning and shipping of Distributed
control system (DCS). This shall include as a minimum

- Manufacture, procure, supply, testing, installation, handling and commissioning of all


equipment and accessories.
- Building of all operator interface, screen displays, database and reports.
- System Hardware & Software configuration.
- FAT of all hardware / software and system integration testing under simulated
conditions.
- Supply, install, test and commission marshalling racks, system cabinets and consoles
/ printers. Including cables, terminals, IS barriers, power supplies and cubicle internal
mountings
- Supply of all system as well as control room furniture as per ergonomic and Owner
requirements.
- Proving of DCS system functionality as per requirements
- Training of Owners personnel at factory and at site on functional, operational and
maintenance aspects of the system.
- Supply of complete technical and as built documentation in electronic form as well as
hardcopy.
- Supply of all software on CDs along with required software licenses.

2.1.2 The detailed scope of work, specific job requirements, exclusions, deviations, additions
etc shall be indicated in the material requisition and job specification.

2.1.3 Where any conflict exists between this specification and other job specification, the
purchaser shall be consulted. Vendor shall not deviate from this specification without
prior approval from the purchaser.

2.2 BIDS

2.2.1 Vendors quotation shall enumerate and include the detailed specifications of each
subsystem and each module of distributed control system, detailed system configuration,
hardware and software capabilities, programming aids, display facilities and other
relevant information.

2.2.2 Vendor shall furnish a detailed list of deviations / confirmations clause-wise described in
this specification. Vendor must provide enough supportive reasons for the deviations
listed.
2.2.3 Vendors quotation shall include catalogues, drawings, technical specification sheets,
operating and maintenance manuals, performance evaluation certificates etc. All
documents shall be in English language only.

2.2.4 Vendor shall also supply the following items.

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Mandatory spares as indicated elsewhere in this specification.


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

2.3 DEFINITIONS

2.3.1 Distributed Control System


The class of instrumentation which in addition to executing the stated control functions
also permits transmission of control, measurement and operating information to and from
a single or a plurality of user specified locations connected via a communication system.

2.3.2 Accessible
A system feature that is viewable by and interaction with the operator and allows the
operator to perform user permissible control action e.g. set point change, auto-manual
transfers or on-off actions.

2.3.3 Assignable

A system feature that permits an operator to direct a signal from one device to another
without the need for change in wiring, either by means of switches or via key board
command to the system.

2.3.4 Configurable
A system feature that permits selection through entry of key board commands of basis
structure and characteristics of a device of system, such as control algorithm, display
format or I/O termination.

2.3.5 I/O
Input / Output with respect to process / operator.

2.3.6 System Size

System size shall be defined as maximum number of process inputs or tags those can
be connected to the system and viewable from any one of the TFT of an operating
console in all hierarchical displays without changing the configuration or without operator
interaction considering
All inputs as close loops
All inputs as open loops

2.3.7 Operator Console


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

2.3.8 Engineering console


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

2.3.9 Switch Over time


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

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2.3.10 Loop integrity


A system shall be said to have loop integrity if the failure of one component in the
system / sub-system does not affect more than one loop.

2.3.11 Interchangeability
System / sub-systems shall be said to have full interchangeability if the functions and
information available on one system / sub-system shall also be available on the other in
totality.

2.3.12 sers memory


Free memory space available in addition to the memory required for system configuration
and other system related functions which a user can utilize to execute his own programs
for plant calculations, process optimization or MIS (like free formatting of certain logs).
The programs shall normally be written in high level languages.

2.3.13 Redundancy
A system component shall be termed as redundant if it automatically takes over the
operation in the failure of the main component without causing any interruption in the
system and upsetting the process. The repaired or replaced device shall be brought in
line only through operator action and can be replaced on line without affecting the
operation of the system.

2.3.14 Scan time

2.3.14.1 Close-Loops
Scan time for a close-loop shall be defined as the cycle time taken by controller to read
and process input, perform control calculations, and update control output for all the
loops configured within the controllers.

2.3.14.2 Open-Loops
Scan time for an open loop shall be defined as the cycle time required to read and
process input and perform computation of all the open loops.

2.3.15 Data base


Data base shall be defined as the information stored, temporarily or permanently in the
system to meet all its functional requirements.

2.3.16 Bus-degradation
Bus-degradation shall be defined as a change in the system performance from the
specified one while loading the communication sub-system from 10 through 100
percent.

2.3.17 Event
An event shall be defined as any action taken by the operator via operator keyboard and
switches on hardwired console like change of set point, change of control mode,
start/stop of motor, open/close of shut down valves, alarm acknowledge etc.

2.3.18 Real time trend


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

2.3.19 Call-up time


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

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2.3.20 Display update rate


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

2.3.21 Central Level


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

2.3.22 Local Level


All those sub-systems which directly interface with field devices shall be referred to as
local level.

2.4 SYSTEM AVAILABILITY

Vendor shall not quote any product / item which has become obsolete or going to be
obsolete in next 10 years time.
All updates / upgrades, hardware upgrades, software patches to fix bugs shall be
provided free of cost for above period. Vendor shall confirm that service support of the
supplied product / items shall be offered for at least 20 years from date of
commissioning. Bidder shall guarantee the availability of replacement spares for this
period. This guarantee shall also include all third party equipment supplied by vendor
alongwith his system. DCS vendor to submit written undertaking for the same to the
owner.

3.0 DESIGN AND CONSTRUCTION

3.1 GENERAL

3.1.1 This DCS system shall be of latest evolutionary type with Open System Architecture
having networking capability with other systems distributed geographically in the various
units of a plant over a plant wide information network such as Ethernet / DEC net or other
industrially recognized open network.

3.1.2 This system shall be designed fault avoidant as a minimum by selecting high grade
components of proven quality and proper design of system electronics. Redundancy shall
be provide, as a minimum, as per this specification to improve the system availability and
reliability. Due considerations shall be given to the environmental conditions particularly
for field mounted sub-system, if specified in job specifications during system design.

3.1.3 All components of the system shall be able to operate satisfactorily from 150C to 300C
and 0% to 95% non-condensing humidity.

3.1.4 The system shall be of modular construction and expandable in future by adding
modules. The type of modules shall be kept to the minimum possible in order to have
interchangeability and low inventory.

3.1.5 The system software shall be governed by the operating system running in a real time
mode and shall be able to meet all specified functional requirements as a minimum. Any
other standard / special software package, if available shall also be offered describing
the full capabilities.

3.1.6 The system shall have a high MTBF value (Minimum 15 years) and shall have a well
proven record of operating satisfactorily in a Hydrocarbon processing plant for a

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minimum of one year. No prototype instrument of an experimental nature shall be


offered or supplied. .Control systems shall be designed with a minimum availability
requirements of 99.99% with a MTTR figure of 8 hours. Minimum level of redundancy
have been specified in the specification. Additional redundancies if required, must be
provided by Vendor to meet these specified availability requirements.

3.1.7 Galvanic isolation shall be provided for all field signals. Isolation shall also be provided
between Engineering / operator console and related sub-system connected to it.

3.1.8 On-line replacement of any module shall be possible in such a way that removal and
addition of a module shall be possible without de-energising the system. Furthermore,
there should not be any interruption of the system while replacing a faulty module
wherever redundant modules are provided.

3.1.9 Unless otherwise specified, all electronic modules / equipments shall meet the
environmental classification class G3 as per ISA-S71.04

3.1.10 The system shall be upward compatible i.e. new enhancements can be incorporated in
the system for future up gradation

3.2 SPARES PHILOSOPHY

3.2.1 Installed engineering spares of 20% shall be provided in each sub-system for each type
of module to enhance the system functional requirements including and hardwired
instrumentation.

3.2.2 In addition the system shall have the following minimum spare compatibility :

3.2.2.1 The controller and I/O system shall have 20% usable spare space for installing
additional I/O modules in future. However, the control processor shall have additional
20% capacity to handle these I/Os. In addition, internal wiring for the same shall be
completed upto I/O terminals.

3.2.2.2 Each operator console shall contain 10% usable spare group and related display
capability in addition to above

3.2.2.3 The system shall have capability to extend its historical trending, logging and users
memory by 40% to meet future expansion with / without adding additional memory
modules.

3.2.2.4 The communication system shall have sufficient capability to execute additional 30%
logics. Further it shall be possible to extend the memory by at least 30% at a later stage.

3.2.2.5 Usable spare space in panels and cabinets to install 20% spare hardwired items like
barriers, trip amplifiers, receiver switches, panel mounted instrument, relays etc in future

3.2.3 Sufficient additional software capacity shall be available in the system to take care of
spares requirement as specified to meet all functional requirements.

3.2.4 Mandatory spare module of 10% or one module of each type, whichever is higher must
be supplied for each type of modules being used including in consoles. This shall include
spare modules for hardwired instruments, assignable recorders, personal computers,
programmable logic controllers etc.

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3.2.5 Consumable Spares


Any paper, ribbon, printer heads and ink required for printers, assignable recorders,
video copier or any other consumable items shall be supplied along with system required
for minimum of six months duration after system acceptance.

3.3 SYSTEM COMPONENT / INSTRUMENT ENCLOSURES

3.3.1 All the equipment covered in this specification shall be located in general purpose non
hazardous area, normally in control room. All control room mounted equipment shall be
weather proof to IP-42.

3.3.2 Intrinsically safe certified transmitters and E/P positioners shall be used if located in
hazardous area. Distributed system shall have either built in intrinsic safety or shall use
external barriers for intrinsic safety. Safety barriers shall also be used whenever intrinsic
safety is specified for contact inputs. All solenoid valves shall be flame proof, in general.

3.3.3 The system as a whole shall be intrinsically safe based on entity concept. It may be noted
that the transmitters and E/P positioners bought separately can be of different make and
models certified intrinsically safe by any of the recognised statutory body lime BASEEFA,
PTB, FM, CMRI etc. Safety barriers selection shall be done based on the type of
transmitter or E/P positioners and shall be certified intrinsically safe by any of the above
statutory bodies. Any limitation or special requirements for cables to meet the intrinsic
safety requirements shall be bought out in the offer.

3.3.4 In case of smart transmitters, the entity parameters of the hand held terminals shall also
be considered while selecting proper barriers.

3.3.5 All intrinsically safe barriers shall be of the isolating type only, shunt diode type of safety
barriers shall not be used. Only single channel type of barriers shall be used.

3.4 POWER SUPPLIES AND DISTRIBUTION

3.4.1 The DCS system shall normally operate on uninterrupted power supply with the following
power supply specifications
Voltage 110 V +/- 10%
Frequency 50 Hz +/- 3 Hz
Harmonic contents Less than 5%

3.4.2 All cubicles lighting shall be on 240 V, 50 Hz normal power supply.

3.4.3 Power supply shall be made available at one point. Further power distribution network
shall be designed such that a single power fault in any instrument branch system shall
not cause a trip of the entire system. Each consumer shall be provided with a separae
MCB of proper rating for isolation and protection of the system. Earth leakage circuit
breakers or isolators shall be provided.

3.4.4 The vendor shall be responsible to derive any other required voltages required for proper
functioning of system. Redundant power supply units shall be considered for DC source.
When several transmitters are powered by a common DC source each power supply
branch shall have a separate switch and fuse. The distribution network shall be designed
in such a way that overload in any branch shall not trip the main power supply. All power
supplies shall be sized for 150%of full load. Status indication of each power supply shall
be made available at operator console. The individual system shall be designed to take
care of reverse polarity from DC source.

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3.4.5 On event of any of the following conditions , system shall go to fail-safe mode
Power Failure (Voltage variation more than +/- 10%)
Frequency Variation more than +/- 3%
Air-Conditioning Failure

3.5 TRANSIENT, STATIC AND EMI / RFI PROTECTION

3.5.1 The system shall be internally protected against system errors and hard ware damage
resulting from :-
Electrical transients on power wiring
Electrical transients on signal wiring
Connecting and disconnecting devices or removing or inserting printed circuit
boards in the Distributed Control System (DCS)

3.5.2 The DCS system shall be capable of accepting various signal inputs for its direct use
while preventing noise errors due to electromagnetic interference (EMI) or radio
frequency interference (RFI) including nearby radio stations, hand held radios, electrical
storms, solenoids, relays or contactors carrying heavy currents. RFI / EMI noise immunity
shall be as per SAMA standard PMC-33.1. The surge withstand capability of input/output
modules shall be as per IEEE standard 472.

3.6 SYSTEM SIZING / LOADING CRITERIA

The contractor shall submit calculation and basis of determining the availability of
equipments and architecture of the system to meet all the requirements in this
specification and at the same time observe the maximum loading indicated. Loading
here is referred to the use of memory, CPU time and communication capacity. The
loading shall consider the worst case of high system activity. During this case, no
degradation of system performance is allowed, maximum loading on various sub-
systems shall be as follows :-

 40% : Processor including memory


 60% : I/O capacity and other hardware
 40% : Communication network (for deterministic networks).
 40% : Foreign device interfaces

3.7 UPS SIZING CRITERIA

3.7.1 Vendor shall calculate the UPS load requirements considering following requirements
The instrumentation load which is required to be considered for must include 20%
installed spares and 20% additional load on the overall value
UPS sizing shall be carried out based upon the in rush current, duration of in rush
current and power factor of all major loads.

3.7.2 Redundant power feeders will be made available (by others) from UPS distribution board

3.7.3 Redundant system in control room shall have separate feeders from power distribution
cabinet in control room.

3.7.4 Non-redundant systems shall have two feeders for power distribution.

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3.8 HEAT LOAD CALCULATIONS

Supplier shall provide Heat load calculations for the total system , considering the
installed spares as well as components which would be installed in space reserved for
future expansion.

3.9 SYSTEM FURNITURE

All system furniture required for mounting and operation of the system including
mounting of table top equipments shall be supplied. Furniture for operating personnels
shall be as defined in job specifications.

4.0 SYSTEM CONFIGURATION & FUNCTIONAL SPECIFICATIONS

4.1 SYSTEM COMPONETS

Basic system configuration shall be as per Job specifications , however the system shall
consist of the following major sub-systems :

- Processor system
- I/O system
- Communication system
- Operator interface system
- Engineer interface system
- Supervisory computer system, as required
- Foreign device interface
- Hardwired instrumentation
- Information network system

4.2 FUNCTIONAL REQUIREMENTS

The system as a minimum, shall meet the following requirements without the supervisory
computer :
- Control
- Data acquisition and monitoring
- Alarming
- Logging and report generation
- Historical data storage
- Trending
- System shall have free memory space available for the user and CPU shall
have additional capability to perform advanced control functions,
processoptimisation programs or generate management reports as specified
in job specification
- Plant process interlocks and safety shutdown shall be independently
performed by programmable logic controller (PLC) which shall have
connectivity with DCS communication system

4.2.1 The system when specified along with supervisory computer, shall meet the fllowing
requirements in addition to above:
- Advanced control
- Unit and plant optimization
- Management information service reports

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4.2.2 Whenever information network is specified,the system shall meet any or all of the
following requirements.
- Centralised information system
- Statistical process control / quality control
- Plant optimization, data reconcillation, overall mass balance etc.
- Plant planning and scheduling
- Computer integrated manufacturing with information transfer to achieve
functions like productionand preventive mainenance scheduling and plant wide
coordination etc.

4.3 PROCESSOR SYSTEM

4.3.1 The control function of the system shall be executed by microprocessor based single or
multi-loop controller consisting of I/O ports and a set of algorithms which are easily
configurable.

4.3.2 This system shall be capable of executing following control functions and set of
algorithms as a minimum :

- General : Monitoring and alarms


- Control : P, PI, PID, adaptive gain, ratio, cascade, feed forward, etc
- Arithmetic : Addition, subtraction, multiplication, division, overaging, square root,
ramp, rate of rise / fall, etc.
- Linerisation :Flow pressure / temperature compensation, linearisation, polynominal
etc.
- Dynamic : Lead / Lag, dead time, timer, etc.
- Modes : Auto , Manual , Cascade or Computer.
- Limiter : Low Limiter, High Limiter, set point.
- Comparator : Less than, greater than etc.
- Selector : Low, High, etc.
- Logic : AND, OR, NOR, NOT, XOR, Start / Stop, etc.
- Miscellaneous :Bumpless transfers, direct / reverse output , Anti-reset windup , slow
fast ramping of setpoint & output etc.

4.3.3 The processor shall be able to scan critical close loop in less than 250 msec and non-
critical close loops in less than 500 msec unless otherwise specified in job specification.
The scan time for open loops shall be less than 1 second.

4.3.4 The controller shall be able to operate in either manual, auto, cascade or computer
mode. Mode change-over in either direction shall be procedure-less and bump-less. It
shall be possible to change set-point, tuning constant, operating mode, control loop
configuration from the central level i.e. operators interface keyboard and engineers
interface keyboard.

4.3.5 In computer mode, controller shall be able to track computer generated set point and
shall hold the last generated value in case of computer failure. In such case, controller
shall fall back on auto mode and continue to operate at the last received set point, in
general. Other options like pre-defined set point operation and fail safe condition shall
also be possible. On the resumption of computer set point again, the controller shall not
return to the computer mode automatically, Computer failure indicator shall be provided
at central and local level.

4.3.6 The size of the memory shall be sufficient for storage of the program instruction required
by the control schemes. Offer shall indicate the amount of memory occupied by the

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actual program and spare capacity available for later program modifications or additions.
A minimum of 60% spare memory space shall be provided at the time of handover of the
system to owner.

4.3.7 Memory shall be non-volatile. However, in case volatile memory is provided, battery
backup shall be provided for a minimum of one year to keep the stored program
intact. A battery drain indication shall be provided at least one week before the
battery gets drained. A potential free contact shall be provided for hardwired annunciation
in the control room.

4.3.8 Watchdog timer shall be a software device. The healthiness of processors shall be
continuously monitored by watchdog timer. Any hardware or software problem in the
processor system including CPU, memory, power supply, communication interface etc
shall cause the watchdog timer to report processor failure.

4.3.9 In case Multiprocessor configuration is offered , the processors must be able to


communicate with each other over the interconnecting datalink. Vendor shall ensure that
system performance shall not degrade when such a system is offered.

4.3.10 Loop integrity shall be maintained in processor system architecture by providing one to
one processor back-up. In case failure is detected in the active processor all the loops of
the failed processor shall be transferred to the back-up processor. The processor system
shall have automatic control transfer switching, which shall transfer the entire
configuration and data base of failed processor to the back-up processor. Design must
ensure that data integrity is maintained during switch over and no portion of data to be
transferred is corrupted before and during switch over to the back-up processor. The
back-up processor must be dedicated to perform only control functions. The indication of
the failed processor shall be displayed at local as well as on the central level. The switch-
over time shall be indicated which shall not be more than loop cycle time.

4.3.11 Loop integrity shall also be applicable to I/O system, power supply modules and any
other device associated with the processor system.

4.3.12 Whenever multi-loop capability of processor is used for acquiring data each input shall
be displayed in the actual engineering units and shall be independently accessible,
configurable and controllable from local as well as central level.

4.3.13 While downloading any changes, made to a particular tag, from engineer interface
system to the processor system the controller output shall be maintained at its last value
and should not be driven to zero value even momentarily.

4.4 I/O SYSTEM

4.4.1 The I/O system shall be capable of accepting process signals from various process
sensors and switches preferably without requiring external or auxiliary signal conditioning
devices. The system inputs shall include 4-20 mA DC, thermocouple, resistance
temperature detector (RTD) and discrete inputs as a minimum apart from others as
specified in the job specifications. It shall be capable of processing linear and non-linear
analog inputs, providing square root extraction for flow signals, linearisation and
compensation for thermocouples. The system shall be able to generate 4-20 mA DC
current signals for analog outputs and potential free contacts for the discrete outputs as a
minimum apart from others as specified in the job specification.

4.4.2 No. of inputs per Inputs/output (I/O) module shall not exceed either of the following :-

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Analog I/O Modules : 16 channels


Discrete I/O Modules : 32 channels

4.4.3 Each I/O shall be galvanically isolated from external control circuit by suitable means.
The minimum isolation level between I/O and logic circuit shall be 1000 volts DC.

4.4.4 Each I/O shall be protected against the reversal of polarity of the signal. Reversal of
polarity on I/O termination shall be indicated in DCS.

4.4.5 Each digital I/O module shall have a LED per channel to indicate the status of each Input
/ output.

4.4.6 Each input shall be provided with filters to filter out any noise in the input line and contact
bouncing noise.

4.4.7 All the inputs shall preferably be double ended i.e. two wires per input and not with
common return for all inputs.

4.4.8 The interrogation voltage to the input / output contact shall be powered from separate
power supply / supplies and shall not be a part of I/O module unless otherwise specified.
The redundant power supply shall be considered so that the redundancy is maintained at
all levels.

4.4.9 Output contacts shall be potential free/dry contacts. Wet contacts / powered contacts /
TTL outputs etc. shall not be acceptable. Vendor must provide arc suppression device
for each output contact. Each output shall be short-circuit proof and protected by fuse.
Visual indication of fuse down must be provided for each output.

4.4.10 All I/O modules shall have facility to detect wire open condition whenever normally open
inputs ( close on alarms ) are considered.

4.4.11 All I/O modules shall be provided with galvanic isolation or optical isolation using isolation
barriers.

4.4.12 The system shall have capability to provide analog outputs for driving indicator /
recorders (load upto 750 ohms). The analog outputs shall be 4 to 20 mA DC unless
otherwise specified. Each channel shall have current limiting such that effect of short
circuit in one channel does not have operation of other channels and current does not
exceed 30 mA.

4.4.13 All 4-20 mA inputs shall be capable of being software configurable on an individual
channel basis to provide energizing power for a 2-wire transmitter or to receive powered
signal from an external device such as 4-wire transmitter. The 2-wire option shall be
capable of driving the transmitters plus an additional load of 600 ohms such as that
imposed by a local indicator.

4.5 OPERATOR INTERFACE SYSTEM

4.5.1 The operator interface system (OIS) shall perform the function of Man Machine
interface and provide the centralized information to the plant operator / Engineer .
Following data shall be available on OIS :

Indication of all analog and digital process variables of control loops, open loops and
all loop related parameters.

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Manipulation of control loops including changing set point, mode, output,


configuration, running and computational constants.
Alarm displays and annunciation.
Graphic displays and status indication.
Logging and trending including historical trend recording
Self diagnostic messages, operator messages
Maintanence oriented manuals for hardware and software maintanence of the
system on engineer interface.

4.5.2 Operator interface system shall consist of operator consoles. Number of operator
consoles shall depend upon the size and operating philosophy of the plant and indicated
in job specifications. The consoles shall be with keyboards , individual or common
electronics , logging printer , hard copy unit as a minimum. Table top console is not
acceptable.

4.5.3 The system shall have global data base available at each operator console electronics
and all the required functions shall be available / executed at operator console. However,
in case distributed data base / console functions are offered, each data base electronics
must be dual. Further any change made in the data base of one console shall
automatically update the data base of other consoles.

4.5.4 All the functions and displays of operator consoles shall be fully interchangeable. In
general each console shall be dedicated a particular area of the plant , however it should
be able to take the functionality of other consoles , if required .

4.5.5 The real time clock of each operator console shall be crystal controlled one which shall
be independent of line frequency. All the real time clocks in the system shall be
synchronized with each other.

4.5.6 Each console shall be an industrial type high resolution 20.1 or larger color screen
capable of displaying alpha-numeric & graphic displays. Multiple colours shall be used to
distinguish parameters such as control, information, process and alarms etc.The display
screen shall be able to display the full alpha numeric tag number of a process variable. A
minimum of twelve (12) digits shall be provided for the tag number and 24 digits for the
process description , unless otherwise indicated in Job specifications.

4.5.7 Data display update rate shall not be more than one (1) seconds. Cursor control devices
must be available with each console like keyboard & mouse & trackball.

4.5.8 Keyboard shall be touch sensitive sealed type easy to operate with each key clearly
identified. It shall be easy to operate and shall meet all the functions to configure, operate
and maintain the system. A conversational user friendly software shall be used for
operation, configuration and maintenance of system. Each entry shall be registered with
an audio beep. The key board shall not be susceptible to dust and moisture. It shall be
provided with key-lock facility to prevent any un-intentional program modification.

4.5.9 The operator, as a minimum shall be able to access following through key board :
Selection of all the displays including the direct selection of loop in alarm page
turning facility, overview, group view and loop view selection etc.
Selection of loop for operation.
To acknowledge alarms as and when they are annunciated on the operator console.
Facility to enter any changed parameter like set point, manipulated variable digital
commands and to cancel any wrong entry while making such change.
Facility for easy positioning of cursor for the selection of any parameter.

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Selection of hardcopy printout, logging printout, alarm history, printout and


assignable trend recorder points.
Auto / Manual / cascade / Computer mode changeover of each Processor.

4.5.10 The OIS shall provide following process displays

4.5.10.1 Overview display

Overview display shall incorporate a minimum of 128 analog or discrete inputs which
can be monitored simultaneously on the screen (referred as page). Each page shall
be organized into a suitable number of groups. Each groups shall be identified
separately. Each group shall further incorporate suitable number of inputs (referred
as tags). Suitable identification and description shall be shown for each group on the
overview display to relate it to a group or loop display.

All analog points in the overview shall be represented as variable lengths indicating
deviation above or below the normal operating value or set point.

Alarms shall be displayed in change of colour against each variable if the variable
crosses a set value. Control loops operating in manual mode shall be indicated.All
input in alarm condition shall be identified by flashing.

In case any hard wired instrumentation backup is provided, overview pages shall be
assigned indicating the tag number and type of hardwired instrument.

4.5.10.2 Group Display

Group display shall be limited to the group of inputs as displayed in the overview display.
Each group shall preferable include eight (8) numbers of inputs. Each input in the
group shall be identified by the tag number, unit of measurements and process
description which shall be displayed on the screen. Display, as a minimum shall show the
following degree of details :-

Process variable in analog form shall show as a percentage of the transmitter span on
a linear scale bar graph of 0-100% or engineering units and in digital form as alpha-
numeric display in engineering units.

Set point value in analog form as a percentage of the transmitter span on linear scale
bargraph of 0-100% engineering units and in digital form as alpha-numeric display in
engineering units.

Output value in analog form as a percentage of linear scale bar graph of 0-100% and
digital form as percentage.

Processor mode i.e. auto, manual, cascade, computer.

Process alarm on process variable, deviation or velocity.

Selected loop within the group shall be identified by cursor marking or similar
identification.

Control valve failure position.

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The contact input / output shall be represented by simulated graphic lamps and
configurable alpha-numeric status description.

Also It shall be possible to control the process from group views. Following control
actions shall be possible.
 Increase / decrease of set point value either slow or fast.
 Change of Processor mode i.e. Auto / Manual transfer.
 Changing output to the final control element.
 For digital points, start/stop or open / close command.

4.5.10.3 Loop Display

Loop display shall provide a separate detailed display for each of the process inputs.
The graphic representation of analog and digital points shall be similar to group display.
However, in addition following information shall also be presented in alpha-numeric form
as a minimum.

Processor tuning constants.


Process variable zero and span values.
Alarm set point on various parameters.
Limits on set point, output, velocity
Processor action (Direction / Reverse)
Failure position of final control element.
Computational constants like ration or bias.
Integrated value.
Output to the final control elements
Engineering units.

It shall be possible to change tuning constant , scale , zero & span , limits on setpoints ,
output , control mode start / stop command through the keyboard of operator console ,
although some functions shall be restricted through key-lock control.

4.5.10.4 Graphic Display.

It shall be possible to display dynamic graphic of different section of plant on the


operator console 20.1 TFT. Graphic displays shall be field configurable only through
engineering key-board with standard / user defined graphic symbols. Different plant
sections dynamics shall be displayed on different pages.

The system shall have the capability of having and developing graphic symbol library
as per ISA-5.1 and 5.3. In addition, standard industrial symbols like distillation
columns, heat exchangers, pumps, compressors, tanks etc shall also be provided as
a standard.

Graphic displays shall be interactive type through which it shall be possible to control
the process. It shall also be possible to send motor start/stop and shutdown valve
open/close command, as specified in job specification from this display.

It shall be possible to view the process variable and alarm points and view and
change set point value, manipulated variable, Processor mode etc from the graphic

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display. Also compressor/pump status and valve status shall be displayed on the
graphic display with different colours.

Various colours used in the generation of graphics like colour of the process lines
utility lines, instrument signal lines and event modifier conditions shall be finalised
during detailed engineering. The colours used to identify event modified conditions
shall generally be as follows unless otherwise indicated during detailed engineering.

It shall be possible to go from any graphic page to related graphic pages or any group
view or alarm summary in single key stroke using soft key function.

4.5.10.5 Trend Display

The system shall be capable of displaying the following trends


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

Historical trend for number of parameters as specified in the job specification.


However it shall be possible to assign any parameter for historical trending.

Historical data shall be stored on the nonvolatile memory device like hard disc in
such a way that such historical data can be utilized for archival storage and
subsequent recall.

Real time and historical trend shall be possible on any parameter or variable like
measured variable, set point, output, calculated variable etc.

It shall be possible to sample and store data of instantaneous and average value at
the intervals mentioned below. However it shall be possible to display by scrolling or
expanding the time base for all the trends.
 At interval 2 second and below for the real time trend.
 At 1 minute, 10 minute and 1 hour interval for historical trend.

Historical data trends shall be displayed for a period of minimum upto 25 hours for a
data sampling rate of 1 minute.

Fast trend requirement, (trends with sample time faster than Real time trend) if any
shall be specified in the job specification.

Selection of the tag number and sampling time for real time and historical trending
shall be possible from operator keyboard.

The system shall also have a multitrend capability in such as way that it shall be able
to display set point, measured variable and output on the same display, the trend of
either the same process variable or any other process variable.

Trend display shall be single line type or bar graph type with additional information
like loop tag number, engineering units, span, present value of the trended point.
Alarm status etc displayed.

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4.5.10.6 Alarm Display

It shall be possible to display process as well as system alarms on the operator


console for operators attention and action. Alarms shall appear immediately on the
operator console as and when they occur on priority basis.

It shall be possible to set process alarm limits from the engineering keyboard i.e.
alarm limits on absolute value of measured variable; rate of change of measured
variable., high and low deviation set points, high, extra-high, low and extra-low points
on process variable and output etc. In addition, it shall be possible to derive alarm
conditions on the basis of few calculations performed by the system.

Alarm messages shall be displayed by flashing the page and group number of the
input under alarm irrespective of type of display. It shall be possible to access the
group or tag in alarm condition with a maximum of two key-strokes of operators
console keyboard. The plant overview display, in addition to display alarm message
shall also be able to provide warning by changing colour of excessive deviation of
process variable from their set value.

All alarms shall be displayed as and when they occur or generated with change in
the colour of display in the following sequence, activating an audio signal :
Continuous flashing - Un-acknowledged alarm
Steady display - Acknowledged alarm

The system shall not put off the audio alarm and visual flashing even after the
condition returns to normal unless it is acknowledged by the operator.

It shall be possible to display summary of all alarms in the sequence of their


occurrence and shall disappear from display only when they are acknowledged and
cleared. The alarm display shall list the following for each alarm as a minimum
 The date and time of occurrence
 Point identification (i.e. Tag numbers)
 Point description
 Type of alarm (absolute value of deviation
 Serial number of alarm in the sequence of its occurrence.

The history of alarm conditions shall be maintained in the data base for alarm history
display and printed on shift-wise basis for the parameters specified in the job
specifications. The alarm display and print out shall list the following for each alarm
as a minimum.
 The data and time of occurrence
 Point identification (i.e. Tag number)
 Point description
 Type of alarm (absolute value or deviations)
 Time of acknowledgement
 Time of return to normal
 Serial number of alarm in the sequence of occurrence

4.5.10.7 Configuration display

Configuration display shall provide a separate detailed display for each loop
indicating the configuration of the loop. When control requires more than one loop, all
interrelated loops shall also be displayed. Following information is required to be
available for configuration display.

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 Loop configuration giving designation of each blow.


 Control block interconnection showing softwaring or hardwaring
 Value of each blow parameter like P&ID, ratio, bias, dead-time, lead-time etc.
It shall be possible to configure & reconfigure the loops from this view using user
friendly software.

4.5.10.8 OIS Logging feature

It shall be possible to log all measured and computed parameters, operator


actions alarms etc. from operator consoles.

Logs shall be required on hourly, shiftwise (8 hourly) and daily basis and some
cases for weekly and monthly basis as specified in job specification.

All parameters required for logging shall be stored in memory in accordance with
data base update rate. However it shall be possible to perform basic arithmetic
calculations such as averaging, summing , efficiency calculations etc prior to
logging.

The log format shall be user definable, in general. However the typical log formats
for hourly, daily and shiftwise reports shall be as defined in the job specifications.
For extended logging like weekly and monthly reports, system shall have
capability of writing programs in high level language. High level language compiler
software sufficient memory space and necessary hardware shall be provided.

Number of log reports shall be as per number of log formats defined like hourly
report format, daily reports format etc. Number of pages in each log report shall
be sufficient to accommodate all the parameters for logging as defined in the job
specifications.

Hourly report shall be printed only as and when initiated on demand by the
operator and shall not be printed automatically after the end of the hour. All other
reports shall be printed automatically at the end of the pre-defined time as well as
on demand by the operator. The maximum storage time for a log information shall
be 15 minutes after the pre-defined print out time for a format, within which time
log report must be printed. In case report could not be printed within the
scheduled defined time, data shall remain stored till the report is finally printed.

4.5.10.9 Logging Hardware

Logging printer shall be used for

 Printing of hourly, shift-wise, daily and weekly log


 Shut down report printing
 Any other report defined in the job specification

Alarm and event printer shall be used for

 Logging the process and system alarm messages as and when the
occur.
 Print the alarm history for every shift of operation or on demand from
operator console
 Logging events such as operator actions as and when they are initiated.

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Alarms and Events shall be clearly distinguishable on the report, preferably by


colour.

Print out shall show as a minimum the tag number, description, data and time of
occurrence, time of acknowledgement and time of return to normal.

4.5.10.10 Self Diagnostics

Following diagnostics shall be available as minimum


 Analog input Diagnostic - Sensor out of range, open or shorted loop, analog-
to-digital converter check
 Analog Output diagnostics Open or shorted loop
 Configuration diagnostics Checking compatibility and availability of selected
I/O hardware & software
 Memory diagnostic Checksum , Parity etc
 CPU / Memory diagnostics O/p of processor from an algorithm checked
against pre-stored answer
 Power diagnostics Monitor availability of supply voltages

The self diagnostic message for a system failure shall appear on the operator console
irrespective of display selected. The choice of the detailed self diagnostic displays
shall be made by a key-lock switch.

The system shall have an extensive set of self-diagnostic routines which shall locate
and identify the system failure at least upto module level including redundant
components.

Failure of a system shall be annunciated with the change in colour. To aid system
maintenance and for effective fault location, following display shall be provided as a
minimum.

 Communication system status display


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

 systems diagnostic display


One display page shall be available for each system which can be called on
demand. The same shall display as minimum system number and type, error
code and description and details of failed module.

4.5.10.11 Data Storage, Archival and Retrieval

Historical data shall be stored on a non-volatile memory device like hard disc which
can be subsequently recalled by operator on any screen. System must support
multiple historical data discs in order to avoid data loss in case of disc crash.
It shall also be possible to store and retrieve this data on removable mass storage
media like CD ROM , floppy disc, cartridge or tape etc.

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4.6 ENGINEER INTERFACE SYSTEM

4.6.1 Engineer interface system shall be primarily an engineers interface which shall normally
be used for configuring, tuning and maintenance of the Distributed Control System. This
shall consist of a console provided with one operator key-board and one engineering
keyboard. This as a minimum shall also have one configuration and maintenance printer.
Exact number of such consoles will be as per Job specification.

4.6.2 Engineering console shall have as a minimum the same capability as operator console.
However the operation of the plant shall be restricted from this console only in tuning
mode. All the plant views as specified under operator console shall also be available on
Engineering console.

4.6.3 It shall be possible to perform all system configuration functions from the Engineering
console typically.
Data base configuration including overview, group, loop, multiloop and multi-
variable control configuration.
Group or multi-group alarm inhibit from the plant under maintenance.
Configuration or re-configuration of alarm settings, their values, addition or deletion
of any control block or components in a loop.
Tuning of control loops like changing, PID, dead time values
Compilation of graphic displays
Setting of real time clock
Compilation of logs/reports/historical trend points.
To call detailed self diagnostic displays for maintenance aid.

4.6.4 Tuning of a control loop shall be possible from engineering as well as from operator
console, the location shall be selected by the operator using a Tuning mode key-lock
switch provided on the operator console. In tuning mode it shall be possible to operate
only the loop under tuning from engineering console. In case of simultaneous
commands from operator and engineering consoles, operator console shall over-ride.

4.6.5 During the normal operation, the engineering console, in no case shall interfere with the
process operation or system software. However, any change in the configuration shall be
down loaded into the system with proper knowledge of the operator.

4.6.6 All detailed diagnostics of the system shall appear on the engineering console with a print
out on the configuration and maintenance (C & M) printer. A common diagnostic
message on the operator console shall indicate the need of the maintenance. C & M
printer shall be used for printing the configuration or configuration changes, printing
system alarms as and when they appear and to print out any engineers command from
engineering console.

4.7 COMMUNICATION SYSTEM

4.7.1 The communication system shall be a digital communication bus, that provides a high
speed data transfer rapidly and reliably between the operator consoles, process I/O
devices, process computer and other devices connected to it.

4.7.2 Communication system shall be dual redundant, consisting of two separate


communication buses and two separate communication system interface for each
device. In case of systems having traffic directors, redundant traffic directors shall also
be provided.

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4.7.3 Communication speed on the communication bus shall be sufficient to update the
operator console data base once in every second. The overall system performance shall
not be degraded whether communication system is 10% or 100% loaded.

4.7.4 In case of main bus failure or any communication device failure, the transfer to the back
up device or bus shall be automatic without interrupting the system operation and without
any operators intervention. Information about the failed device/bus shall be displayed on
the operator console.It shall be possible to connect or disconnect a device from the
system without disturbing the operation.

4.7.5 In general, the transmitting message shall identify the receiving device. The transmitting
device shall receive a reply from the receiving device on the receipt of correct message.
Lack of response shall be considered as a receivers failure.

4.7.6 The mechanism used by the communication system for error checks and control shall be
transparent to the application information. Error checking on all data transfer shall be
done by cyclic redundancy check and other advanced codes.

4.7.7 All communication cables to be routed in the field shall be fibre optical type. Specific
convertors shall be provided wherever required. All fibre optical cables shall be routed
through hard HDPE conduits and shall be totally enclosed within using HDPE matching
fittings. The HDPE conduits shall be as per IS-4984 or equivalent IEC standard. The
outer colour of the conduit shall be orange with black fittings throughout the run. Use
separate conduits for laying redundant fibre optical cables. Preferably separate routes
may be followed for redundant cables. Wherever fibre optical cable is to be routed
underground, this should only run in concrete trenches with HDPE conduits provided as
above. All such trenches shall be sand filled after installation.All optical fiber cable shall
be armoured type , rodent resistant.

4.7.8 In case of foreign device interfaces (PLC, ASC etc) with DCS, the failure of One
Communication carrier card shall not affect the redundancy of more than one foreign
device interface

4.8 PLC INTERFACE WITH DCS

The PLC shall be interfaced to the offered Distributed Control System bus. The interface
shall be dual redundant unless otherwise specified. The interface shall facilitate the
following functions as a minimum :
Display of all input points under alarm/first out alarm connected to PLC or generated
in PLC on the main operator console.

Generate shut-down reports on the logging printer of distributed control system.

To receive certain operational commands from the hardwired console for the
operation of certain output devices connected to PLC.

To display diagnostic messages of PLC

4.9 THIRD PARTY INTERFACE

4.9.1 Third party interface shall be capable to transfer data from the foreign devices like
analyser system, gas chromatographs, gas turbine system etc to other sub-systems

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connected to communication system and vice-versa whenever specified in the job


specification.

4.9.2 Each device interface shall be redundant unless otherwise specified in job specification.

4.9.3 Interface hardware and software shall be suitable to match the foreign device
communication requirements like hardware interface, communication protocols etc.

4.9.4 While writing software or mapping the input / output in the interface device it must be
ensured that integrity of the data to be transferred like resolution, correctness etc shall
be maintained.

4.9.5 Redundant interface switchover shall be designed based on the type of redundancy
available in the foreign devices.

4.9.6 The total responsibility of selection of hardware, writing or software, switchover of


redundant interface etc shall be of distributed control system vendor only. All necessary
information assistance and help shall be rendered by the Foreign device vendor.

4.9.7 The exact requirements of input/outputs to be transferred shall be as per job


specifications.

4.10 OPEN SYSTEM CONNECTIVITY

4.10.1 The system shall be capable of interfacing with other plant systems and computers over
a well established communication network like Ethernet conforming to IEEE 802.3

4.10.2 The system software shall be support industry standards like UNIX, Windows NT,
OSF/MOTIF, TCP/IP and DDE, SQL, RDBMS etc as applicable.

4.10.3 The method of data access by any user on this network shall be by I/O Tag name and
not by any physical or logical address.

4.11 INTERFACE WITH SMART TRANSMITTERS

4.11.1 System shall be provided with suitable hardware and software to interface with the
communication protocol of specified smart transmitters.

4.11.2 In case smart transmitters are specified with HART PROTOCOL, the maintenance data
related to these transmitters shall be made available on a separate personal computer.
The system shall meet the following requirements as a minimum
The system shall allow the maintenance functions like configuration. Calibration and
monitoring of transmitters data from the associated personal computer in addition to
Hand held terminal whenever used.
The hardware used shall allow unrestricted transfer of digital signal without degrading
the analog data i.e. process variable
The software supplied shall be CORNER STONE OR EQUIVALENT compatible with
the specified transmitter protocol. The software shall allow the following data to be
displayed on the PC :-
 Complete configurational data base of all transmitters including data of
commissioning, last calibration, next due calibration etc
 Historical data for calibrations and configuration changes
 Event and log reports
 Multiple authorisation levels for carrying out Configuration changes and
Calibration adjustments

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 Manual editing of data base with Password and / or keylock protection

4.12 DOCUMENTATION NODE (DN)

4.12.1 Contractor shall be responsible to supply completely engineered documentation node


including necessary hardware of proper size and the software necessary to meet the
requirements of the node. The relational data base shall be generated by the vendor to
display and print out all unit documentation on the documentation node.

4.12.2 The node shall comprise of a workstation or a PC along with the accessories like
streamer tape, CD drive and a laser printer. The node shall meet the following
requirements as a minimum :
Store complete unit documentation
Store all instrument specification sheets including for field services for all the units.
The specifications will essentially consist of tag number, location, service and all
major attributes to uniquely identify the instruments in the refinery.
Link DCS documentation with unit documentation and instrumentation specification.
Updation and maintenance of documentation file.
Generation of new drawings and document and load these in the system if required.
Provision of transferring / accessing information to / from MS access/ Excel formats
from/to other PCs on network.
Print out various documents as required.

4.12.3 The documentation node shall be dedicated one. The sizing of the node shall be carried
out based on the above facts. Any information should be accessible from the system in a
menu driven program only. Vendor shall be responsible for the complete application
engineering of documentation node including those of packages. Documentation data as
available from sub packagers will be made available to the vendor.

4.12.4 Following documents should be possible to be printed from the documentation node as a
minimum. Vendor shall indicate the capability of their offered system and shall engineer
the same as per Owners requirements :
Loop wiring diagram for every input and output including field interconnection upto
instrument inclusive of junction box.
Loop schematic and instrument hook-up drawing showing sample tubing, fittings,
joints,etc.
Alarm and trip settings (software and hardware along with field settings) for DCS and
PLC tag numbers in tabular form in total or in part as per requirements based on type
of instruments / parameters.
Transmitter calibration ranges, span, elevation / suppression provided.
Safety valve set points.
DCS PLC input / output tag list with location.
The document containing all information attributed to the particular tag number like its
loop wiring diagram, cable schedule number, tubing hook up number, installation
standard number etc.
Provision of viewing / printing logic diagrams, PLC configuration (if possible).
Generate any report in the user definable format.
DCS point database.

4.12.5 It shall be possible to add delete modify any attribute , data, specification, parameter etc.
from the system with proper protection, pass word protection may be provided.

4.13 HARDWIRED INSTRUMENTATION

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4.13.1 Hardwired instruments shall be stand alone type and shall meet their functional
requirements fully without depending on DCS system. Even power supply and
input/output circuits of hardwired instruments shall be totally independent of DCS system.
However hardwired consoles shall be installed alongwith operator interface station as
man-machine interface which shall be equipped with annunciators, indicating lamps,
pushbuttons, selector switches etc.

4.13.2 Hard wired instruments shall be microprocessor based. Each instrument shall have as a
minimum the necessary firm-ware to meet its functional and operational requirements.
Each device shall have its own analog to digital / digital to analog converter. The display
shall preferably be bargraph type.

4.13.3 Processor shall be digital type capable of performing automatic control based on the set
points given locally or from a remote device like another processor or distributed control
system or supervisory computer. The processor as an instrument shall also have
provision for manually controlling the process by means of a manual loader and cascade
/ computer / auto-manual transfer switch. The operation of the transfer switch shall be
procedure-less and bumpless while changing the mode. During such a change the output
shall not change by more than 1% of span. Processor shall have a facia giving
continuous indication of process variable, set value, processor output and processor
mode. It shall be possible to remove an instrument for maintenance without upsetting the
process by use of device like service station. Operation of the Processor like set point
change, manual control, Processor mode change shall be possible from the front of the
rocessor. The processor shall be flush panel mounting type on the panel/hard wired
console. Configuration and tuning of processor shall be possible through a portable and
pluggable configurator.

4.13.4 Recorder shall have independent circuit and pen drive assembly for each channel.
Recorder shall have capability of continuous line marking or digitized marking of input
value with high resolution. Recorder chart drives shall be of multi-speed type and shall be
operator selectable. Recorders shall be flush panel mounting type on the panel / hard
wired console.

4.13.5 Manual loader unit shall have continuous display of process variable and manual loader
output. It shall be possible to manually change the output to control valve. Manual
loaders shall be flush panel mounting type on the panel / hardwired console.

4.14 ALARM AND ANNUNCIATOR SYSTEM

4.14.1 The alarm logic shall be executed in single input plug-in type logic modules. Where
integral logic has been indicated, the logic module shall be accessible from the front of
the annunciator after opening the swing door. The design of each module shall be such
that by simply jumpering suitable point, it may be changed from normally open mode of
operation to a normally closed mode of operation and vice versa.

4.14.2 Lamps shall be replaceable from the front. The power consumption of each lamp shall be
approximately 10 watts.

4.14.3 The initiation of alarm condition in the annunciator shall take place approximately 330
millisecond after the condition sensing contact have assumed the off-normal state.

4.14.4 Hooter in general shall be solid state type with audibility of the order of 100 dB at a
distance of 3 metres.

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4.14.5 An interruption of power supply for a duration of 20 milliseconds or less shall not affect
the functioning of the annunciator.

4.15 CABINETS

4.15.1 Following cabinets shall be required in general


Power distribution cabinets (for AC distribution and DC distribution).
Safety barrier mounting cabinets (if field is hazardous).
Processor system cabinets.
Trip amplifier and other auxiliary card mounting cabinets.
Interposing Relay cabinets ( for MCC interface & powered digital O/ps ).
Marshalling cabinets.

4.15.2 All the cabinets and panels shall be completely wired and/or tubed, if required.

4.15.3 All the cabinets shall be of free standing, enclosed type and shall be designed for bottom
entry for cable connection. Cabinets structure shall be rigid and shall be provided with
removable lifting lugs to permit lighting of the cabinets. Cabinets shall be of RITTAL
make.

4.15.4 Cabinets shall be fabricated from cold rolled steel sheet of minimum 2 mm thickness
suitably reinforced to prevent warping and buckling. Doors shall be fabricated from cold
rolled steel sheet of minimum 1.6 mm thickness. Cabinets shall be thoroughly deburred
and all sharp edges shall be grounded smooth after fabrication.

4.15.5 Cabinet finish shall include sand blasting, grinding, chemical cleaning, surface finishing
by suitable filler and two coats of high grade lacquer with wet sanding between coats.
Two coats of paint in the panel colour and final coat shall be given after assembly at site
for non-glossy high satin finish. Colour of the cabinets shall be as per job specifications.

4.15.6 Each cabinet shall be of maximum 2100 mm height, 1200 mm width and 800mm depth.
Construction shall be modular preferably to accommodate 19 standard electrical racks.
All racks shall be of same height. Maximum swing out for pivoted card racks doors and
drawers shall be limited to 800 mm.

4.15.7 Cabinets shall be equipped with front and rear access doors. Doors shall be equipped
with lockable handles and concealed hinges with pull pins for each door removal. Keys
shall be same for all system cabinets. Similarly all auxiliary / marshalling / non-system
cabinets shall have common key.

4.15.8 In order to effectively remove dissipated heat from the cabinet, vent louvers backed by
wire fly screen shall be provided to cabinet doors, in addition to ventilation fans. In case
of failure of any fan , alarm should be generated on DCS. The cabinets shall also be
provided with Temperature monitoring which will generate alarm in case of high
temperature.

4.15.9 Illumination shall be provided for all cabinets by fluorescent lamps and door operated
microswitches.

4.15.10 Components, within the cabinet shall be laid out in all accessible and logically segregated
manner. Clamping rails shall be provided for incoming cables to prevent excessive stress
on the individual terminal. All metal parts of the cabinet including door shall be electrically
continuous and shall be provided with a common grounding lug.

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4.15.11 The signals shall be segregated in Marshalling cabinets as indicated below :


IS Analog 4-20 mA cables (through safety barriers)
Non-IS Analog 4-20 mA cables
IS Digital contact / alarm signals (through safety barriers)
Non-IS Digital contact / alarm signalse)
Power cables
System communication cables
MCC interface signals

4.15.12 All cabinets , panels & racks shall be designed to avoid congestion for ease of
maintenance.Additionally the rack / cabinets shall be designed as per following
guidelines
No cabinets shall have more than 600 terminals
All spare cores shall be terminated on the marshalling rack. No cable / core shall be
left unterminated in the rack / cabinet
No terminals or terminal strips shall be located on the side panel of the rack /
cabinet.

4.15.13 Items like Isolators , Trip amplifiers , Monitor switches , R/ I Converter , if used shall be
installed in separate cabinet called as Auxiliary cabinet. Signal Isolators shall be provided
wherever an analog signal is to be sent to two sub-systems.

4.15.14 All Digital Output terminals shall be fused type provided with LED indication.

4.15.15 All IS signals shall be terminated on Light blue colored terminal strip.

4.15.16 All cabinets shall have bottom cable entries , provided with removable gland plates. Each
marshalling panel shall have copper bus bar mounted on insulator for termination of
multi-cable screens coming from field. A minimum distance of 300mm shall be provided
between gland plates and terminations to enable easy installation of cables.

4.15.17 Cables shall be supported throughout their run inside cabinets. Clamping arrangements
shall be provided to secure cables at the point they leave the cabinet. There shall be
provision for adequate segregation and separation of power , analog signal , digital signal
, main & redundant network cabling. Cable trunks shall be sized to have 40% spare
capacity after all cabling & wiring has been installed.

4.15.18 All live terminations at a voltage above 60 VAC or DC with respect to earth , shall be
protected against accidental contact by covers requiring tools for removal. Covers shall
carry appropriate warning labels.

4.15.19 Each cabinet shall be provided with 1 no. Electro-static discharge wrist strap , which
shall be used while handling electrostatic sensitive components.

4.15.20 Wiring colour code within cabinet framework and accessory equipment shall be as
follows
Power supply (Line) : Red
Power supply (Neutral) : Black
Ground : Green
Alarm system : White
Control & Shutdown : Yellow
Analog signal intrinsically safe : Light blue
DC Wiring : Red positive
: Black negative

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4.16 CABLING

4.16.1 Vendor shall supply and install all interconnecting cables which shall include but not
limited to the following :
Cabling between Marshalling racks , System cabinets , Barrier cabinets & ESD
system
Cabling between Relay racks , Auxiliary consoles , System cabinets
Power supply cabling to all system components from Power distribution cabinets
Earthing cables of IS ground , Signal ground , cabinet body ground , system
consoles , peripherals inside control room.
Communication cabling
Earthing cable from pit to cabinets.
Interconnections shall preferably be done preferably with the help of pre-fabricated
cables with plug-in connectors at both ends.

4.16.2 All interconnecting cables shall be preferably armoured and laid in ducts / tray to protect
from rodents. If unarmoured cables are used , then these shall be suitably routed in
flexible conduits. The cables shall be routed below false flooring in cabinets rooms and in
trenches in console rooms.

4.16.3 All the cable entries / exit shall be through bottom plate only with suitable glands.

4.16.4 Field cables from instruments / Junction boxes / MCC are excluded from Vendors scope
of supply.

4.17 EARTHING

4.17.1 Each panel cabinet console and other equipment in control room shall be provided with
an earthing lug. All these lugs shall be properly secured to the earthing bus as per the
earthing philosophy indicated in design basis.

4.17.2 All circuit grounds of electronic instruments, shields and drain wires of signal cables shall
be connected to instrument ground bus which is electrically isolated from the AC mains
earthing bus. This bus shall be typically 25 mm wide and 6 mm thick of copper. The
instrument ground bus is connected to independent instrument system ground buses
through insulated wires.

4.17.3 Cable shields of thermocouple extension cables for grounded junction thermocouple
shall not be grounded in the control room.

5.0 TESTING AND ACCEPTANCE

5.1 GENERAL

5.1.1 On the basis of guidelines specified in this specification, vendor shall submit their own
testing, installation, commissioning and acceptance procedure. For hardware, the
procedure shall include purpose of test, test definition of input, procedure, results,
expected and acceptance criteria. For software, it shall include details of the method, list
of test sequence of execution, results expected and acceptance criteria.

5.1.2 The testing and acceptance of the system shall be carried out on the mutually agreed
procedure and criteria based on these guidelines and vendor standard procedures.

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5.2 FACTORY ACCEPTANCE TEST (FAT)

5.2.1 Vendor shall test and demonstrate the functional integrity of the system hardware and
software. No material or equipment shall be transported until all required tests are
successfully completed and certified Ready for Shipment by the owner/consultant.

5.2.2 The purchaser reserves the right to be involved and satisfy himself at each and every
stage of inspection. The purchaser shall be free to request any specific test on any
equipment considered necessary by him although not listed in this specification, as a part
of approval of factory testing procedure. The cost of performing all tests shall be borne
by the vendor.

5.2.3 Vendor to note that acceptance of any equipnent or the exemption of inspection or
testing shall in no way absolve the vendor of the responsibility for delivering the
equipment meeting all the requirements specified in Material Requisition.

5.2.4 It shall be vendors responsibility to modify and/or replace any hardware and modify the
software if the specified functions are not completely achieved satisfactorily during FAT.

5.2.5 The schedule for the FAT shall be included in the Vendors proposal. Factory acceptance
test procedure shall be submitted for approval at least 4 weeks before the FAT at vendor
works.

5.2.6 Vendor shall not replace any system component/module/sub-system unless it is failed. A
log of all failed components/modules in a system shall be maintained .If malfunction of a
component/module in a system repeat, the test shall terminate and vendor shall replace
the faulty component/module. Thereafter the test shall commence all over again. If a
system fails during the test and is not repaired and made successfully operational within
4 (four) hours of active repair time after the failure, the test shall be suspended and
restarted all over again only after the vendor has replaced the device in the acceptable
operation.

5.2.7 The inspection and FAT shall be carried out in two phases The minimum requirements
for testing during these two phases shall be as follows:-

5.2.7.1 Under first phase vendor shall perform tests at his works to ensure that all components
function in accordance with their respective specifications for each type of test. A test
report shall be submitted to the owner/consultant for review within two weeks of
completion of each type of test giving details. All systems shall undergo a minimum of 3
days burn-in period. The burn-in time shall start after the system in fully assembled
condition is powered up and shall include any such time for which the system has been
kept powered even for system generation.

Following tests shall be performed by the vendor and report shall be forwarded to the
owner/consultant.
Quality control tests shall be carried out to assure quality of all components and
modules in accordance with vendors quality control and assurance procedures.
Vendor shall forward the details of these procedures for owner/consultants review.
System pretest which shall be physical check of all subsystem components ,
modules and racks.
System Power-up test which shall functionally check the systems hardware and
software including diagnostic software at sub-system level by stimulating the inputs.

5.2.7.2 Second phase of test shall systematically, fully and functionally test all the hardware and
software in the presence of purchaser representative. All the systems shall be inter

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


purchased item shall also be connected to the system. Barrier cabinets shall be used as
the connecting points for test inputs and outputs.

The duration of the testing shall be mentioned by the vendor with reasons. System shall
be shipped to site only after this testing and certified ready for shipment by
owner/consultant.

Following steps will be carried out


Data review : Owner/consultant shall perform a comparison of all current data. Any
revision or changes required shall be informed to the vendor. The test reports
forwarded by vendor after first phase testing shall be reviewed. Owner/Consultant
has right to witness any test performed in first phase, if deemed necessary.

Visual and mechanical testing : Visual and mechanical testing shall be carried out in
principle to assure correct, proper, good and neat workmanship by the vendor.

Functional testing shall include the simulation of each input and output to verify
proper system response for both analog and discrete signals. The testing, as a
minimum, shall include the following:-

 Complete system configuration loading

 Demonstration of all Processor functions from local as well as from central


level e.g. changing of running constants, loop tuning, checking of algorithm
functions changing algorithms, changing Processor mode, changing
Processor action etc.

 Checking of scan time values

 Checking of loop configuration for correctness with respect to ranges, limits,


alarm points, engineering units etc.

 Checking of all types of TFT displays including process and system displays
on operator Engineering and PLC consoles.

 Checking of correct functioning of key-board operation for operator and


Engineering console.

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


units in case of main units failure. This shall be carried out for processors ,
power supplies , communication bus and any other redundancy specified.

 Checking of Processor loading

 System diagnostics check for all sub-systems on local level as well as on


operator/engineering console. These shall include failure of a sub-system,
module, power supply, interface unit, failure of transfer to redundant module
on main module failure etc. and other detailed diagnostic displays. Diagnostic
alarms for any ventilation fan failure shall also be checked.

 Testing of proper functioning of all printers and hard copy units.

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 Testing of system features like interchangeability between consoles,


synchronisation of system clocks, selective running from Engineering
console, key-lock functions etc.

 Checking of various log formats, shut down reports, I/O mapping and other
MIS formats printing.

 Checking of shutdown and interlock configuration and proper operation


thoroughly.

 Proper system operation at power supply specifications specified in the


Material Requisition.

 Checking of proper operation of all interfaces with the system like interface
with PLC, computer, analyser system etc. as specified in Material Requisition.

 Checking of bus-degradation while loading the bus from 10% to 100%

 Simulation of power failure and restarts.

 Checking of all hardwired instrumentation including all alarm cards, alarm


annunciator system, switches and other indicating instruments.

5.2.7.3 Testing record

Each test carried out during second phase shall be recorded. Any deficiency or
problem shall be clearly brought-out and shall be corrected.
Any change in the data or configuration etc. informed to the vendor shall be
recorded and carried out by the vendor.

5.2.7.4 The vendor shall notify the owner/consultant at least three weeks prior to final system
testing. In the event that representatives arrive and the system is not ready for testing,
the vendor will be liable for back charges for any extra time and expenses incurred.

6.0 INSTALLATION, TESTING AND COMMISSIONING

6.1 Vendor shall offer the services of the installation team which would install the equipment
in the control room, lay the interconnecting cabling inside the control room, check out,
test and commission the system.

6.2 Vendors responsibility at site shall include all activities necessary to be performed to
complete the job including:
Receipt of hardware/software and checking of completeness of supplies.
Installation of the system including free supply equipment & interconnection
cabling
Check out of the equipment installation.
Checking of interconnection, hardware and software configuration, overall
system functioning etc.
Loop checking
Commissioning and on-line debugging of the system.
Performance of final acceptance test & Assistance in plant commissioning.

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6.3 Exclusion from DCS vendors responsibility shall include the following:
All civil works in the control room including false flooring, control room lighting
and air conditioning ducting.
Laying and identification & termination of field cables ( in marshalling racks )
Field instrument installation and calibration

6.4 All equipments shall be inspected thoroughly by vendor after its receipt at site for
completeness and proper functioning. Vendor must initiate the remedial action in case
unsatisfactory operation of any equipment or item is observed during this testing with an
intimation to Engineer-in-charge.Vendor must document all observations including details
of malfunctions observed, if any. Items/equipments requiring total replacements must
document reasons for the same.

6.5 Vendor shall arrange all necessary tools & equipments like welding machine etc , for
erection of cabinets / consoles , cable laying , glanding & termination.

6.6 All cabinet / consoles shall be installed on separate base frames independent of the false
flooring. Adequate care shall be take during movement of the equipments on false
flooring to prevent it from being damaged. Proper leveling shall be ensured by vendor
and demonstrated to Owner / Consultant. Any minor civil works required for installation
shall be done by Vendor.

6.7 All erection hardware and consumables like nuts & bolts , primers , paints , cable glands,
grommets etc shall be supplied by vendor.

6.8 Labeling & cable identification

6.8.1 All labeling shall use an identification system that is directly interpretable without requiring
reference to additional documentation. Vendor shall provide details of labeling protocol
for approval before implementation.

6.8.2 All labeling shall be with prime reference to the node or stating software address. Any
other hardware reference should be included on all cabinet labels , by using small size
characters.

6.8.3 All cabinets / racks / enclosures shall be labeled in front and rear for easy identification.

6.8.4 All internal & intercabinet wiring shall be ferruled with permanent markers bearing
identifications that can be cross referenced with appropriate documentation. Colored
ferrules shall be used with proper coding philosophy.Tagplate shall be provided for the
cable no. identification on the top of the related terminal strip in the marshalling cabinet.

6.8.5 System cables shall be uniquely labeled at both ends with reference to source and
destination component address.

6.8.6 All cabinet , console , rack , terminal etc labels shall be engraved plastic laminate ( white
background with black lettering ) fixed with self tapping screws.

6.9 Loop checking

6.9.1 Vendor shall be responsible for loop checking which shall also include checking of the
interconnection, at control room end, configuration and ensuring over all system
functioning.

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6.9.2 Calibration and installation of field instruments, installation of junction boxes,


interconnection between instruments and junction boxes, laying of single, multi pair
cables upto control room, tagging all field cables, performing continuity/insulation test of
cable, core identification of field cables etc. shall not be in the vendor scope. This work
shall be carried out by the field contractor.

6.9.3 Vendors scope of work, as a part of system installation and loop checking shall include
checking termination of all field cables in control room, checking of interconnection
between instrument / equipment, ferruling and tagging of interconnecting cables in
control room, ferruling of field cables in control room and performing overall loop
performance check.

6.9.4 Loop checking shall be carried out to check the functional performance of all elements
comprising the loop and thereby ensuring proper configuration, functioning and
interconnection.

6.9.5 Vendor shall coordinate with the field contractor for smooth and proper loop checking.
Any discrepancy found during checking shall be brought to the notice of Engineer-in-
Charge. Complete loop checking shall be performed in the presence of the Engineer-in
Charge or his authorised representative. All reading shall be recorded on a suitable
format which shall be handed over to the vendor by the field contractor after completing
calibration record of each field device. On the completion of loop checking, remaining
information related to loop checking shall be filled by the vendor. Completely filled format
duly signed shall be submitted for approval, to Engineer-in Charge.

6.9.6 All the components of the loop shall be checked for proper functioning. All field
instruments connected to control room shall be loop checked at 0%, 50% and 100% of
FS (for both increasing and decreasing signals). The input signals shall be simulated
using various simulator and applied from field after disconnecting the field cable
connection.

6.9.7 Receiver alarm cards shall be checked by the vendor for different setting on both
increasing and decreasing signals. Shutdown schemes shall be checked for proper
functioning, configuration and actuation.

6.9.8 Performance of individual loops may be accepted for an overall accuracy of + 1.0%
unless otherwise specified. Where deviation exists, recalibration of instruments, based
on the scope of work, shall be carried out either by field contractor or by vendor.

6.9.9 Signal from Processors/shutdown schemes to control valves/shutdown valves shall be


checked at the respective valves. The stroke checking including checking of time of
operation of control valves/shutdown valves also forms a part of loop checking. Vendor
shall coordinate this activity with field contractor and record the same in the loop
checking format.

6.9.10 For the loop checking of loops connected to substation, vendor shall be responsible to
coordinate with the Electrical Contractor.

6.9.11 After loop checking is completed, vendor shall connect back any terminals and
connections removed for loop checking.

6.10 Site Acceptance Test (SAT)

6.10.1 The purchaser shall provisionally takeover the system from vendor after site acceptance
test. SIte acceptance test shall be started only after the satisfactory performance of loop
checking and verification of records by Engineer-in-charge.

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6.10.2 The site acceptance test shall be carried out in the presence of purchasers
representative and Engineer-in-charge or his authorised representative.

6.10.3 Vendor shall carry out the following functional tests, as a part of site acceptance test as a
minimum :-
Hardware verification as per final bill of material.
Visual and mechanical check-up for proper workmanship, identification, ferruling,
nameplates etc.
System configuration as per approved configuration diagram.
Demonstration of all system diagnostics.
Checking of correct change-over of redundant devices
Checking of proper functioning of all disc drives, alarm summary, printers etc.

6.11 Performance Test

The owner shall take over the system after satisfactory full functional performance test
for a period of 3 weeks.
During above period, any malfunctioning of the system components shall be replaced /
repaired as required free of cost. Once the system failure is detected, the acceptance
test shall start all over again from the beginning. The warranty period commences from
the day owner takes over the system.

6.12 Testing/Calibration Equipments

6.12.1 Vendor shall make available all consumable, instruments and equipments necessary for
testing, calibration, maintenance etc. as required by the defined scope of works. All
instruments and equipments used for the above purpose shall be of standard make with
accuracy better than the accuracy expected from the calibrated/tested instruments, and
certified by National Physical Laboratory or other equivalent agencies. These
instruments/equipments are necessary only during testing/calibration/maintenance

6.12.2 Vendor shall arrange for adequate number of test equipments like meggers , multimeters
, CROs , 2-wire transmitter simulators , thermocouple / RTD simulators etc as required.
Also test equipment of adequate specifications to monitor main system power supply
from UPS shall be arranged by vendor to establish power quality before system is
powered ON.

7.0 PROJECT MANAGEMENT

The vendor shall appoint a project team headed by Project manager dedicated to this
contract for complete duration of the project. The appointment shall be subjected to
Owner / Consultants approval.Project manager shall submit Monthly progress report
indicating progress and delays together with an up to date schedule. Monthly progress
meetings shall be held with Owner / Consultant to review progress , further execution
plan , activity schedule etc. Venue shall be decided mutually at Owner / Consultants
office or Vendors office.The Owner / Consultant shall have right to call the meeting if
deemed necessary.

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8.0 TRAINING

8.1 Vendor shall include for training of the engineering /operation/maintenance staff. The
training shall include but will not be limited to the following in general.
The different hardware components to be supplied by the Bidder.
Software training
Maintenance training on the individual instrument being supplied.
Training on the operation of the entire systems as per functional requirement.

Details of training plan for all categories will be decided mutually at a later date.

8.2 Site training facility and training kit

The training kit shall essentially be used for refresher and training courses for process
engineers, operating and instrument maintenance staff. The training kit shall be simple
control system with process simulator for a group of loops and shall include:
An operator console with an operator key board and engineering keyboard.
Processor with auto backup facility
One each of the varieties of modules used in data acquisition.
Signal simulator
All necessary software & hardware to interface with plant DCS

Vendor to provide the details of the kit offered alongwith the proposal.

Training kit system shall be stand alone with respect to hardware and software and in no
way be lined with the main system.

9.0 DOCUMENTATION

9.1 ENGINEERING DRAWINGS

9.1.1 The vendor shall provide a complete set of drawings covering each part of the supply for
the owner/consultant record. The vendor shall include owners project number on each
of his drawings in order to ease owner/consultants record keeping.

9.1.2 As a minimum following engineering drawings shall be prepared by vendor and


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

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


comments until it is approved

9.1.3 One set of documentation shall be used exclusively for the purpose of marking all the
modifications done during erection and commissioning .All field modifications shall be
carefully recorded by the vendors commissioning personnel and countersigned by
Owner / Consultant. All such changes shall be incorporated into final set of drawings
called as AS-BUILT documentation

Vendor shall furnish all the manuals necessary to test, operate and maintain Distributed
Control System hardware and software.

9.2 HARDWARE DOCUMENTATION

The following documentation for all hardware supplied and as built under this contract
shall be submitted for review two months before the start of factory acceptance testing.

The specifications for all off-the-shelf hardware manufactured by vendor, his sub-
contractors or suppliers. Suppliers name and identification of ordered hardware and
expected delivery data to vendors premises shall also be supplied alongwith this.

Documentation relating to off-the-shelf hard ware and hardware developed by vendor


including description, specifications, theory of operation, maintenance procedures,
installation information and drawings. This information shall exclude all non-
applicable information.

Where more than one size, rating or type of construction appears on the submitted
catalogue data, those characteristics applicable shall be identified. Non applicable
information shall be suppressed.

Test plans and test reports for each item of hardware, to be supplied.

Bill of material listing all hardware to be supplied including manufacturers part


numbers, name plates data, approximate volume, weight and overall dimensions.

Spare parts catalogue for all items (at component level) to be supplied.

Recommended spare parts for two years.

9.3 SOFTWARE DOCUMENTATION

The following documents shall be submitted for review before 90 days of the shipment of
the system, for the software packages included in the supply:

The specifications for all software to be obtained in house or from subcontractors or


suppliers. The details supplied shall also include the name of the suppliers, software
identification including latest modification data.

Reference manuals, operating manuals, programming manuals and other software


manuals (if any).

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

Input and output details for each program.


Listing of assembled programs with label and symbol tables in assembler/compiler
language.

9.4 SYSTEM MANUALS

Manuals shall be submitted for assuring satisfactory operation and maintenance of the
system. Detailed literature for installation and maintenance of all hardware should be
provided to the owner.

9.4.1 Instruction Manual

Following information shall be provided as a minimum :

A general functional description of the whole system


General software description
General instructions and start up procedures
System software details including its interaction with application programs and other
programs used as supporting software.

9.4.2 Maintenance manuals

9.4.2.1 The maintenance manual shall include details of


Preventive maintenance procedures
Trouble shooting procedures including failure analysis

9.4.2.2 A section on repairs shall provide enough information on repairs including removal,
repairs, adjustment and replacement.

9.4.2.3 The maintenance manuals shall contain a list of all maintenance parts to facilitate quick
identification of the parts for replacement and ordering. Standard hardware structural
parts, or other parts not requiring maintenance shall not be included here. At the end of
the list of parts requiring maintenance, a list of special tools required for the maintenance
of each unit shall be given. List of manufacturers of each part shall also be included.

9.4.3 The final system manuals shall be furnished to owner within a month of completion of
final satisfactory field testing. All field modifications shall be incorporated and system as
built drawings and documents shall be included.

10.0 WARRANTY

10.1 Vendor shall be fully responsible for the manufacture in respect of proper design, quality,
workmanship and operation of all the equipment, accessories etc. supplied by the
vendor. Warranty shall be for 36 months from the date of successful completion of SAT
(Site Acceptance Test). Warranty shall be inclusive of all systems supplied by DCS
vendor inclusive of bought out items like bulk power supply, barriers, UPS (if supplied),
PCs etc.

10.2 It shall be obligatory on the part of vendor to modify and/or replace any hardware and
modify the operating, application and diagnostic software free of cost, in case any

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malfunction is revealed even during on line operation after taking over within the warranty
period.

10.3 Vendor shall also provide the total maintenance of the system during warranty period.
The cost for warranty maintenance, if any, shall be included in the proposal separately in
vendor proposal outline and pricing details.

10.4 Any version updating, release of software during the warranty period shall be done free
of cost to the Owner by DCS vendor.

11.0 MAINTENANCE CONTRACT

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

12.0 SHIPPING

12.1 All the material used for packing, wrapping, sealers, moisture resistant barriers and
corrosion preventers shall be of recognised brands and shall conform to the best
standards in the areas for the articles which are packaged.

12.2 Workmanship shall be in accordance with best commercial practice with the requirement
of applicable specifications. There shall be no defects, imperfections or omissions which
would tend to impair the protection offered by the package as a whole.

12.3 The package shall be suitable for storing in tropicalised climate, the ambient conditions
being specified in the job specifications.

12.4 Shipment shall be thoroughly checked for completeness before final packing and
shipment.

13.0 REJECTION

Vendor shall make his offer in detail with respect to every item of the purchasers
specifications. Any offer not conforming to this shall be summarily rejected.

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Page 1 of 19

SPECIFICATION NO: 44NC-4600-0000/J.SS/0103/A4

TITLE: STANDARD SPECIFICATION FOR PROGRAMMABLE


LOGIC CONTROLLER

PROJECT REFERENCE:

- Project No: 44NC-4600

- Project Location: Manali, Chennai

- Project Title: RESID UPGRADATION PROJECT

- Client: Chennai Petroleum Corporation Limited

- Project Manager Authorization: B.B. DARAK Date:

- Client Authorization: Date:

APPROVALS
Rev. Issue Pages Revision Description By Check Approve
No. Date

0 12- Mar-10 19 Issued For Feed ADM MSD BSP


 Entire Specification SPECIFICATION ISSUED FOR:
Issued this Revision  In-house Review  Purchase
 Revised Pages Only  Client Approval  Construction
Issued this Revision  Enquiry  Engineering

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TABLE OF CONTENTS

1.0 GENERAL

1.1 SCOPE
1.2 BIDS
1.3 DRAWINGS AND DATA

2.0 DESIGN AND CONSTRUCTION

3.0 TESTING AND ACCEPTANCE

3.1 GENERAL
3.2 FACTORY ACCEPTANCE TEST (FAT)
3.3 INSTALLATION, TESTING AND COMMISSIONING
3.4 FIELD INSPECTION
3.5 LOOP CHECKING
3.6 SITE ACCEPTANCE TEST (SAT)
3.7 PERFORMANCE TEST

4.0 GENERAL REQUIREMENTS

5.0 SHIPPING

6.0 REJECTION

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1.0 GENERAL

1.1 SCOPE

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

1.1.2 The related standards referred to herein and mentioned below shall be of the latest
editions at the time of purchasers enquiry.

ISA-S 71.04 Environmental Conditions for Process Measurement and Control


System. Airborne Contaminants

1.1.3 The detailed scope of work, specific job requirements, exclusions, deviations, additions
etc shall be indicated in the material requisition and job specification.

1.1.4 Where any conflict exists between this specification and other job specification, the
purchaser shall be consulted. Vendor shall not deviate from this specification without
prior approval from the purchaser.

1.2 BIDS

1.2.1 Vendors quotation shall enumerate and include the detailed specifications of each
subsystem and each module of programmable logic controller, detailed system
configuration, hardware and software capabilities, programming aids, display facilities
and other relevant information.

1.2.2 Vendor shall furnish a detailed list of deviations / confirmations clause-wise described in
this specification. Vendor must provide enough supportive reasons for the deviations
listed.

1.2.3 Vendors quotation shall include catalogues, drawings, technical specification sheets,
operating and maintenance manuals, performance evaluation certificates etc. All
documents shall be in English language only.

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1.2.4 Vendor shall also supply the following items.


Mandatory spares as indicated elsewhere in this specification.
Spare parts for start-up, commissioning and two (2) years trouble free operation
Consumables for six (6) months such as printer ink cartridges etc.
Special tools and test equipments.

1.3 DRAWINGS AND DATA

1.3.1 After placement of purchase order, vendor shall submit certified drawings and
specification sheet for each instrument and its accessories which shall include the
following, as a minimum :
Configuration diagram
Detailed dimensional drawings of internal components
Power consumption in volt-amperes
GA (General Arrangement) drawings
Rack layout including physical I/O module locations.
Logic / Ladder diagrams
Input / Output (I/O) assignments
Power supply distribution drawings
Heat Dissipation figures for all components
Functional Design Specification ( Hardware and Software )
FAT / SAT procedures
Wiring drawings for system cabinet & marshalling racks.
I/O mapping with DCS including MODBUS address.

1.3.2 The required number of reproducible and prints should be dispatched to the address
mentioned adhering to the time limits indicated.

2.0 DESIGN AND CONSTRUCTION

2.1 Programmable Logic Controller (PLC) shall be microprocessor based system which shall
be used for implementation of plant safety shutdown/interlocks, and plant operation
wherever specified in job specification. For critical applications, as highlighted in the
engineering design basis and job specification, the PLCs shall be TMR / QMR (Triple
modular redundant / Quadruple modular redundant) type certified to TUV Class AK5 as a
minimum. For other applications, the PLC shall be with dual processor and dual I/O
certified to TUV Class AK5 as a minimum. The PLC shall incorporate open system
architecture, redundant processing systems and mass storage devices.

2.2 The system shall be designed fault avoidant, as a minimum, by selecting high grade
components of proven quality and proper design of system electronics. Redundancy shall
be provided as a minimum, as per this specification to improve system availability and
reliability. Due consideration shall be given to the environmental conditions particularly for
field mounted subsystems, if specified in the job specification.
0 0
2.3 The system shall be able to operate satisfactorily from 15 C to 40 C and 0 ~ 95% non
condensing humidity range unless otherwise specified. Wherever required, the
components shall be tropicalised to suit Indian conditions

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2.4 The system shall be modular in construction and expandable in future by adding
additional modules which shall be easily accessible for maintenance and repair. The
modules shall preferably be suitable for inserting in 19 rack. The types of modules shall
be kept to minimum possible in order to have interchangeability and low spares
inventory.

2.5 The system shall be highly reliable and shall have well proven record of operating
satisfactorily in a hydrocarbon processing plant for a minimum of one year for a similar
application. Prototype system or instruments of experimental nature shall not be offered.

2.6 The PLC shall have a very high noise immunity in order to ensure safe and reliable
operation when subjected to electrical radio frequency interference and electro-magnetic
disturbances expected in a plant. The surge withstand capacity for input / output modules
shall be as per IEEE Standard 472.

2.7 The system shall be programmed in principle as per the logic diagrams enclosed with the
job specifications. However vendor shall prepare their own logic / ladder diagrams
depending upon the capability of the programmable logic controller offered by them.
Purchaser reserves the right to revise or review the logic diagram even after acceptance
of the offer.

2.8 The system shall have extensive set of self diagnostics hardware and software for easy
and fast maintenance of PLC. Routine checks should run automatically at frequent
intervals for identifying any fault in software or hardware. Diagnostics shall be required at
local as well as console level. Diagnostics shall be available upto the channel.

2.9 Pop up menu to be configured in DCS operator workstation to capture any degradation
of PLC.

2.10 Rack to rack connectivity shall be separate for separate legs of the QMR PLC

2.11 Separate power supply units shall be provided for individual I/O (input-output) rack and
processor unless otherwise specified in the job specifications. Suitable battery back-up
shall be provided to protect volatile memory. Redundant power supply distribution shall
be such that redundancy is maintained at all modules and even up to the channels for
field termination unit.

2.12 Operation of the PLC shall be completely unaffected by the momentary power loss of the
order of 20 milliseconds, unless otherwise specified. This feature shall be demonstrated
during FAT.

2.13 The scan time of programmable controller shall be of the order of 100 milliseconds
including spare I/O channels. Scan time of PLC is defined as the cycle time taken by the
system to read input, process input executing logic and update control output for all the
logics configured within the system. Other activities like diagnostics routines, output /
dump of data to peripherals, or any other activity which consume processor time shall
also be accounted while computing scan time.

In case any plant unit requires faster scan time, the same may be adopted for that
application.

2.14 Isolation shall be provided between programming panel and related subsystem if there is
any possibility of high voltage from 20.1 TFT being transmitted to other subsystems.

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2.15 On-line replacement of any module shall be possible in such a way that the removal and
addition of the module shall be possible without de-energizing the system. Further there
shall not be any interruption in the system while replacing a faulty module except for the
inputs / outputs which are being handled by that module. System degradation of any kind
is not acceptable.

2.16 Spares philosophy

2.16.1 Installed engineering spare modules of 20% shall be provided in input/output subsystem
for each type of module with a minimum of one module of each type to enhance the
system functional requirements. All installed spare shall be fully wired upto field
termination level.

2.16.2 In addition the system shall have the following minimum spare capability :
I/O racks of PLC shall have 10% usable spare slots for installing I/O modules of each
type in future. These racks shall be part of the offer.
The processor system shall have the capability to execute logics for additional I/Os
as per 2.16.1 and 2.16.2. In addition it shall be possible to extend memory by
additional 20% at a later stage.
Power supply modules shall be capable to take load of the spares as outlined above.
The PLC console shall have capacity to meet all requirements for the additional input
/ outputs as outlined above.
Whenever relays are used to interface process input / outputs with PLC, 20%
additional relays shall be provided. In addition, 20% spare space shall be provided in
cabinets to install 20% additional relays in future.

Vendor shall design all systems / racks based on the above. Additional terminals shall be
provided to enable termination of above spare I/Os and also to terminate spare cores of
existing multipair cables. This shall be adhered to under all circumstances.

2.16.3 Wherever possible, all equipment shall be standardized to ensure commonality of


spares, minimal training and greater economies as far as maintenance and additional
procurement is concerned

2.17 Paper, ribbon, printer heads and ink required for printer, copier, or any other consumable
item shall be supplied with the system required for minimum of six (6) months duration
after SAT. Any consumables required for system development, testing and
commissioning shall be provided by vendor and not included in the 6 month consumable
supply.

2.18 Safety barriers shall be provided by the vendor for intrinsically safe input/output circuits
wherever specified. In such cases, the system shall be designed intrinsically safe based
on entity concept. The barriers shall be certified by a statutory authority like BASEEFA,
CENELEC, FM, PTB, CMRI etc for the use in the area classification as specified
elsewhere in the job specification. The proper selection of the safety barriers shall
be the vendors total responsibility. The safety barriers shall not be zener type barriers.

2.19 No single mode failure shall affect the system whenever redundant system configuration
is specified.

2.20 Unless otherwise specified all electronic modules shall meet the requirements of
Environmental classification class G3 as per ISA-S 71.04

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2.21 The system as offered shall meet the requirement of Y2K compliance without any
modification, addition or replacement of any system hardware and software.

2.22 System configuration

Basic system configuration shall be as per the job specifications. However the system
shall consist of the following major subsystems :

2.22.1 Input / Output Subsystem

2.22.1.1 I/O devices interface with PLC shall be at I/O racks only. The I/O modules shall be
mounted in the I/O racks.

2.22.1.2 The maximum number of input / outputs per module shall be limited as follows :-

Sr. No. Type of Configuration No. of I/Os


1 DI 32
2 DO 16
3 AI 16

2.22.1.3 Each I/O shall be protected against reversal of polarity of the signal.

2.22.1.4 Each module shall have LED for each I/O channel to indicate the status of each input /
output.

2.22.1.5 Each input shall be provided with filters to filter out any noise in the input line or noise
because of input contact bouncing.

2.22.1.6 PLC inputs shall be provided with potential free/dry contacts unless otherwise specified.

2.22.1.7 The interrogation voltage to the input / output contact shall be powered from separate
power supply / supplies and shall not be a part of PLC unless otherwise specified. This
power supply shall be supplied at one point and shall be distributed by the vendor.

2.22.1.8 In case of triple / quadruple redundant system, if standard system architecture does not
allow for triplicate / quadruplicate signal conditioning circuits per I/O, then signals shall be
externally multiplied before connecting to I/O modules.

2.22.1.9 Output contacts from the PLC shall be potential free/dry contacts. Wet contacts /
powered contacts / TTL outputs etc. shall not be acceptable. Vendor must provide arc
suppression device for each output contact.

2.22.1.10 All output cards shall have output contact rating of 24 VDC 2 Amp inductive to drive
solenoid valves, MCC controls though interposing relays. Each output shall be short-
circuit proof and protected by fuse. Visual indication of fuse down must be provided for
each output.

2.22.1.11 PLC I/O cards shall have facility to detect wire open condition whenever normally open
inputs ( close on alarms ) are considered.

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2.22.1.12 In addition to digital input / output, PLC shall be able to cater for following types of I/Os
- Analog inputs:- 4-20 mA , 1-5 V DC , 0-10 V DC.
- Analog outputs:- 4-20 mA , 1-5 V DC , 0-10 V DC.

All I/O circuits shall be provided with galvanic isolation or optical isolation using isolation
barriers.

2.22.1.13 In case of triple / quadruple redundant system hot replacement of I/O modules shall be
provided. Additional slots must be provided in the I/O nest for hot replacement of these
modules. No output shall be affected while replacing these modules in either case. For all
modules, channel to channel isolation shall be provided.

2.22.1.14 All I/O cards shall have facility for sequential time stamping with 1 milisecond resolution.

2.22.1.15 Fail-safe DO cards shall have built-in SMOD (secondary means of De-energization), this
enables the watchdog and/or processor to de-energize the outputs in case of internal
fault.

2.22.2 Processor System

2.22.2.1 The processor system shall be TMR / QMR architecture. The processor shall have
capability to implement all the control functions required to implement the logic schemes
attached with the job specifications as Logic / Ladder diagram

2.22.2.2 The size of the memory shall be sufficient for storage of the program instruction required
by the logic schemes. Offer shall indicate the amount of memory occupied by the actual
program and spare capacity available for later program modifications or additions. A
minimum of 50% spare memory space shall be provided at the time of handover of the
system to Client

2.22.2.3 Memory shall be non-volatile. However, in case volatile memory is provided, battery
backup shall be provided for a minimum of 1 year to keep the stored program
intact. A battery drain indication shall be provided at least one week before the battery
gets drained. A potential free contact shall be provided for hardwired annunciation in the
control room.

2.22.2.4 Watchdog timer shall be a software device. The healthiness of processors shall be
continuously monitored by watchdog timer. Any hardware or software problem in the
processor subsystem including CPU, memory, power supply, communication interface
etc shall cause the watchdog timer to report processor failure.

2.22.2.5 Whenever dual processor is specified, redundancy shall be provided such that in case of
failure of the main processor, the standby processor shall take-over automatically. The
changeover shall be bumpless. Redundancy shall be provided for complete processor
subsystem including CPU, memory and power supply.

2.22.2.6 In case of triple redundant system all the three processors shall execute the same
instructions / programs and check their results and majority vote to correct any faulty
result. The faulty processor diagnostic shall be made available. Failure of a single
channel shall not affect the system. In case of quadruple modular redundant system, all
the 4 processors shall execute the same instructions / programs. The faulty processor

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diagnostic shall be made available. Failure of a single quad channel shall not affect the
system. In case multiprocessor configuration is offered, the processor must be able to
communicate with each other over the interconnecting data link. Vendor shall ensure that
system performance shall not degrade when such system is offered..

2.22.2.7 In case of failure of complete processor system i.e. both processors in case of dual
configuration and two or more in case triple / quadruple redundant system outputs
shall take fail safe state automatically unless otherwise specified in the job
specification.

2.22.2.8 In case multiprocessor configuration is offered, the processors must be able to


communicate with each other over the interconnecting data link. Vendor shall ensure that
system performance shall not degrade when such system is offered.

2.22.2.9 It shall be possible to generate the first out alarm by PLC in case where a group of
parameters are likely to trip the system.

2.22.2.10 TMR PLC functional configuration shall be 3-2-0 and for QMR PLC shall be 4-2-0.

2.22.3 PLC CONSOLE .

2.22.3.1 The PLC console shall be used for program storage, fault diagnostics and alarm
monitoring. It shall also be possible to use this for plant operation whenever specified.
For programming, a separate laptop shall be provided. It shall also be possible to have
the programming funtionality in the PC and all functionality of the PC on laptop by using
suitable passwords
2.22.3.2 The PC consists of a 19 colour monitor unless otherwise specified, one programming
keyboard, and operating keyboard whenever specified. The programming consoles shall
have latest hardware, operating system and windows based graphics user interface
(GUI). It shall include Ethernet connectivity, DVD compatible CD-RW drive, floppy drive,
SCSI port, 32 bit CPU with 600 MHz system clock, 128 MB RAM expandable to 256 MB
as a minimum.

2.22.3.3 PLC console when used for plant operation shall be supplied with dedicated operator
keyboard with a set of user configurable / assignable function keys. Even when touch-
screen is specified, the console in addition shall be supplied with operator keyboard
which shall have the same capability as the touch-screen as a minimum.

2.22.3.4 The keyboard shall preferably be touch sensitive sealed type easy to operate with each
key clearly identified. It shall be provided with a lock and key to prevent any unintentional
program modification. Key sequences shall be as short as practicable and the keyboard
layout shall be arranged so that the general flow of keying sequences shall be from left to
right, where practicable, major functions shall be accessed using a single key stroke.

2.22.3.5 All illegal entries shall be rejected by console and shall be identified by warning signal on
20.1 TFT.

2.22.3.6 Manual operation / forcing of any element connected to PLC shall be possible from
keyboard.

2.22.3.7 It shall be possible to modify, add or delete the application program on-line with
password protected access. System should have capability of logging the engineering
changes made along with detail of activities, user name and time stamp.

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2.22.3.8 PLC console 20.1 TFT shall display logic and / or ladder diagram indicating power flow
and shall show description and real time status of each contact. It shall also be possible
to display process alarms and diagnostic message as and when they appear. Further it
shall also be able to display I/O map in a user defined format.

2.22.3.9 Whenever PLC console is used for the operation of the plant, it shall be able to display
process, dynamic graphics, overview and group displays, real time and historical trends.
It shall be able to operate the plant i.e. start and stop rotating machinery, opening and
closing of valves etc from dynamic graphics and group displays. All such displays shall
be user configurable.

2.22.3.10 It shall be possible to print the ladder / logic diagram on the PLC printer. In addition,
printer shall also be able to print the following :
Diagnostic messages as and when they appear
Diagnostic reports on demand
Processor alarms related to PLC as and when they appear and alarm report
whenever initiated
Shutdown report as and when initiated
I/O map showing status of all inputs and corresponding outputs in a user defined
format
Screen print

2.22.3.11 The printer softwares for all printers shall be loaded in all operator consoles so that any
printer may be selected at any given time by any console. The log and alarm printers
shall be A3 132 column type with reliable paper feed mechanism for paper handling.
Screen displays shall be sent to any of the laser printers. The laser printers shall be
capable of printing 15 pages a minute and shall support paper sizes upto A3. Sufficient
memory shall be provided to support full page graphics printing.

2.22.3.12 In addition to self-diagnostic alarms, PLC console shall be provided with a common fault
alarm with potential free contact which shall be connected to the hardwired annunciator.
PLC self diagnostic alarms shall be mapped to DCS for alarming.

2.22.3.13 In addition a service unit or hand-held programming unit for trouble shooting and initial
check-ups from local level shall be quoted separately.

2.22.3.14 Where multiple process units are connected to the same PLC, a common workstation
shall be provided. These workstations shall display unit database for all units.

2.22.3.15 The operator stations shall have password access to various levels ranging from
operators, supervisors to engineering personnel.

2.22.4 Communication subsystem

2.22.4.1 The communication subsystem shall consist of communication processor with


communication ports / adaptors and cables for communication with processor and I/O sub-
systems.

2.22.4.2 Communication system shall be redundant.

2.22.4.3 In case of redundant communication subsystem, on the failure of the device, the
redundant device shall take-over automatically without interrupting the system operation.
Information about the failed device shall be displayed locally as well as on the PLC

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console. It shall be possible to manually switch-over the communication from main


bus/device to redundant bus/device without interrupting the PLC functions.

2.22.4.4 The mechanism used by the system for error check and control shall be transparent to
the application / information / programme. Error checking shall be done on all data
transfers by suitable codes.

2.22.4.5 The total load on any of the communication buses at any point of time shall not exceed
50%.

2.22.5 System power supplies

2.22.5.1 Programmable logic controller shall operate on uninterrupted power supply with following
specifications
Voltage 110 V + 10%
Frequency 50 Hz + 3%

2.22.5.2 Power supplies in the system shall be provided as follows :-


Each I/O rack shall be provided with separate power supply unless otherwise
specified in job specifications. Each power supply shall be sized to take full load of
the I/O rack. In case of triple / quadruple redundant system, each I/O rack signal
conditioning panel shall be provided with dual redundant power supply.
Processor subsystem shall be provided with separate power supply as a minimum
unless otherwise specified in job specifications. Failure of power supply for one
processor shall not affect the system operation / processor switchover.
In normal operation, the redundant power supply shall share the load. In case of
failure of one module the other power supply shall take the full load. Power supply
shall be sized taking into account the spare I/Os into account. Failure of power
supply module shall be alarmed to DCS through mapping from PLC

2.22.5.3 All power feeders shall be with an individual circuit breakers / Isolator and power on
indicator. All power supply bus bars and terminals shall have suitable removable insulating
covers. All power supply feeders shall be protected by robust transient suppression devices
within each cubicle or enclosure. Where the same PLC is used for multiple units, vendor
shall offer a facility wherein sequential unit wise power on can be carried out and overload
tripping circuits are arranged in such a manner to offer unit wise shutdown of the plant in
case of main power failure.

2.22.6 System loading

2.22.6.1 The contractor shall submit calculations and basis to determine the ability of equipment and
architecture of the system to meet all the requirements in this specification and at the same
time observe the maximum loadings defined in this para. Loading here refers to the use of
memory. CPU time and communication capacity. The loading shall consider the worst
case of high system activity. During this case, no degradation of system performance is
allowed. Maximum loadings on various sub-systems shall be as indicated in engineering
design basis.

2.23 Self diagnostic

2.23.1. The system shall have an extensive set of self-diagnostic routines which shall be able to
identify and provide information on the system failures upto channel level including

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redundant components and power supplies through detailed display pages and report print
outs.

2.23.2. At the local level, an individual LED shall identify failure of a module in any subsystem.

2.23.3. Self-diagnostics shall be provided to detect faults (which make the contacts permanently
close or open) in the input and output modules or input and output signal conditioning
modules in case of triple / quadruple modular redundant system whenever specified in the
job specifications. This may be achieved by automatically running the testing software at
cyclic intervals. The testing software cycle may be field adjustable by engineer. However,
the system performance shall not be degraded whenever testing feature is specified.

2.23.4. Testing softwares shall be capable of detecting faults in case of normally closed system as
well as in normally open system.

2.23.5. Feedback shall be provided internally in case of triple / quadruple redundant system from the
output voting logic system to detect any latent faults of the system.

2.23.6. No internal self diagnostics shall be capable of preventing or delaying normal system
operation and system availability. The self diagnostics shall be carried out with the main
purpose of reliability and integrity as paramount aims.

2.23.6.1. The minimum requirements for system diagnostics shall be as follows :-


Analog input diagnostics Sensor out of range, open or shorted loop, analog-to-digital
converter check.
Analog output diagnostics Open or shorted loop.
Configuration diagnostics Checking the compatibility and availability of selected I/O
hardware and software.
Memory diagnostics Checksum, parity check etc.
End-to-End CPU / memory diagnostics
Processor executes a test control or arithmetic algorithm, then compares results with
pre-stored answer.
Power system diagnostics Monitor the availability of supply voltage.
For all 2 out 3 voting logics, in addition to individual and voted alarm, contractor shall
provide a maintenance alarm indicating discrepancy shown by any of inputs.
The PLC system shall be able to generate a common alarm (High Priority) for PLC
diagnostics, power supply failure, fan failure, battery life over etc.

2.24. System software

2.24.1. The system software shall include all programs for the PLC and PLC console which are
required to perform all the PLC functions including communication, self diagnostics and shall
include separate SOE software. Any software supplied shall be of the latest version with long
term support from software vendor. It shall be responsibility of vendor to ensure software
protocol compatibility for third party systems and transfer of data between the same. The
PLC console operating system shall be Windows XP or latest version available.

2.24.2. When fully tested, the configuration software shall be stored in a central point non volatile
memory. Logic program shall be recorded on the floppy disk or cassettes, tape, two copies of
which shall be delivered with the system. All databases shall be field configurable and
expandable without software redesign.

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2.24.3. The PLC programming language for implementation of logic operation shall be based on

Ladder diagrams i.e. series parallel connection of relay contacts ( LD )


Functional block diagrams ( FB )

If a single PLC is used for multiple process units, then each logic sub system shall be
suitably grouped for I/Os, logic, diagnostic with proper identification.

2.24.4. Details of the diagnostic package and its related equipment and software shall be supplied
by the vendor with the offer. A list of additional diagnostic packages available including their
description and capabilities shall be provided as a separate quote.

2.24.5. Development software for the generation of various displays including dynamic graphics
shall be provided. Where the PLC console is the sole window to the Process, it shall have
the functionality as indicated in clause number 2.22.3 above.

2.24.6. System software for the report generation for reports like hourly on demand per shift daily
and weekly report shall be provided, whenever specified in job specifications in the user
defined format.

2.24.7. All system software including operating system software, network software and any other
proprietary software supplied shall be with suitable number of Licenses valid for the next 15
years. All updates / upgrades, software patches to fix bugs shall be provided free of cost for
above period.

2.25. Power supply distribution

2.25.1. Two feeders of 110 VAC, 110 VDC and 240 VAC power supply shall be made available at
one point. Further distribution of power supply shall be in vendors scope. Also, any other
voltage level required for operation of PLC shall be derived by vendor using above power
supplies.

2.25.2. The distribution network for interrogation voltage shall be designed such that a single fault in
any branch shall not cause trip of the logic other than where the fault has occurred.

2.25.3. Power distribution network must use bus bars of adequate capacity with DPDT (Double Pole
Double Throw) switches and HRC (high rupture capacity) fuses in each branch network.
Vendor may select circuit breaker if short circuit characteristics do not match the HRC fuse.

2.25.4. All cubicles lighting shall be on 240 V 50 Hz AC normal power supply.

2.26. PLC system cabinets

2.26.1. All cabinets shall be RITTAL make.

2.26.2. All PLC system cabinets shall be completely wired with all modules in place. Inside cabinet
wiring shall preferably be done using pre-fabricated cables.

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2.26.3. All the cabinets shall be free standing, enclosed type and shall be designed for bottom entry
of cables. Cabinet structure shall be sound and rigid and shall be provided with removable
lifting lugs to permit lifting of the cabinets

2.26.4. Cabinet shall be fabricated from cold rolled steel sheets of minimum 2 mm thickness suitably
reinforced to prevent warping and buckling. Doors shall be fabricated from cold rolled steel
sheet of minimum 1.6 mm thickness. Cabinets shall be thoroughly deburred and all sharp
edges shall be grounded smooth after fabrication.

2.26.5. Cabinet finish shall include sand blasting, grinding, chemical cleaning, surface finishing by
suitable filter and two coats of high grade lacquer with wet sanding between two coats. Three
coats of paint in the cabinet colour shall be given for non-glossy high satin finish. Colour of
the cabinets shall be as per job specification.

2.26.6. Each cabinet shall be maximum 2100 mm high (excluding 100 mm channel base). 1200 mm
wide and 800 mm deep in general. Construction shall be modular preferably to accommodate
19 standard electric racks. All cabinets shall be of same height. Maximum swing out for
pivoted card racks, doors and drawers shall be limited to 800 mm.

2.26.7. Cabinets shall be equipped with front and rear access doors. Doors shall be equipped with
lockable handles and concealed hinges with pull pins for easy door removal.

2.26.8. In order to remove dissipated heat effectively from cabinets, vent louvers backed by wire
mesh screen shall be provided in cabinet doors. Each cabinet shall be with internal
temperature device and cooling fans. An alarm shall be logged on the operator console in
case of excess temperature in any of the cabinets or cooling fan failure.

2.26.9. Illumination shall be provided for all cabinet by incandescent lamps, which shall be operated
by door switch.

2.26.10. Equipment within the cabinet shall be laid out in an accessible and logically segregated
manner. Cable glands shall be provided for incoming and outgoing cables to prevent
excessive stress on the individual terminals. All metal parts of the cabinet shall be electrically
continuous and shall be provided with a common grounding lug.

2.26.11. Each I/O module shall be provided with separate terminals for individual inputs and outputs.
All inter cubicle and internal signal wiring shall be done using minimum 1.0 mm2 stranded
copper conductor, and power wiring shall be done using minimum 1.5 mm2 stranded copper
conductor. All terminals shall be suitable for minimum 2.5 mm2 cables.

2.26.12. All cabling inside each panel shall follow a common colour coding for cables. The same shall
be based on the type of signals as listed below.
Digital Input
Digital Output
Analog Input
Analog Output
110V DC power supply
110V AC power supply
230V AC power supply
24V DC power supply
Earthing (Frame)
Earthing (IS Barrier)

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2.26.13. All panels shall be segregated based on type of signals. Also, IS and Non IS signals shall be
suitably segregated.

2.26.14. All cabinets shall be uniquely identified on the basis of unit, type of I/O and serial number.
Legend plates shall be made from SS 316 plate with characters 15mm high.

2.27 system software and database back-up

2.27.1 The system shall have an automatic and on demand data protection scheme for the
preservation of all data during a planned unplanned outage. The entire control software shall
be backed up including vendor software control database, user-built programs, source code
and data files.

2.27.2 Back-up copies produced on bulk devices shall be removable for remote storage . On line
backup shall not degrade system performance.

2.27.3 To correct from an outage, any component of the system must be able to be reloaded from
bulk. The contractor shall quote the maximum time required to reload the entire system for
backup bulk storage.

2.28 Earthing

2.28.1 Each cabinet, console and other equipment supplied as a part of PLC system shall be
provided with an earthing lug. All these earthing lugs shall be properly secured to the AC
mains earthing bus

2.28.2 All circuit grounds, shields and drain wires of control cables shall be connected to the system
ground bus, which shall be electrically isolated from AC mains earthing bus. This bus shall be
typically of 25 mm wide and 6 mm thick of copper.

2.28.3 All barriers, if used shall be securely grounded. Safety barrier ground wire shall be capable of
carrying a maximum fault level current of 0.5 A at 250 V r.m.s per barrier.

3.0 TESTING AND ACCEPTANCE

3.1 GENERAL

3.1.1 On the basis of guidelines specified in this specification, vendor shall submit their own testing,
installation, commissioning and acceptance procedure. For hardware, the procedure shall
include purpose of test, test definition of input, procedure, results, expected and acceptance
criteria. For software, it shall include details of the method, list of test sequence of execution,
results expected and acceptance criteria.

3.1.2 The testing and acceptance of the system shall be carried out on the mutually agreed
procedure and criteria based on these guidelines and vendor standard procedures.

3.2 FACTORY ACCEPTANCE TEST (FAT)

3.2.1 Vendor shall demonstrate functional integrity of the system hardware and software. No
material or equipment shall be transported until all required tests have been successfully
completed and the material / equipment have been certified Ready for Shipment by
purchaser.

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3.2.2 Purchaser reserves the right to involve and satisfy himself at each and every stage of
testing. They shall be free to request specific tests on equipment considered necessary
by them, although not listed in this specification, but agreed as a part of factory
acceptance test procedure. The cost of performing all tests shall be borne by the vendor.

3.2.3 Vendor to note that acceptance of any equipment or the exemption of inspection / testing
shall in no way absolve the vendor of the responsibility for delivering the equipment
meeting all the specified requirements.

3.2.4 It shall be vendors responsibility to modify and/or replace any hardware or software if the
specified functions are not completely achieved satisfactorily during FAT.

3.2.5 Schedule of FAT shall be included in the Vendors proposal.

3.2.6 Vendor shall not replace any component / module / subsystem unless it has failed and a
log of such failures shall be maintained during FAT. If a malfunction of module /
component in a subsystem repeats, the test shall be terminated and vendor shall
replace the faulty component module. Thereafter test shall start all over again. If a
subsystem fails during FAT and is not repaired and made successfully operational within
4 hours of active repair time after the failure, the tests shall be suspended and restarted
all over again only after vendor has replaced the device into acceptable operational
condition.

3.2.7 Testing and FAT shall be carried out in two phases. The minimum requirements for
testing during these two phases shall be as follows :-

3.2.7.1 Under the first phase, vendor shall perform tests at his works to ensure that all
components function in accordance with the specification for each type of test. A test
report shall be submitted for purchaser review within two weeks of completion of this test.
All subsystem shall undergo a minimum of 30 days burn in period. Following tests shall
be performed by the vendor and reports shall be forwarded to purchaser.

Quality control test which shall be carried out to assure quality of all components and
modules. System pre-test which shall be of physical check of all modules, racks,
cabinets etc. System power-up test which shall test functionally all hardware and
software.

3.2.7.2 The second phase of testing shall systematically, fully and functionally test all hardware
and software in the presence of purchaser representatives. All subsystems shall be
interconnected to simulate, as close as possible the total integrated system. Following
minimum tests shall be carried out.

Visual and mechanical testing

High voltage and insulation testing

3.2.8 Functional testing

This shall include the simulation of each input and output to verify proper system
response. The testing as a minimum shall include :-
- Complete system configuration loading

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- Demonstration of all PLC system builder functions including additions / deletions of an


input/output, addition / deletion of a rung or an element in a rung generation of dynamic
graphics and other views, report generation etc.
- 100% checking of logics configured in the PLC by connecting switch/ lamp at input /
output.
- Checking of scan time.
- Checking of all PLC console displays, keyboard and touch-screen operation,
printer/hard copier function etc.
- System redundancy checks including correct change over of the backup unit in case of
failure of main unit.
- System diagnostic checking for all subsystems on local level as well as on
console, including checking of the testing software for I/O modules signal
conditioning modules, when specified.
- Checking of output status on processor failure.
- Checking of first-out alarm generation.
- Simulation of power failure and system restart auto boot-up of system configuration
and program after power restoration

3.2.9 Vendor shall notify the purchaser at least three (3) weeks prior to factory acceptance
test. In the event that representative arrives and the system is not ready for testing,
vendor shall be liable for back charges for any extra time and expense incurred.

3.3 INSTALLATION, TESTING AND COMMISSIONING

3.3.1 Vendor shall offer the services of an installation team which would install the equipment
in the control room, lay the interconnecting cables inside control room, check-out, test
and commission the system.

3.3.2 Vendors responsibility at site shall include all activities necessary to be performed to
complete the job including ;
Receipt of hardware/software and checking completeness of supplies.
Installation of the system including free supply equipments if any.
Inter-cabinet cabling and termination.
Check out equipment installation.
Checking of interconnections, hardware and software configuration, overall
system functioning etc.
Loop checking
Commissioning and on-line debugging of the system
Involvement during plant commissioning and performance of final acceptance
test.

3.4 FIELD INSPECTION

3.4.1 All equipments shall be inspected thoroughly by vendor after its receipt at site for
completeness and proper functioning. Vendor must initiate the remedial action, in case
unsatisfactory operation of any item is observed, with intimation to Engineer-in-charge.

3.4.2 Vendor must document all observations including details of any malfunction observed.
Items / equipments requiring total replacement must document the reasons for the
same.

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3.5 LOOP CHECKING

3.5.1 Loop checking shall be carried out by vendor including checking the interconnections,
configuration and overall system functioning.

3.5.2 Vendor shall coordinate with the field contractor for smooth and proper loop checking.
Any discrepancy found during checking shall be brought to the notice of the Engineer-in-
charge. Complete loop checking shall be performed in his/her authorised
representatives presence.

3.6 SITE ACCEPTANCE TEST (SAT)

3.6.1 The purchaser shall provisionally takeover the system from vendor after system
acceptance test. System acceptance test shall be started only after the satisfactory
performance of loop checking and verification of records by Engineer-in-charge.

3.6.2 The system acceptance test shall be carried out in the presence of purchasers
representative and Engineer-in-charge or his authorised representative.

3.6.3 Vendor shall carry out the following functional tests, as a part of system acceptance test
as a minimum :-
Hardware verification as per final bill of material.
Visual and mechanical check-up for proper workmanship, identification, ferruling,
nameplates etc.
System configuration as per approved configuration diagram.
Demonstration of all system diagnostics.
Checking of correct change-over of redundant devices
Checking of proper functioning of all disc drives, alarm summary, printers etc.

3.7 PERFORMANCE TEST

The owner shall take over the system after satisfactory full functional performance test
for a period of 3 weeks.
During above period, any malfunctioning of the system components shall be replaced /
repaired as required free of cost. Once the system failure is detected, the acceptance
test shall start all over again from the beginning. The warranty period commences from
the day owner takes over the system.

4.0 GENERAL REQUIREMENTS

4.1 Vendor shall comply fully with the general requirements of PLC system including logistic
support services, documentation, warranty, maintenance contract and shipping
instructions.

4.2 Maintenance Contract


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

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4.3 Availability of System


Vendor shall confirm that support for supplied system hardware and software shall be
available for a period of 10 years from the date of commissioning.

4.4 Training
Bidder shall include the training of the engineering /operation/maintenance staff at the
system supervisor as well at site. The training shall include but will not be limited to the
following in general.
The different hardware components to be supplied by the Bidder.
Software training
Maintenance training on the individual instrument being supplied.
Training on the operation of the entire systems as per functional
requirement. Details of training plan for all categories will be divided
mutually at a later date.

4.5 Annual Maintenance Contract


Bidder shall quote separately for Annual Maintenance Contract for a period 5 years from
the date of commissioning.

5.0 SHIPPING

5.1 All the materials used for packing, wrapping, seals, moisture resistant barriers and
corrosion prevention shall be of recognised brands and shall conform to the best
standards for the articles which are packed.

5.2 Workmanship shall be in accordance with best commercial practices and requirements
of applicable specifications. There shall be no defects, imperfections or omissions, which
would tend to impair the protection offered by the package as a whole.

5.3 The packing shall be suitable for storing in tropical conditions, as specified in job
specifications. Shipment shall be thoroughly checked for completeness before final
packing. Vendor shall be responsible for any delay in installation or commissioning
schedule because of incomplete supply of equipment.

6.0 REJECTION

Vendor shall make his offer in detail with respect to ever item of the purchases
specifications. Any offer not conforming to this shall be summarily rejected.

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SPECIFICATION No.
SPECIFICATION FOR A133-00-6-82-0001 Rev. 1
HEALTH, SAFETY & ENVIRONMENT
MANAGEMENT AT DCU,CPCL Page 2 of 101
CHENNAI

TABLE OF CONTENTS

Section I Safety Management Program


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

Section II - Occupational Health and Welfare Facilities


16.0 Welfare Facilities
17.0 Occupational Health Services
18.0 Sanitation and Hygiene Measures

Section III - Site Safety Program


19.0 Personal Protective Equipment (PPE)
20.0 Housekeeping
21.0 Safety Signs
22.0 Site Electricity
23.0 Form Work
24.0 Excavations
25.0 Hot Work
26.0 Fire Prevention and Control
27.0 Compressed Gases and Combustible Liquids
28.0 Working at height
29.0 Manual Handling
30.0 Sling and Lifting Gears (Rigging)
31.0 Lifting Appliances
32.0 Lifting Activities
33.0 Construction Vehicles
34.0 Construction Machineries
35.0 Noise

Format No. 8-00-0001-F1 Rev. 0


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TABLE OF CONTENTS

36.0 Confined Space


37.0 Radiography
38.0 Hand Tools
39.0 Demolitions
40.0 Temporary Structure/Fixtures

Section IV Liquidated Damages


Penalties for Violation/Non-Adherence of Safety Procedures and
41.0
Practices
42.0 Compensation in case of Accidents

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

Format No. 8-00-0001-F1 Rev. 0


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SPECIFICATION No.
SPECIFICATION FOR A133-00-6-82-0001 Rev. 1
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CHENNAI

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

Format No. 8-00-0001-F1 Rev. 0


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Section I Safety Management Program

0.0 Definitions
Owner : Chennai Petroleum Corporation Limited, Manali Refinery, Chennai
Consultant : Jacobs Engineering India Private Limited
Contractor : Person, Firm or Corporation to whom the work will be awarded by EIL.
LSTK Contractor: Engineers India Limited (EIL)
Shall : Mandatory requirement.
Should : Guideline that is strongly recommended.
May : Guideline that is to be considered.
Supervisor : Contractors engineer responsible for specific tasks.

1.0 Purpose
The field HSE specification set forth is the minimum requirements that shall be implemented
during the project execution. The contractors are required to implement these standards and any
additional requirements as per local laws and statutory requirements and best practices in industry
whichever are higher. Owner, consultant and EIL may issue further changing requirements from
time to time as the work progresses to fit changing site conditions, which will be binding on the
contractor.

The owner is fully committed for providing safe and healthy working conditions for all employees
working on the project and our goal is zero incidents in our operation. Safety is an overriding value
that the operation shall be conducted in such a manner that reasonably practicable measures are
taken to protect people not only in our employment but also others who may be affected by our
activities.

We believe that incidents are caused and eliminating the causes of incident can prevent them.

Safety is the responsibility of every employee but line management is ultimately responsible for the
implementation of safety requirements.

Everyone involved must be committed to achieving high standard of HSE Performance with proactive
approach at all levels in the organization with excellent teamwork.

All personnel should share a sense of empowerment on safety matters with an effective
communication system to facilitate the flow of safety information both up and down through the
organization

2.0 Compliances
All activities shall be in compliance with relevant local laws, statutory requirements, codes and
practices pertaining to health & safety of employees

2.1. Contractors or other third parties in the refinery shall abide by


Fire & Safety rules and regulations of the Refinery (Latest revision)
Security instruction issued by refinery management time to time
All requirements under the Factory Act 1948
The Contract Labour Act 1970
All requirements of Worker Compensation Act 1923 & ESIS Act including all amendments thereto.
Other statutory requirements shall also be applicable as mentioned.

Attachment 1: Legal Obligations / Requirements for Construction

2.2. The Contractors shall not employ minors (persons below the age of 18 years) in any part of the
refinery.

2.3. Contractor shall display notice at the conspicuous place showing the rates of wages of the workers,

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hours of work, wage periods, date of payment of wages, names and addresses of the Inspectors.
having jurisdiction and date of payment of unpaid wages, in English, Hindi and in the local language
understood by the majority of workers.

2.4. Contractors personnel shall abide by the applicable instructions as may be issued from time to time
to handle any emergency situations, such as explosion, fire, terrorist attacks, major accident, etc. In
the event of such emergencies, the Contractors personnel shall stop their work and proceed to a
safe designated place assembly point in the area of their work and inform the Engineer-in-Charge
immediately. If needed, they shall be safely evacuated.

2.5. Contractors vehicles, trucks, tractor, cranes and other portable equipments e.g. Air Compressor, DG
Set, Dewatering pumps etc. used inside Refinery premises (where Hydrocarbon is used as fuel) for
execution of the job must be mechanically sound and have an approved spark arrester and have
exhaust complying pollution norms. Idle running of those vehicles and equipments shall be avoided.

2.6. The Owner or the Engineer-in-charge or EIL may at any time require the Contractor to subject any
contract workman, to a medical examination, generally or in relation to specific jobs such as in
canteen, tank cleaning, work at height, etc.

2.7. Contractor shall not carry any work without having supervisor at site. If it is required to work
simultaneously in more than one location under the same contract, one supervisor must be put in
each of the locations. If a supervisor has to leave his site for any reason, he must stop his activities
for that period of time.

2.8. Female employee shall not be allowed to bring their child to workplace inside Refinery premises.
Contractor shall make suitable arrangement in case need, outside Refinery premises at his own cost.

2.9. The Contractor shall not be entitled to any extra or additional payment or other compensation for the
compliance with all applicable safety rules.

2.10. The requirement to comply with all applicable safety rules shall not entitle or justify the Contractor to
demand or claim any time or cost overrun.

2.11. The Contractor shall be solely responsible for any and all liability under the Workmens
Compensation Act, and other applicable laws with respect to all those engaged by the Contractor or
any sub-contractor.

2.12. In addition to this specification, contractor shall adhere to Health Safety Environment Procedure
(HSEP) of owner, consultant and EIL.

3.0 Objectives
3.1 General
The contractor shall practice safety leadership, demonstrate visible commitment to the project's
safety policy and strategic objectives, and provide resources to promote a culture that embraces and
accepts absolute safety behavior
Developing, signing, distributing, and emphasizing the safety policy at the outset of the project.
Leading and driving the project safety program in order to achieve a world class performance,
together with active participation at all levels with owner and consultant to ensure safe completion
of the project.
Implementing proactive monitoring system that provides feedback to ensure continuous
improvement in HSE performance.
Ensure compliance with all applicable laws, statutory requirements, codes of practices and
standards set forth.
In essence NO SAFETY NO WORK.

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3.2 Targets
The following Safety targets apply to the Project:

Injuries and Illness - Zero


Environmental Incidents - Zero
Property Damage - Zero
Vehicle Incidents - Zero

4.0 Contractors Safety Policy and Safety Assurance Plan


4.1 The contractor shall formulate a Safety & Health policy and shall be signed by authorised person.
The copy of the Safety & Health Policy shall be displayed at conspicuous places at work sites in
English, Hindi and a local language understood by the majority of construction workers.

4.2 The contractor shall submit copy of safety policy, HSE plan and safety assurance plan to
owner/consultant/ EIL in the standard form for implementation and monitoring of HSE requirements.

Attachment 2: Safety Assurance Plan

5.0 Site Safety Organisation


5.1 Contractor shall post a qualified and experienced Safety Manager and deploy Safety Engineers /
Officers, Supervisors and observers in every shift, to exclusively oversee and ensure compliance with
all applicable safety rules. Contractor shall notify the name of the safety manager, safety officer/
engineer and other safety personnel along with their bio-data to the owner /consultant and EIL for the
approval. Only on approval by the owner/consultant/ EIL, these personnel are authorised to work.

5.2 Qualifications of Safety Managers and Safety Engineer/officer shall not be less than as prescribed in
local regulations and the general requirements are described as under.

(a) A person shall not be eligible for appointment as Safety Officer unless he :

(i) Possesses a recognised degree in any branch of engineering or technology and has had practical
experience of working in factory in a supervisory capacity for a period of not less than 2 years; or a recognized
degree in physics or chemistry and has had practical experience of working in a factory in a supervisory
capacity for a period of not less than 5 years; or a recognised diploma in any branch of engineering or
technology and has had practical experience of working in a factory in a supervisory capacity for a period of
not less than 5 years.

(ii) Possesses a degree or diploma in industrial safety recognised by the State Government in addition to
possessing other qualification laid down in the said sub rule.

(iii) had adequate knowledge of the language spoken by majority of the workers in the region in which the
factory where he is to be appointed is situated.

(b) Notwithstanding the provision contained in clause (a), any person who:-

Possesses a recognised degree or diploma in engineering or technology and has had experience of not less
than 5 years in a department of the Central or Union Territory, State Government which deals with the
administration or the Factories Act! 1948; or

Possesses a recognised degree or diploma in engineering or technology and had experience of not less than
5 years, Full time, on training education consultancy, or research in the field of accident prevention in industry
or in any institution, shall also be eligible for appointment as a Safety Officer:

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5.3 Contractor shall submit site safety organization chart along with HSE plan.

Attachment 3: Site Safety Organisation Chart

5.4 Working hours per shift shall not exceed 12 hours per day.

5.5 Contractor shall appoint safety personnel as given below for every work shift:

Safety Observer : At all times minimum one observer for workers not exceeding 100 in numbers.
That means contractors are expected to deploy additional safety observers when
number of workers crosses beyond 100 and thereon.

Safety Supervisor: In addition to above, contractor shall depute one Safety Supervisor for every 250
workers.

Safety Engineer : In addition to above, one safety engineer/ officer for every 1000 workers.

Safety Manager : Minimum of one Safety Manager at all times required to be at site.

Requirement of Safety Personnel for every shift


No. of Workers
deployed Safety Engineer/
Safety Observer Safety Supervisor Safety Manager
Officer
1- 50
One
51-100
101-150 One
Two
151-200
201-250
Three
251-300 One
One
301-350
Four
351-400 Two

401-450
Five
451-500
Up to 1000 Ten Four
Up to 2000 Twenty Eight Two

5.6 In case any of the safety personnel leave the contractor the same shall be intimated to the owner/
Consultant/ EI L. The contractor shall recruit new personnel and fill up the vacancy.

6.0 Roles & Responsibilities


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

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

6.1 All Employees involved in project


Take reasonable care for the health and safety of him and other persons who may be affected by
his acts or omissions at work.
Co-operate with his management or others to enable compliance with statutory requirements.
Report to their immediate supervisor about hazardous situations and defects found in premises,
plant and equipment.
Avoid improvisation, which might entail risk.
Consider and suggest means of eliminating hazards.
Co-operate in maintaining a safe and healthy working environment.
Attend safety-training classes as and when organized.
Attend safety meetings if invited.
Participate in safety campaigns when organized.
Never intentionally or recklessly interfere with, or misuse, anything provided in the interests of
health, safety or welfare.

Draw to the attention of management /supervision improvements to health and safety which
appear to be necessary or advisable.
Immediately report any incident/ near misses to his/her supervisor.
Demonstrate leadership and commitment to HSE, setting a personal example at all times.

6.2 Contractors Construction Manager


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

6.3 Contractors Safety Personnel


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

6.4 Contractors Supervisory Personnel


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

7.0 Safety Meetings


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

7.1 Safety Kick-Off Meeting


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

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Contractors HSE plan.


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

7.2 Weekly Safety Meetings


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

Consultants Safety Representatives


Consultants discipline head
Owners representative

7.2.1 Weekly meeting in weekdays shall be predetermined with mutual agreement between contractor and
owner/consultant.

7.3 Monthly Safety Committee Meeting


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

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Chairman Owners Representative


Secretary Owners Safety Manager
Consultants RCM
Consultants Safety Representatives
Consultants discipline head
Members Contractor/EIL RCM
Contractor /EIL Safety Representatives
Contractors/EIL discipline head
Workers Representative

7.3.2 Site safety committee meeting shall be conducted at least once in a month. The agenda shall include
Review of previous minutes
Review of site safety performance
Monthly safety statistics
Contractors safety performance
Challenges ahead
SOR trend
Safety inspection & Audit reports
Issues by owner/ Consultant/ E IL

7.3.3 Contractor/EIL shall send circular to all safety committee members about the date and venue of
monthly safety committee meeting at least seven days prior to the day of meeting.

7.4 The Minutes of the meeting shall be prepared and sent to all members within 1 working day
preferably by mail/fax followed by hardcopy. Safety Committee meeting minutes shall also be
displayed in the notice board for wider publicity to all concerned.

Attachment 4: Minutes of Meeting

8.0 Pro-Active Safety Monitoring


Contractor shall implement proactive safety monitoring programs that provides feedback to ensure
continuous improvement in safety performance and compliances.

8.1 Safety Observation Report (SOR)


8.11 The SOR is used as a tool for supervisors to record good safety practices unsafe acts/conditions and
the steps taken (immediately and as follow-up) to correct the unsafe practices and recommendation
to prevent its recurrence.

8.12 It is everyones responsibility to take immediate corrective action if any unsafe act/ conditions are
observed.

8.13 Contractors job supervisor is responsible to close-out the SOR by taking corrective action during
follow-up action.

8.14 SOR shall be submitted to consultant and it shall be summarized periodically for effective tracking, to
analyse the trend and identify frequently occurring unsafe act/ conditions for improved safety
implementation.

Attachment 5: Safety Observation Report (SOR)

Attachment 6: Safety Observation Report Summary Sheet

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8.2 Method Statement


Contractors shall submit method statements for each work to owner/ Consultant/ E IL at least
seven days prior to the commencement of the work. The method statement shall detail:
The job to be undertaken
The steps of activities required completing the job.
The individual trades/disciplines involved in the activity.
Plant, equipment, tools to be used in the activity.
Any hazardous substances/chemicals to be used along with their MSDS.
A detailed description of how the work will be done including control measures and procedures to
complete each activity and the overall job safely.

Compliance with the procedure on the work method statement and relevancy to current operations
shall be monitored on a daily basis and also shall be discussed on safety meetings.
8.3 Safe Plan of Action (SPA)

8.31 The SPA is the primary tool used at site to identify and plan to mitigate safety hazards. This form
shall be completed by the contractors supervisor along with crew before starting a new activity and
kept at the work place for ready reference.

8.32 The SPA has sections for the employees to:


State the task to be performed
Location of the task to be performed
Safety hazards anticipated
Steps to be taken to prevent the risks identified
Equipment, tools, or materials needed for protection against the hazard and to perform the work
safely.
Authorisation by reviewing and approving personnel
The name(s) of the Supervisor(s) for each activity.
The name of the person in overall charge of the job.
Duration of the job.

8.33 It is the responsibility of the supervisor to ensure that all resources (equipment, tools, materials etc)
identified through SPA are implemented and all the steps identified to prevent the hazards are
implemented while executing the job.

8.34 It is the responsibility of the job supervisor to communicate the SPA to all workmen involved in that
specific task

8.35 A copy of SPA shall be displayed proximity to the actual works location in Hindi /vernacular language
& English.

Attachment 7: Safe Plan of Action (SPA)

8.4 Safety Inspections


The purpose of safety inspection is to identify any variation in construction activities and operations,
machineries, plant and equipments for ensuring an activity whether it is executed in accordance to a
general set of safety rules.

All equipments, machineries, tools, slings, lifting gears, lifting appliances involved in site shall be
inspected periodically.
Monthly colour coding program shall be implemented by the contractor and after the periodical
inspection, stickers for the corresponding month shall be pasted. Documents related to the inspection
shall be maintained and submitted to owner/ Consultant/ EI L regularly.

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Month Colour code


January & July Yellow

February & August Orange


March & September Pink
April & October Green
May & November Red
June & December Blue

8.41 General Inspection (Safety Walk Around)


General inspections shall be performed at predetermined intervals and the inspection shall involve
contractors RCM and contractors safety manager, owner/ Consultant/ E I Ls representatives.

Attachment 8: General Inspection Format

8.42 Routine Inspections


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

Attachment 9: Routine Inspection Plan

8.5 Safety Audit


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

Contractors construction manager holds the ultimate responsibility in ensuring implementation of


safety audit program during the construction work.

8.5.1 Monthly Safety Audit


Monthly Safety Audit shall be performed once in a month with prior notice. It shall be organised by
consultants safety manager with representatives from owner and contractor with a pre-determined
format.
These audits will play a vital role in assessing the Contractors Safety performance rating.

Based on the audit team observation, the evaluator shall allot the score based on the compliance
observed of the requirement and summarise the overall scoring of the audit.

The audit findings along with the recommended corrective actions with target date shall be circulated
to the respective contractors. The contractor should complete the recommended corrective actions
and submit the corrective action report.

The date for the audit shall be agreed by the owner/ Consultant/ E I L and

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contractor.

Attachment 10: Safety Audit Checklist

9.0 Site Safety Training and Competence of Employees


Contractor must ensure that his employees are adequately trained and experienced to carry out
their work safely. Training should continue throughout the project and should include regular
toolbox discussions.

Contractor must also ensure that specific hazards likely to be experienced on the site are notified
to their workforce together with any precautions to be taken and local rules to be observed.

Where particularly severe or unusual hazards arise, consultant reserves the right at no additional
cost to request contractors employees to attend safety training and instruction sessions, whether
carried out on site or externally.

Contractor shall provide a dedicated training room for conducting training for their workers.

9.1 Initial site orientation / safety induction and ID cards


9.11 All personnel working on the site shall be required to attend a safety induction briefing before
commencing work. Safety induction shall cover all topics included in the attached checklist.

Attachment 11: Safety Induction

9.12 The contractor shall conduct a site visit for his new employees in groups of less than 25 to familiarize
the new employees with essential services, their work place, and general site layout.

9.13 It is the responsibility of the contractor to familiarize all new personnel to the project on the actual
location of assembly points, fire alarm points, first-aid center, welfare facilities and other important
locations.

9.14 Contractors are responsible for arranging site safety induction for their workmen and they shall
inform consultants safety representative at least one day in advance.

9.15 Induction card duly stamped as Safety Inducted and the date of induction by contractor shall be
issued after the completion of Induction.

9.2 Toolbox Talks


Contractor shall conduct job specific and weekly tool box talks to encourage two way
communications with the employees.
Contractor shall maintain records of Toolbox Talks and shall be submitted to Consultant on regular
basis.

Attachment 12: Tool Box Talk

9.21 Job specific tool box talk


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

9.22 Weekly tool box talk


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

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Contractors and their supervisory staff shall undergo a one-day training programme annually from
owner on Safe Working Practices in the Refinery Premises so as to familiarize themselves with the
safety rules, regulations and practices. Contractor shall be in possession of valid safety training
badge while working in the Refinery premises.

The Contractors shall ensure that their supervisors must undergo Fire & Safety Training &
subsequent Test at Fire Station before starting the job. All contractors must disclose to CLM Cell the
name of supervisors and arrange safety training at Refinery Fire Station, before obtaining a gate
pass. CISF will issue the gate pass meant for supervisor, only after getting the confirmation from Fire
& Safety. It is the duty of supervisor to train his work force in Fire & Safety on regular basis. The
violation of this will be viewed seriously.

9.4 Site safety training


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

Personal Protective Equipment Scaffold


Housekeeping Fall prevention and protection
Work permit Hot work
First-aid Heavy lifting and Rigging
H2S Fire prevention and protection

Mock drill including fire rescue, evacuation etc Electrical Safety


Excavation Hand and power tools
Manual handling Confined Space Entry
Driving Safety Pre-commissioning Safety
Working at Height Lock-out and Tag-out

Completion of specific hazard training is mandatory before working on such tasks. A list of all trained
persons shall be maintained at site.
The contractor shall prepare the training calendar for safety activities and submit to owner/
Consultant/ EI L on monthly basis.

Attachment 13: Safety Training Matrix

Contractor shall maintain records of training register and copy shall be submitted to owner/
Consultant/ EI L after completion of training program

Attachment 14: Training Register

9.5 Safety Hand Book


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

10.0 Safety Awareness and Promotional Activities


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

10.1 Safety Posters


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

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posters, banners and sign boards around the work site.


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

10.2 Safety Update Board


Contractor shall display safety statistics board at conspicuous locations such as site, contractor site
office; workers rest shed etc and shall be updated on regular basis.

Attachment 15: Safety Update Board

10.3 Safety Notice Board


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

10.4 Safety Campaigns


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

10.5 Safety Competitions


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

10.6 Awards and Recognitions


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

10.7 Important days to observe


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

11.0 Documents and Information to be submitted by Contractor


11.1 Apart from safety policy, safety plan, safety organisation chart, safety assurance plan contractor shall
also submit the documents as required.

11.2 Contractor shall submit Man Power Report on daily basis at least by 10.00 am every day.

11.3 Contractor shall submit Weekly Safety Report every Monday as per the approved format. The data
shall be from Monday to Sunday.

11.4 Contractor shall submit the listed supporting documents along with the weekly safety report.
Safety Induction
Tool box Talks
Safety Observation Report (SOR)
Safety Observation Summary Sheet
Safety inspection reports
Safety Audit Report (if any)
Safe Plan of Action (SPA) of each activity.
Method statements

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Safety training and mock drill records


Incident and Investigation Report (if any)

Attachment 16: Weekly Safety Report

11.5 Contractor shall submit Monthly Safety Report as per the approved format

Attachment 17: Monthly Safety Report

Test Certificates for lifting tools and tackles, lifting gear, lifting equipment and appliances.
Test certificates of air receivers.
Information relating to hazardous materials used and their MSDS.
Employers liability insurance certificate.
Copies of all Statutory Registers maintained by the contractor when asked for.

11.6 Display of Safety Instructions


The Contractor shall display a Safety Policy at a prominent place at his site office and each work
spot.

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

12.0 Incident Reporting


12.1 Any incident at site how slight they are or which entails a person reporting to hospital or leaving site
for treatment shall be verbally reported immediately to owner/ Consultant/ EI Ls representative. This
will enable the owner/ Consultant/ EI L to reach to the scene of incident / dangerous occurrences to
monitor/assist any rescue work and/or start conducting the investigation process so that the
evidences are not lost.
12.2 The return date of injured workmen back to the work shall be reported to owner/ Consultant/ EI L
promptly.
12.3 Written reports of all incidents and dangerous occurrences shall be submitted within 6 hours as per
format attached

Attachment 18: Incident and Investigation Report

12.4 Contractor shall ensure that any incident that occurs is fully investigated to find root cause and
preventive measures are adopted to prevent its reoccurrence. owner/ Consultant/ EI L shall have a
right to conduct independent inquiry of the incident.
12.5 Near misses and minor incidents should also be investigated by the Contractor as soon as possible
as they are signals that there are inadequacies in the safety management system.
12.6 Incident reporting chain and emergency contact numbers shall be displayed at conspicuous locations
at site and contractor offices.

Attachment 19: Incident Reporting Chain and Emergency Contact Numbers

13.0 Site Emergency Response Action Plan

13.1 A detailed site emergency procedure shall be worked out and communicated to all employees at site.

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Necessary arrangements shall be made to deal with such emergency situations. An emergency
response team will be formed to tackle such situations.

13.2 The contractor shall ensure that an Emergency Response Plan is prepared to deal with emergencies
such as
Fire and explosion
Collapse of lifting appliances and transport equipment
Collapse of building, sheds or structure etc.
Gas leakage or spillage of dangerous goods or chemicals
Excavation collapse
Fall of person from height

13.3 The following shall be considered to establish emergency procedures.


Make a list of available emergency services and confirm their communication channels.
Set up emergency response teams.
Ensure that supervisors clearly understand their responsibility and role in the site emergency
procedures.
Designate first aid and provide medical supplies and other material and equipment that may be
required for emergency use.
Determine emergency evacuation routes for work areas and construction site.
Make sure that all personnel clearly understand emergency warning siren signals or other warning
signals used by owner.
Designate a supervisor to conduct a head count and give instructions to evacuees as necessary.
Post-emergency information for each work area on the site.

13.4 Contractor shall conduct an onsite emergency mock drill once in every month for all his workers.

13.5 Bombs, Unattended Baggages/Objects


The following actions shall be taken by the contractor and his employees/workmen about Bombs,
Unattended baggage / Objects lying in secluded places in the Plant.
On noticing any bomb/ unattended baggage or object lying in the plant area, they should
immediately inform the CISF control room on Telephone No.3685 & 3660 and OWNER Fire
Control Room No. 3630 & 3663.
They should not touch the object or try to open the baggage or fiddle with the wires or battery if
found attached to the object.
They should move away to a safety distance of approximate 300 m. without creating any panic.
In case of unattended baggage, they should help CISF personnel in identifying the claimant.
They should not move to the area unless clearance is given by security personnel.

Dos & Donts in case of Bomb/Unattended baggage lying secluded places in the Plant.

Sl. Sl.
Dos Donts
No. No.
1. On noticing any bomb or unattended 1. Do not touch the bomb / unattended
baggage, in form CISF Control Room baggage.
by quickest possible means or on 2. Do not lift any attended baggage
Intercom Telephone No. 3685 / 3660
and OWNER Fire Control Room on 3. Do not go very close to the object
101 / 3630 / 3663.
2. Move away from the bomb/unattended 4. Do not create panic.
baggage.
3. Help security personnel in identifying 5. Do not fiddle with wires or battery if
unattended baggage. found attached with any object.

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

14.0 Site Access and Security Procedures


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

14.2 Gate Pass/ ID Card


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

14.4 Working in Night


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


Gambling, fooling on the work, horseplay, mock fighting or fighting is strictly forbidden in the
Refinery premises Project area.
Fooling on the job, mock fighting or fighting within the Refinery premises will not be tolerated.
Gambling within the Refinery premises is strictly forbidden.
Entering the Refinery premises while in possession of weapons such as knives & gun etc. is
prohibited.
Contractor personnel shall not pick up quarrel or get into arguments with Refinery personnel or
act in any misunderstanding, such problems should be referred to appropriate Refinery personnel.

Working under influence of alcohol/ narcotics and entering Refinery premises while in the
influence of alcohol/ narcotics is strictly forbidden. The contractor should ensure compliance of
above by him and all his workmen.
Contractors are prohibited from using Cellular phones within the Refinery premises, except to the
extent permitted by the Owner by special or general order / instruction.

Carrying Match Boxes / Lighters and No Smoking


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

Unsafe Practices: Any unsafe practices or disregard of normal safe working practices by contractor
personnel when pointed out by company personnel shall be immediately corrected.

14.6 Disciplinary Actions


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

15.0 Permit to Work System


15.1 A permit to work system is a safety strategy designed to protect personnel and plant and which
consists of an organized and predefined safety procedure. It forms a clear record of all foreseeable
hazards, which have been considered in advance of the construction operations.

15.2 The contractor shall not commence the job without the valid permit for the area and for the job.
Clearance shall be obtained from the area-in-charge and shift engineer

15.3 The following is the list of some of the activities, which would require permit, and list may change
depending upon work situation.
Working at Height
Excavations
Lifting Operations
Hot Work
Electrical Works (Isolation & Energisation)
Confined Spaces
Radiography
High Pressure test
Commissioning of equipment

15.4 Before starting any work, contractor shall apply at least one day ahead for fire & safety permit for
excavation, electrical, gas welding and cutting work to Engineer-in-Charge of work/ works who in turn

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will arrange for such permits. The contractor shall take all the precautions given in the permit before
starting of the work to the full satisfaction of the Engineer-in-Charge of the sections. On account of
operational problem it is possible that the clearance and permit may get delayed for which the
contractor shall not ask for the idle charges. Fire equipment such as fire extinguishers, fire hoses,
control type nozzles, personal protective equipment, Blow man air apparatus etc required for safety
precautions are to be arranged by contractor himself. However in case of emergency on
authorization from Engineer-in-Charge those items will be issued from the Refinerys Fire Station on
chargeable basis and shall be returned after completion of the work / works in working conditions, to
the full satisfaction of the Fire & Safety Officer. In case of any damage to the fire & safety equipments
issued or used by the contractor, the contractor shall bear the cost of such damage in full and the
same will be recovered from his bills.

15.5 Safety measures stipulated in the respective Work Permits shall be strictly complied at all times when
within the premises of the Owner.

15.6 Owner/EIL reserves the right to cancel a work permit without assigning reasons. When called
upon to stop the work by the Engineer-in-charge/EIL, the Contractor shall immediately cease to
continue the work. Before re-commencement, fresh work permit must be obtained.

15.7 The Engineer-in-Charge/EIL reserves the right to terminate the contract and forfeit any or all
amounts due to him in case he finds that the precautions written on the permit are not strictly
adhered to by the Contractor.

15.8 Permit to work shall be valid for a shift (8 Hours) only. However, Engineer may extend the permit to a
maximum of another 4 hours if necessary.

15.9 A copy Permit to Work shall be displayed, during its validity, in a conspicuous location in close
proximity to the actual works location to which it applies.

15.10 Hot work Permit


The entire job is to be carried out within the running unit of Refinery. The Contractor shall take all
necessary safety precautions and obtain required certificates/ fire permits / safety/ work permits etc.
from the competent authority before carrying out any hot works during the execution of the entire
works covered by this tender.

A hot work permit issued by the concerned department or area-in-charge must cover any work
carried out within Refinery. In addition a clearance must be obtained from the concerned
departments officer or supervisor prior to commencement of any job. A hot permit is required for:

Any work involving open flames, spark such as welding, gas cutting, soldering, grinding, concrete
breaking, use of hurricane lamps and internal combustion driving vehicles / Radiography / Crane
lifting / Vessel entry.
Sand blasting, Trucks, Jeeps, Cranes, Lifts, Cars or any kind of vehicle driven by an internal
combustion engine or by batteries
Use of gasoline, diesel or electrical power engines or tools.
Entry of vehicles inside battery limits of process area within tank dykes and adjacent to pump
houses and loading gantries etc.

While carrying out the hot job, the contractor and his workmen must ensure the following safety
measures and job should be carried with
Valid hot job permit,
Availability of tested and proper fire extinguisher at the work places
Provision of running fire water hose at work place.

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Section II - Occupational Health and Welfare Facilities

16.0 Welfare Facilities


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

16.1 Drinking water


16.11 The contractor shall make in every worksite, effective arrangements to provide sufficient supply of
wholesome drinking water. Quality of the drinking water shall conform to the requirements of national
standards on Public Health.

16.12 While locating these drinking water facilities due care shall be taken so that these are easily
accessible within a distance of 200m from the place of work for all workers at all location of work
sites.

16.13 All such points shall be legible marked Drinking Water in a language understood by a majority of the
workmen employed and shall be situated within six meters of any washing places, urinals or latrines.

16.2 Latrine and urinals (Centralized toilet shall be arranged by EIL at site)
16.21 EIL shall provide sufficient latrine seat and urinal facility in the worksite.

16.22 When women are employed, separate latrine and urinals accommodation shall be provided by EIL.

16.23 Notice shall be displayed outside each block of latrines or urinals a containing therein "For Men
Only" or "For Women Only", where both male and female workers are employed, written in the
language understood by the majority of such workers.

16.3 Canteen
16.31 In every workplace wherein not less than 250 workers are ordinarily employed the contractor shall
provide an adequate canteen.

16.32 The charges for food stuff shall be based on no profit no loss basis. The price list of all items shall
be conspicuously displayed in such canteen.

16.33 Building of the canteen shall be situated at the distance not less than fifteen point two meters from
any latrine or urinal or any source of dust, smoke or obnoxious fumes.

16.34 Waste water from canteen shall be carried away in suitable covered drains and shall not be allowed
to accumulate in the surroundings of canteen
16.4 Centralized toilet for male and female shall be provided at site by EIL on behalf of Contractor.

17.0 Occupational Health Services


The owner/EIL at project site shall provide a centralized first-aid center for the treatment of minor
injuries and illness. However all major injuries and illness cases shall be referred to the Hospitals and
contractor shall make his own arrangement for such treatment as required.

EIL shall provide stretcher and shall be readily available in an emergency.

Centralized First Aid centre along with Stretcher and Emergency vehicle shall be provided at
site by EIL on behalf of Contractor.

The contractor shall maintain injury record. A separate first-aid register shall be maintained and it
shall be submitted to owner/ Consultant/ EI L on regular basis.

17.1 First Aid Box


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

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workers. Every First-aid box is distinctly marked First-aid and is equipped with the articles specified
in Attachment

Attachment 20: Contents of First-Aid box

17.2 Hospital Tie-up and Emergency vehicle


17.2.1Contractors shall require to tie-up with the hospitals located in the neighbourhood for attending
medical emergencies.

17.2.2 Emergency vehicle shall be arranged by EIL during all working hours for the purpose.

18.0 Sanitation and Hygiene Measures


18.1 Prevention of mosquito breeding
Empty cans, oil drums, packing and other receptacles, which may retain water shall be deposited
at a central collection point and shall be removed from the site regularly.
Still waters shall be treated at least once every week with oil in order to prevent mosquito
breeding.
Drainages shall be cleaned regularly.

The contractor at periodic interval shall arrange to prevent mosquito breeding by fumigation /
spraying of insecticides.

18.2 Prevention of snake bite


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

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Section III - Site Safety Program


19.0 Personal Protective Equipment (PPE)
19.1 The contractor shall provide all required PPE to his employees & workers, which are duly inspected
and approved by the owner/ Consultant/ EI L. NO PPE ZONE would be identified separately.

All PPE provided by the contractor shall confirm to Bureau of Indian Standards (BIS).

Attachment 21: Bureau of Indian Standards for PPE

Copy of Manufacturers test certificates of PPE used shall be submitted to owner/ Consultant/ EI L.

19.2 The contractor shall:


Maintain records of issue and replacement of PPE.
Maintain 10% PPE stock of total requirement available at their store and stock record.
Issue PPE to worker free of cost.
Maintain all personal protective equipment in good working condition.
Periodically check and replace all defective / broken personal protective equipment.

Contractor shall submit PPE issue register and PPE stock record to owner/ Consultant/ EI L on
regular intervals.

Attachment 22: PPE Issue Register

Attachment 23: PPE Stock Register

19.3 As a minimum, every worker shall wear safety shoes, safety helmet and safety goggles at project
site.
Depending upon the job requirement other PPE shall used.
Head Protection Safety Helmet
Foot Protection - steel toe cap shoes, steel toe cap gumboot
Eye Protection - Goggles, Helmet mounted face shield
Hand Protection - Gloves
Respiratory Protection - Nose mask, Self Contained Breathing Apparatus
Hearing Protection - Ear plugs, Ear muffs
Personal Fall Protection - Full body harness with double lanyard, Rope-grab fall arrester, etc
Body Protection - Full body apron

19.3.1Head Protection
Safety helmet shall be worn by all persons at all times on project site. It shall consist of
suspension cradle and chin strap.
All persons on the project site shall wear chin strap at all time.
Logo of corresponding main contractor shall be affixed on the safety helmet.
Damaged helmet shall not be used and should be discarded from the site immediately.

19.3.2Foot Protection
All personnel shall wear suitable safety footwear with steel toe cap at all times while on the project
site.

19.3.3Eye/Face Protection
Contractor shall provide suitable eye/face protectors where there is a potential of injury to the
eyes and face from dust, flying particles, molten metal, chemicals, fumes or vapors, light radiation

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or combination of these.
Operation Hazards Eye Protectors

General site use Dust, flying particles Safety goggles (Plain)


Sparks, harmful rays,
Welding goggles (Black Shade) -
Gas Cutting molten metal, flying
eyecup type
particles.
Sparks, intense rays, molten
Electric (Arc) welding Welders hood mounted on helmet
metal
Grinding Flying particles Face shield mounted on helmet
Chipping goggles (Plain) eyecup
Chipping Flying particles
type
Chemical resistant goggles and face
Chemical handling Splash, acid burns, fumes
shield.

Contractor shall inspect the goggles used by workmen and shall replace the defective goggles
immediately.
Eye protection for Helpers exposed to light radiation from welding, gas cutting activity shall be
provided with black shaded welding goggles.

19.3.4Hand Protection
Contractor shall choose and use suitable gloves for the task.
Protection Level
Hand protector Sharp Activity
Heat Chemical Electricity
objects
Cotton dot type Inspection work, Climbing
Medium Poor Poor Poor
glove Ladders.
Leather & cloth
Good Medium Poor Poor Scaffolding
type glove
Leather riggers Hot work, Rigging, Manual
Good Good Poor Poor
Gloves Handling.
Rubber moulded For use with Chemicals &
Poor Medium Good Good
gloves Acids
Rubber Gloves Poor Poor Poor Good Electrical works

In addition to above, gloves shall be used by personnel involved in works with possibility of the
risk from abrasion, cutting, tearing, chemical, or other burn, infection.

19.3.5Respiratory Protection
19.3.5.1 Respiratory protective equipment to be used in confined space and activity involving any
chemicals shall be as advised by owners Engineer-in-Charge / Fire & Safety Dept.

19.3.5.2 Supplied Air Respirators and Self Contained Breathing Apparatus (SCBA) used for working in
hazardous atmosphere shall be advised by owners Engineer-in-Charge / Fire & Safety
Department. The same shall confirm to BIS and shall be approved by owner/ Consultant/ E IL.

19.3.5.3 Contractor shall organise practical demonstration training on the methodology to use SCBA or
Supplied Air Respirators in consultation with owner/ Consultant/ E IL.

19.3.5.4 Air Purifying Respirators


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

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dust mask.
Contractor shall use chemical cartridge respirators while performing outdoor spray painting.

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

19.3.7Personal Fall Protection


Full body safety harness shall be required when working two meters or above. It shall be fitted
with double lanyard and the maximum length of the lanyard shall be not greater than 1.8 m.
The lanyard shall be fitted with shock absorber and anchoring hook shall be of scaffold type snap
hook.
Full body safety harness fitted with shock absorber shall be used while working 3 m or above.

19.3.8Body Protection
Full body apron suitable for the task such as hot work, chemical handling shall be used.
Contractor personnel shall not wear loose clothing while working around moving or rotating
equipment.

20.0 Housekeeping
20.1 Contractor shall maintain very high standard of housekeeping at all times.
Keep the site neat and tidy. Keep adequate number of skips / waste bins.
Keep the access clear of all obstructions.
Remove the nails or bend them down from the wooden scrap and remove them from job site.
Store the material in an orderly manner.

20.2 The contractor shall on daily basis keep the premises and surrounding area free from accumulation
of waste materials or rubbish caused by activities.

20.3 At the completion of days work contractor shall remove these materials to avoid Slip/ Trip hazards
and provide safe areas for movement of all workers and supervisors.

20.4 Empty gas cylinders shall be removed from the site and shall send back to the contractors store.

22.5 Contractor should establish regular maintenance program of sweeping and hosing to minimise
accumulation of dirt and dust in such areas.

20.6 If the Contractor does not clear the area after the completion of work, the same shall be got done by
owner /EIL and recoveries shall be made from the bills of the Contractor at double the rate at which
the owner /EIL has got it done.

20.7 On completion of the job the contractor shall remove all his construction material, tools etc. and
remove all temporary constructions and leave the job site thoroughly cleaned up and ready for use. A
job will not be considered completed until all surplus material, scrape and debris / rubbish are
removed from the job site.

20.8 When required contractors should suspend other operations and do housekeeping.

20.9 Waste Disposal

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Waste generated at site shall be segregated at source and disposed off in accordance with
environmental control regulations and municipality rules. Consultant shall be informed of procedure
followed by the contractor before disposal.

20.9.1Scrap yard shall be identified and waste shall be disposed temporarily at designated scarp yard.
Scrap yard shall be barricaded and shall be clearly marked as Scrap Yard in English and other local
languages.

22.9.2All receptacles shall be constructed of metal or other suitable types of containers of non-flammable
materials. Cardboard, wooden boxes or crates and similar types of containers shall not be used for
the collection of combustible waste.

22.9.3Skips containing combustible waste should be strategically placed to ensure fire does not spread in
the case of combustion within a skip.

22.9.4Contractor shall maintain routine housekeeping inspection record and shall be submitted to
owner/consultant/ EIL.

21.0 Safety Signs


Contractor shall post safety signs which give a general safety message in workplaces to draw
attention rapidly to the objects and situation affecting health and safety.

21.1 Colours of safety signs, dimension and layout shall confirm to IS 9457:2005
Red : Prohibition signs
Yellow : Warning signs
Green : Mandatory action signs
Blue : Safe condition signs

21.2 Bands
The band colour for indicating hazard location shall be the combination of Yellow and Black.
The band colour for indicating prohibition shall be the combination of Red and White.
The band colour for indicating mandatory action shall be the combination of Blue and White.
The band colour for indicating safe condition shall be the combination of Green and White.

21.3 Tags
Contractor shall implement tag system for scaffold, LOTO and unsafe equipment.

22.0 Site Electricity


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

22.2 Power Supply


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

If the electricity supply is in contractor scope, the contractor shall assess required electrical loads and
shall install required capacity diesel generators for power supply.

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

22.3 Diesel Generator (DG)


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

22.3.1Contractor shall display the following details near the DG.


Name with photograph and contact number of authorised person to operate the DG
Single Line Diagram (SLD)
Safety signs
Cardio Pulmonary Resuscitation (CRP) and electric shock first-aid treatment chart.
Location of nearest first-aid box availability.
List of emergency services contact numbers.

22.3.2Contractor shall inspect DG periodically and the record shall be submitted to owner/consultant/ EIL.

Attachment 24: Diesel Generator checklist

22.4 Distribution System


Contractor shall ensure that all distribution board (DB) used in the site shall be of IP type which
specification confirms to national standards.
The contractor shall provide sufficient ELCB (maintain sensitivity 30 mA) / RCCB for all the
equipments (including Portable equipments), electrical switchboards, distribution panels etc. to
prevent electrical shocks to the workers
Earth Leakage Circuit Breaker (ELCB) should be provided on all distribution boards and main
switchboards. Single switch multiple socket system would not be permitted.
Rating of fuses and circuit breakers used for the protection of circuits should be coordinate with
equipment power ratings. Use of makeshift wires or conductors as fuse wire is strictly prohibited.
Protection against lightning shall be ensured to all equipment kept in open at sites.

22.5 Cables
Periodic check shall be carried out for defective cables, cracked or perished insulation, loose
joints in conduits, damaged fuse boxes and switchboards, loose pins, faulty sockets and defective
earth wire.
Kinking, twisting, binding or crushing of cables shall be avoided all the time. No electrical
equipments shall be left open or unsecured at the end of the days work.
All power distribution cables should be taken overhead with sufficient headroom.
Cabling passing under the walk way and across way for transport and mobile equipment shall be
laid in ducts at a minimum depth of 0.6 meters.
All switch boards, extension boards, etc. should be protected from rain and water. No water
logging should be allowed around switchboards.

22.6 Plugs, Sockets and Couplers

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The contractor shall ensure plugs; sockets and couplers used shall be splash proof type. The
minimum degree of Ingress Protection should be of IP44 in accordance with national standards.

Plugs and fittings used shall be of the weatherproof type and they should be colour coded in
accordance with the internationally recognised standards

110 volts: Yellow.


240 volts: Blue.
415 volts: Red.

No loose connections or tapped joints shall be allowed any where in the work site, office area, stores
and other areas. Proper cable connectors as per national standards shall only be used to connect
cables

Plugs shall be used to connect with sockets. Inserting the leads into the sockets shall be strictly
prohibited.

22.7 Lighting
The contractor shall provide sufficient lighting at site, of the right type and at the right place.
A far as possible contractor shall provide flood lighting to cover maximum work area.
The access and storage yard shall be well illuminated.
Luminaries should be robust and water proof especially at the point of the cable entry.
Hand held lamps used shall be of 115V and suitably guarded to protect from any mechanical
damage.
Light fitting for hazardous environment shall be of flame proof type which specifications shall
confirm to national standards.
Contractor shall use only 24V lamp in to confined space It shall be guarded and of flame proof
type.

22.8 Power Tools


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

22.9 Lock-Out and Tag-Out (LOTO)

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Contractor shall form a LOTO procedure and shall be implemented during any maintenance,
repair, pre-commissioning and commissioning activities.
The equipment shall be isolated from energy sources before carrying any maintenance work.
LOTO register shall be maintained and shall be controlled by a designated person.
Contractor shall be responsible for arranging locks for locking the feeders or panel boards.
All locks shall be neatly labelled for easy identification and the keys of the locks shall be
maintained by the designated person.

22.10 Earthing
Contractor shall ensure all earthing shall confirm to IS 3043:1987
Body of electrically operated tools, equipments, distribution board, electrical panel etc shall be
grounded properly.
Earth pit shall be clearly marked and earth resistance shall be measured on monthly basis and
register shall be maintained by contractor.

23.0 Form Work


Contractor shall ensure no workers shall be allowed to work above vertically protruded reinforcing
steel unless it has been bent over or capped.
Reinforcing steel for wall, pier, column and similar vertical form work structures shall be guyed
and supported to prevent collapse and to guard against possible wind pressure.
Pump concrete or similar system using discharge pipe shall be provided with pipe supports.
Compressed air hose in discharge pipe systems shall be provided with positive fail-safe joint
connectors to prevent separation of section when pressurised.
Banks man shall be deployed for backing the transit mixer and wheel stopper shall be paced.
Form work an shoring shall be designed, erected, supported, braced and maintained so that it will
safety support all vertical and lateral loads that may be imposed during concrete pouring.
No persons shall be allowed closed to the shoring during pour operation.
Scaffolds used for supporting Form Work should be constructed on a firm ground with a base
plate. The staging should as per IS 3696. Staging should be inspected frequently even after
completion of concrete work, or after completion of intended use.

24.0 Excavations
24.1 The contractor shall obtain work permit from owner/consultant/ EIL before starting excavation

24.2 Contractor shall prepare a method statement by considering the following factors
Nature & type of the soil
Weather and moisture conditions
Underground utilities
Methodology adopted to avoid cave-in
Depth and width of excavation
Duration of the excavation job
Proximity of other structures, services
Dewatering systems

24.3 Contractor shall stabilise the sides of an excavation by designing the shoring, if the depth is 4 metre
or more and which shall be approved by owner/consultant/ EIL.

24.4 All excavations and trenches depth of 0.60 m or more shall be hard barricaded.
The hard barricade shall be made of steel pipes of minimum 40 NB.
The hard barricade shall have hand rail at 1100mm and mid rail at 550 mm and the spacing
between two vertical members should not be more than 1000 mm.
The hard barricade shall withstand a lateral load of 100 kg.
The hard barricade shall be provided at least 1.0 meter away from the edge of the excavation.

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24.5 Excavations and trenches depth less than 600 mm shall be cordoned off and suitable sign boards
warning tapes posted.

24.6 Access shall be provided by mean of portable ladder or ramp if the depth is more than 1.5m.

24.7 Portable ladders shall be provided at intervals of not more than 15 m, depending on the number of
workmen present.

24.8 All excavated materials shall be deposited minimum 1.5 m away from the edge of the excavation.

24.9 Excavating equipments and vehicle shall be operated 2.0 m away from excavated area.

Attachment 25: Excavation Checklist

25.0 Hot Work


Any work involving open flame/ spark shall be considered as hot work.
All hot work involved equipments and fitting shall confirm to relevant IS Standards and the
manufacturers test certificate shall be submitted to owner/consultant/ EIL.
Contractor shall obtain hot work permit from owner/ consultant prior to the commencement of the
job.
Fire watcher shall be engaged for each hot work activity and shall be competent in using fire
extinguishers
Work area beneath or adjacent to hot works shall be made free from combustible materials, and
cordoned-off to prevent personnel being injured by welding spatters.
Barriers or screens shall be erected whenever necessary to protect the workmen working near by.
Suitable safety signs & notices shall be displayed near the hot work area.
Contractor shall use non asbestos fire blankets to avoid falling of spatters. Manufacturers test
certificate shall be submitted to owner/consultant/ EIL.
Fire extinguisher shall always be carried with each welding set, preferably a dry chemical powder
type.
After hot work, contractor shall ensure a good housekeeping by sweeping the work area, stacking
the materials, winding the cables/ hoses and placing the equipments properly.
Appropriate PPE mentioned in clause 19.0 shall be used depending up on the hot work activity.

Attachment 26: Hot Work Activity Checklist

25.1 Welding Activity

25.1.1As far as possible D.C. Generator / Rectifiers should be used in preference to A.C. Transformer sets.

25.1.2The contractor shall get welding transformer certified by the owner/consultant/ EIL Electrical Engineer
before start of work and shall obtain a certificate valid for a period of three months renewable after
every three months.

25.1.3A copy of the certificate shall be displayed on respective welding sets.

25.1.4The contractor shall ensure


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

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Grounding from welding return connection shall be done only on work piece. Return connection
shall not be grounded with scaffold member, pipe racks or pipes containing flammable liquid or
gases.
Used electrode shall be collected and shall be disposed properly.

25.1.5Periodic Inspection shall be carried on the welding transformer and the record shall be submitted to
owner/consultant/ EIL

Attachment 27: Welding Set Checklist

25.2 Gas Cutting Activity


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

Attachment 28: Gas Cutting Set Checklist

25.3 Grinding/ Cutting Activity


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

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All grinding/ cutting machines shall be guarded.


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

Attachment 29: Grinding Machine Checklist

26.0 Fire Prevention and Control


26.1 The contractor shall take every precaution and use all reasonable means to prevent an outbreak of
fire and shall tender immediate assistance in case of fire. Any outbreak of fire in or near the
workplace shall immediately be reported to the owner/consultant/ EIL.

26.2 The contractors shall provide adequate number of well-maintained fire extinguishers at each work
area.

26.3 Extinguishers should be sited in such a way that it is not necessary to travel more than 15 meters
from the site of the fire to reach the extinguishers. The location of fire extinguishers shall be clearly
marked by sign boards.

26.4 Contractor shall provide fire extinguishers as per IS 2190:1992

Type of occupancy Recommended scale of equipment to be installed


One 4.5 kg capacity carbon dioxide extinguisher for every 100
Office, Computer installations, 2
m of floor area or part thereof with minimum of
record rooms,
two extinguishers so located as to be available within 10 m
2
5 kg capacity dry powder extinguisher for every 600 m area
Workshops, painting shops,
with minimum of four extinguishers per compartment.
generator rooms
Extinguishers should be available within 15 m radius.
Flammable liquid stores, 2
5 kg capacity dry powder extinguisher for every 600 m area
storage in drums and cans in
with minimum of four extinguishers per compartment.
open, paints and varnishes
Extinguishers should be available within 15 m radius.
godown.
One 10 kg dry powder extinguisher or 6.8 kg carbon dioxide
2
extinguisher for 100 m of floor area or part thereof,
Storage area of LPG and other
with minimum of one extinguishers of the same type for
industrial gases.
every compartment; extinguisher should be available within a
radius of

26.5 The contractor shall ensure that workmen are trained in the use of fire extinguishers, understands the
basics of fire fighting and train the workmen to become familiar with such Fire Fighting Procedures

26.6 Fire drills should be held at regular intervals to ensure personnel are familiar with the location, of
Assembly Point and response expected of them in case of emergency.

26.7 Smoking on site is strictly prohibited. No Smoking signboards shall be displayed at prominent
location including stores/ storage places.

26.8 Care of flammable materials, oily rags, waste etc. shall not be left lying around or allowed to
accumulate. Covered metal skips should be used for disposal of flammable waste.

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26.9 If hot work operations are to be carried out, non-flammable screens and blankets shall be used to
confine sparks hot metal or slag. A fire extinguisher should also be readily available.

26.10 Chemicals and other such goods should be stored in stable racks properly labelled. Mutually
reactive chemicals should be kept away from each other. Storage place should have proper
ventilation.
26.11 Fire extinguishers shall be Periodically Inspected and the record shall be submitted to
owner/consultant/ EIL.

Attachment 30 Fire Extinguisher Checklist

27.0 Compressed Gases and Combustible Liquids


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

27.2 Combustible Liquids


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

28.0 Work at Height


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

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No loose materials shall be kept on working platform and shall be kept on baskets.
Safety net shall be used for all height works, where ever feasible.

28.1 Scaffolds
Scaffolding shall be properly designed and erected, with its intended use, where additional,
anticipated loads are to be applied; the structure shall be redesigned and modified accordingly. All
scaffolding material shall be as per relevant IS specification.

Light Duty Scaffold


Distribution load on platform is 0.75 KN/sq.m. (Maximum bay length 2.7 m)
Medium duty scaffold
Distribution load on platform is 1.5 KN/sq.m. (Maximum bay length 2.4 m)
Heavy duty scaffold
Distribution load on platform is 3.0 KN/sq.m. (Maximum bay length 1.8 m)

Bamboo and wooden scaffolding is prohibited. Only steel pipe scaffold shall be permitted.
Return cable of welding machine shall not be connected with scaffolds member.
Scaffold shall be inspected every week or after any adverse weather condition like rain, cyclone
etc.
Scaffold inspection record shall be submitted to owner/consultant/ EIL immediately after inspection.

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

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Attachment 31: Scaffolding Checklist

28.1.2Scaffold Dismantling
Scaffold shall be dismantled by scaffolders under the supervision of competent supervisor.
Area shall be cordoned-off before commencement of scaffold dismantling.
Warning/ notice board shall be displayed as Scaffold Dismantling under progress Shall be
displayed in Hindi, English or vernacular languages.
Dismantling shall be from top to bottom plan wise.
Bracing shall be removed first and then all horizontal members in one plane.
After reaching to second last horizontal plane, first bracing of 3 m from ground level plane shall be
installed. Then the horizontal members from second level shall be removed.
Loose members shall be segregated and shall be collected in boxes and shall be lowered
properly.
Loose scaffold member shall be lowered down by rope and not by using men chain or throwing.
While dismantling or erecting scaffold spanner shall be used with proper string in hand to avoid
any fall.

28.1.3Mobile Scaffolds
Mobile scaffold shall be used on a level and smooth surface only.
The minimum base dimensions for mobile scaffolds used internally and externally shall be 3.5 and
3.0 times respectively.
If the tower is exposed to movement or exposed to more than light winds, physical ties shall be
used.
Mobile tower scaffolds shall have wheels fitted at base with a locking device.
Mobile scaffold shall not be moved by carrying any workmen or loose materials.

28.1.4Ladders and Staircases


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

29.0 Manual Handling


The contractor shall ensure that no worker lifts by hand or carries overhead or over his back or
shoulders any material, article, tool or appliances exceeding in weight as said below.
Adult man : 55 Kg
Adult woman : 30 Kg

Capability of worker for manual material handling should be considered in before assigning the task.

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Contractor shall train the workmen on safe lifting posture.


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

30.0 Slings and Lifting Gears (Rigging)


30.1 General
Slings include wire rope slings, synthetic web slings, chain slings and metal mesh sling. Lifting gears
include block, hook and shackles.

The contractor shall offer his slings and lifting gears for inspection and approval of
owner/consultant/ EIL before putting it in to the job.

Contractor shall submit manufacturers test certificate and test certificates from Govt. approved
certifying authorities for all of his lifting gear and slings.

Lifting gear in use shall be thoroughly examined once at least in every twelve months by a competent
person.

The Safe Working Load (SWL) and manufacturers serial numbers shall be clearly marked on the
slings and the lifting gears, either by tagging, stamping, engraving or embossing. These markings on
lifting gears and slings shall be inspected and a register shall be maintained.

If SWL and manufacturers serial numbers is not clearly marked, those slings and lifting gears shall
be prohibited to use.

Attachment 32: Slings and Lifting Gear Register

30.2 Wire Rope Sling


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

Attachment 33: Monthly Wire Rope Inspection Checklist

30.3 Chain Sling


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

30.4 Synthetic Webbing Slings


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

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Attachment 33: Monthly Web Sling Inspection Checklist

30.5 Hooks
Hooks shall be fitted with safety latch on hook opening so that slings cannot be displaced.
Loads shall be applied only in the part designed to take them, Point load shall be avoided as point
load results in overstressing the hook causing it to break.
0
The hook shall be removed from the service if there is a visible crack and if it is twisted 10 out of
place.

30.6 Shackles
Contractor shall use the correct pin for each shackle. Rebar, mild steel bolts are not acceptable
replacement for shackle pin.

30.7 Spreader Beam


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

31.0 Lifting Appliances


31.1 General
Lifting appliances means mobile cranes, derricks, tower cranes, overhead cranes, chain pulley
blocks, forklift, strand jacks, hydraulic jacks etc.

All lifting appliances including all parts and gears thereof, whether fixed or movable shall be
thoroughly tested and examined by a competent person at least once in a year or after it has
undergone any alterations or repairs liable to affect its strength or stability. Within the validity, if the
lifting appliances are shifted to a new site, re-examination by the same competent person for
ensuring its safety shall also be done.

Contractor shall maintain list of lifting appliances, lifting appliances maintenance register and shall be
submitted to owner/consultant/ EIL on regular basis.

The contractor shall not employ any person to drive or operate lifting appliances unless he is above
twenty-one years of age and possesses a valid heavy transport vehicle driving licence as per Motor
Vehicle Act and Rules.
The operator shall possess the knowledge of the inherent risks involved in the operation of lifting
appliances.

The operator shall be is medically examined and the report shall be submitted to owner/consultant/
EIL.

The laminated photocopies of test certificates issued by competent person, the operators photo,
manufacturers load chart shall be displayed in the operator cabin.

Safe Working Load (SWL) shall be clearly displayed on lifting appliances.

Hooks shall be fitted with safety latch on hook opening so that slings cannot be displaced.

Lifting appliances shall be periodically inspected and reports shall be submitted to owner/consultant/
EIL.

Attachment 35: Crane Register

31.2 Hydraulic Mobile Crane


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

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indicators, etc. shall be periodically examined and maintained always in working condition.
Boom shall be free from bents, cracks, rust, flaking or cracked paint, bulges, greases etc.
Hydraulic pipes any fittings shall be free from any leak.
The operator cabin shall have wind shield, wipers etc. The wind shield shall be clean ad free from
cracks.
Fire extinguisher shall be provided at operator cabin.

Attachment 36: Daily Crane Inspection by Operator

Attachment 37: Monthly Crane Inspection

31.3 Chain Pulley Blocks


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

31.4 Tower Cranes


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

32.0 Lifting Activity


32.1 Lifting of Material
Contractor shall designate a rigging co-ordinator who shall have adequate knowledge, skill,
experience, qualification and training who shall successfully demonstrate to solve problems related to
safe crane operation. This rigging co-ordinator shall prepare a rigging plan, supervise and control all
lifting activities.
Contractor shall submit a detailed method statement/ rigging plan for critical and heavy lift by
considering following
Rigging sketch
Details of the crane
Rated capacity of crane
List of rigging hardware
Rated capacity of rigging components
Weight of the rigging gear
Weight of the load
Total weight of the lift (Weight of the rigging gear + Weight of the load)
Dimension of the load
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Crane Radius
Boom Length
Safe working limits of the crane as per load chart
Ground and site condition
Placement of crane
Swing radius
Sling angles
Hand signal and necessary communication to be used.

Contractor shall submit all manufactures operator manual, third party test certificate to
owner/consultant/ EIL.

Before beginning any crane operation the supervisor and operator shall complete the pre-lifting
checklist. The same shall be submitted to owner/consultant/ EIL.

Attachment 38: Per-Lift Checklist

The outrigger of the crane shall be fully extended prior to the lift and shall be padded on firm base.

The operator shall have valid operator license.

Lifting activity shall not be carried out when wind velocities is 25km/hr or greater or during other
adverse condition.

Sufficient clearance shall be maintained while working near over head power lines
Up to 250,000 volts at least six meter clearance shall be maintained.
Above 250,000 volts at least 7.5 meter clearance shall be maintained.

Contractor shall deploy only the riggers having sufficient knowledge, experience and skill.

A trial lift shall be carried out, raising the load a short distance above its pick-up point, to check the
stability of the crane, and the efficiency of the brakes.

Tagline shall be used to control the load swing.

Crane boom swing radius shall be barricaded and safety sign boards shall be displayed.

Signal man shall be provided with retro-reflective jacket and he is the only authorised person to give
signal to the operator.

No person shall move beneath the load and travel on the load.

32.2 Lifting of Personnel


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

33.0 Construction Vehicle


33.1 Dumpers, trailers, trucks, excavators, transit mixers, road rollers, tractors piling rigs, cranes, tipper,
lorry loaders, skip wagons, crawler tractors, scrapers, graders, tankers etc are considered as
construction vehicles.

33.2 The contractors shall provide a list of vehicles needed to be used at site and formulate a procedure
relating to construction vehicle inspection, operation and maintenance. It must be consistent with the
manufacturer's recommendations and consultants requirements.

Contractor's construction vehicles are to be periodically inspected and maintained according to pre-
determined schedule. Records of all inspection and maintenance shall be maintained and submitted
to owner/consultant/ EIL on regular basis.

Vehicle maintenance or repairing work shall not be carried out inside the construction site.

33.3 Operators entering site shall be instructed to follow the safe system of work adopted on site. These
shall be preferably, written instructions showing the relevant site rules, the site layout, delivery areas,
speed limits, etc.

33.4 All vehicle operators shall undergo medical fitness test, audiometric test and vision check test. The
medical certificates of those operators shall be submitted to owner/consultant/ EIL.

33.5 Vehicle operator shall possess valid driving license.

33.6 All construction vehicles shall have


RC and Pollution under Control (PUC) certificate
Exhaust shall be fitted with flame arrestor.
Horn, mirrors, head and tail lights, indicators, reflectors etc.
Parking brake and brake light
First Aid kit
Fire extinguishers

All Vehicles shall be fitted with audible reverse alarms and maintained in good working condition.
Reversing shall be done only when there is adequate rear view visibility and under the directions of a
banksman.
All vehicles shall be equipped with wind shields and wipers. Cracked or broken wind shields shall be
replaced.

33.7 At start of each shift operator shall check oil, fuel, water and hydraulic levels, that all gauges are
working and the vehicle is functioning smoothly.
33.8 The maximum speed limit on the construction site is 20-km/ hr. The maximum speed limit in work
areas is 15-km/ hr.

Personnel must not be transported while standing on the bed of trucks or trailers or on material
handling / earth mounting equipment or they shall not be allowed to sit on doors.
Material extending from vehicle bed shall be indicated with red flag.
The latch on the dumper skips shall be in working order and release mechanism shall function
smoothly.
The operators shall turn-off the engine and remove the ignition key before leaving the vehicle.
Before moving the vehicle operator shall walk around it to see the area is clear. No one shall be
allowed to sit or lie around or beneath the vehicle.

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Wheel stopper shall be provided to while parked at slopes, place near any excavations etc.

33.9 Parking and Vehicle movement in Refinery Premises


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

Attachment 39: Construction Vehicle

34.0 Construction Machinery


The contractor shall ensure at the construction site all motors, cogwheels, chains and friction
gearing, flywheels, shafting, dangerous and moving parts of machinery are guarded. The guard of
dangerous part of machinery is not removed while such machinery is in motion or in use.
34.1 Air receivers / compressors
Contractor shall ensure that air receivers/ compressors shall be
In good condition and properly maintained.
Individually identified and marked with their safe working pressure.
Be accompanied by a valid test certificate.
Fitted with a properly set pressure relief valve.
Examined and the pressure relief valve tested by an independent examiner at yearly intervals.
A register containing relevant details about the air receivers, compressors shall be maintained at
site such as identification numbers, dates of inspections, pressure ratings etc.
All compressed air fittings shall be wired and/or restrained to prevent them from whipping should
the coupling separate.

Only hose clamps designed for compressed air service shall be used. Worm drive (jubilee) clips
are not acceptable.

35.0 Noise
Noise must be kept to a minimum at all times and must not exceed acceptable and/or any work
activity which is likely to expose any employee on site to a noise level of 85 db(A) or above,
assessments should be carried out. In such circumstances, the contractor must keep stocks of
ear defenders or other suitable hearing protection and issue to the workmen who are exposed to
the higher levels of noise.
The Contractor shall ensure that noise generated from all powered mechanical equipment shall
be effectively reduced using the most modern techniques available including but not limited to
silencers and mufflers.
The Contractor shall construct acoustic screens or enclosures around any parts of the works from
which excessive noise may be generated.
Grinders, Cutters, Jack Hammer (pneumatic drills), Engine driven plant and the like, all give off
levels of noise that is harmful.
Earplugs and earmuffs are the commonest form of hearing protection to be used.

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36.0 Confined Space


36.1 General
A confined space is large enough and so configured that an employee can bodily enter and perform
assigned work, has limited or restricted means for entry or exit and is not designed for continuous
employee occupancy.

A person passes through an opening into a confined space and is considered to have occurred as
soon as any part of the entrant's body breaks the plane of an opening into the space is confined
space entry.

The danger may be as a direct result of a process being undertaken by persons in confined space
and the activities such as spray painting, use of cleaning fluids (solvents), hot work, abrasive
blasting, arc air gouging were considered as dangerous activities.

The hazards involved are asphyxiation, fire and explosion, oxygen enrichment or deficiency, dust and
fumes, electrocution, heat exhaustion.

36.2 Preparation
Contractor shall prepare method statement and submit to owner/consultant/ EIL for review at least
seven days prior to the commencement of the activity. Method statement for work in confined space
shall address the following as minimum.
Work scope and methodology
Nominated supervisors for obtaining permit to work and overall controller of the work activity.
Nominated stand by persons
Tools and equipments to be used
Explosion proof fittings
Flame proof lighting arrangement including emergency lighting
Ventilation arrangement
Access
Fire safety and fire extinguisher requirements
First-aid facilities
Rescue procedure and availability of equipment/ resource for rescue

36.3 Authorization
Nominated supervisor is a competent construction engineer who has adequate knowledge, skill,
experience and familiarity about working in confined space.
Contractors nominated supervisor shall ensure that workmen and other supervisors employed for
work in confined space are trained and competent in performing such task before signing the work
permit.
All entry into confined spaces shall be controlled by means of a permit to work and this shall be
obtained from owner/consultant/ EIL.
No new activity shall be introduced in to a confined space without permission and signed approval of
permit to work from owner/consultant/ EIL.

36.4 Access
Clear and safe access shall be maintained continuously while workers are in confined space.
Ladder shall be of suitable size and length.
Adequate lighting shall be provided at all access and egress points.

36.5 Communication
Effective communication shall be maintained between personnel in confined space and outside by
combination of visual/ voice or portable radio.

36.6 Ventilation
Contractor shall check the oxygen level and confined space entry shall only be permitted if level of
oxygen by volume is in between 19.5 percent to 23.5 percent.
The oxygen level shall be surveyed at regular interval while any task is performed in confined space.
The oxygen level survey details shall be maintained in log register.
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Exhaust fan or other mechanical means shall be used to bring Lower Explosive Limit (LEL) 0% or
toxic gas below Threshold Limit Value (TLV). Also Self Contained Breathing Apparatus (SCBA) shall
be used if necessary.
Whenever spray painting is carried out in confined space, forced ventilation shall be provided to
avoid any accumulation of flammable vapours.

36.7 Electrical Safety


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

36.8 Fire Safety


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

36.9 Emergency Rescue


Stand by person shall be deployed at the entrance of confined space to assist in rescue if any.
Stand by person shall be trained in rescue and his duties include evacuation of all entrants in
confined space. Also communicate for any emergency services and assist in rescue.

Stand by person shall be familiar with all possible hazards in confined space and remain outside
confined space entry until relived by another stand by person.
Rescue equipments such as full body safety harness, tripod, lifelines, Self Contained Breathing
Apparatus (SCBA), stretchers, Man basket, crane shall be kept readily available.

37.0 Radiography
Radiography camera must be operated only by licensed radiographers certified by BARC under
the direct supervision of site-in-charge.
Contractor shall submit list of competent persons involved in radiography at least seven days prior
to the commencement of the job.
Contractor shall submit a list of authorised person involved in radiography associated works such
as isolation of sources, radiation survey meter surveyor, area cordon-off crew.
Field radiography shall be carried out during night time where there is no occupancy around.
All radioactive sources must be clearly identified with its strength of the source, activity at different
levels. A warning label should be displayed indicating Danger Radioactive Material.
The area shall be cordoned-off whenever radiography is carried out and the distance to be
cordoned-off is determined by the type and strength of radiation source to be used, the type of
exposure given, nature of occupancy and the total exposure time per week.
The radiation levels along the cordon should be monitored by suitable and calibrated radiation
survey meter to confirm the cordon-off distance is adequate.
Everyone involved in field radiography activity shall wear personnel monitoring badges.
Radiation warning symbols shall be conspicuously posted along the cordon in English, Hindi and
vernacular languages. It shall be readable from a distance of 7 m under normal illumination.
All safeguards should be implemented to ensure that workmen are not crossing the barricades.
The boundary of cordon on all sides shall be adequately illuminated throughout the duration of
radiography.
Red warning lights must be posted at night along boundary of cordon and especially at the point
of entry.

38.0 Hand tools


Contractor shall ensure that all hand tools used shall be of correct type, size and weight for the job.
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Hand tools used for electrical operations shall be properly insulated and shall be non-conductive
type.
Screwdrivers used shall correct size of tip to fit the slot of the screw.
Screw drivers shall not be carried in pockets of clothing.
Hammers handles shall be made of smooth timber. Hammer head should be secured to wooden
handles with proper wedges.
Chisels edges shall be kept sharp all the time. The original shape and angle shall be maintained.
The chisel should be handled by tongs. Holding chisel by hand while chipping shall be avoided.
Shovel blade shall not be allowed to become blunt, turned, split or jagged.
Only spanners and adjustable wrenches shall be used. Improvised extension of spanners may
cause shearing of bolt and slip of tool.
The ordinary wrenches shall not struck by hammer.
Pipe wrenches should be large enough for the job. It should not be struck with hammer nor, shall
be used as hammer.
Pliers used for electrical works shall be fitted with insulated handle.
The hacksaw blade to cut shall be set in hacksaw frame. The teeth shall point forward direction
and sufficient tension should be applied to ensure the blade is maintained rigid.

39.0 Demolition
Prior to the commencement of any demolition work and also during the process of demolition
contractor shall follow the following additional precautionary steps shall be observed.
All roads and open areas adjacent to the particular site shall either be closed or suitably
controlled.

All underground / overground power / telephone cables or water / sewerage lines in the vicinity of
the particular site shall be either suitably diverted or made non-functional for the duration of the
demolition activity.
All practical steps shall be taken to prevent danger to persons employed from risk of fire or
explosion or flooding. No floor, roof or other part of the building shall be overloaded with debris or
materials as to render it unsafe.

40.0 Temporary Structure/Fixtures


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

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Section IV Liquidated Damages

41.0 Penalties for Violation/Non-Adherence of Safety Procedures and Practices


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

Event Penalty

Absence of Resident / safety Engineer of Contractor in


Rs 1000 per meeting
EIL/OWNERs safety meeting
Failure to have regular site safety Inspection (by contractors
Rs 1000 / week
themselves) every week
Failure to conduct Health / Safety / Environment (HSE)
meetings by Contractor at site (in-house) and maintain Rs 1000/month
records

Failure to submit HSE reports/check Lists, etc., by 5th of Rs 1000 /month and Rs 100 / day
every month to EIL/OWNER for further delay
Working without clearance Rs 5000/occasion
Hot work without proper Clearance / permit Rs 10000 / occasion
For not providing shoring / strutting / proper slope and not
keeping the excavated earth at least 1.5M away from the Rs 5000 / occasion
excavated area

41.2 In case the violation / non-compliance of above Safety, Health & Environment rules results in results
in any Physical Injury or Fatal Accident, an additional penalty as given below shall also be imposed
on to the Contractor:

41.3 For any reportable physical injury as per Indian Factories Act - 1948: Additional penalty of 0.5 % of
the contract value subject to a maximum of Rs.2,00,000 (Rs. Two Lakhs Only) per injury in addition
to the penalty of Rs.5000 as per 41.2 above

41.4 For Fatal accident: Additional penalty of 1 % of the contract value subject to a maximum of
Rs.10,00,000 (Rs. Ten Lakhs Only) per fatality in addition to the penalty of Rs.5000 as per 41.2
above.

42.0 Compensation in case of Accidents


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

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42.1 In case of fatal accidents: Rs.1.0 lacs (Rs. One Lakhs) within 5 days of accident.

42.2 In case of loss of both the limbs (hand / legs/eyes/ ears) : Rs.50,000/- (Rs. Fifty Thousand ) within 1
week.

42.3 In case of loss of one limb (hand / legs/eyes/ ears) : Rs.25,000/- (Rs. Twenty Five Thousand ) within
1 week.

42.4 In case of any injury not specified above, Rs.1000/- (Rs. One Thousand) to Rs.5000/- (Rs. Five
Thousand) as directed by Engineer-in-charge within 1 week.

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CHENNAI

LEGAL OBLIGATIONS / REQUIREMENTS FOR CONSTRUCTION

Factories Act, 1948,


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

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HSE ASSURANCE PLAN

SR ACTIVITY FREQUENCY EXTENT OF CHECKING REMARKS

NO OPERATING CHECKING SUB CONTRACTOR LSTK CONSULTANT


/OWNER
Area Engr Safety Supervisor Safety Officer CONTRACTO
R

1. HSE Policy Communicate to all Once in the Review Contractor to submit.


working at Project site. beginning. implementation
As applicable system

2. Safety committee Through meetings at To be formed consisting Owner, Consultant, Contractor / Sub Contractor and Representatives of workers.
predefined interval.

3. Training (Induction and For everyone As per Training Requirement in HSE Manual Entry passes to be issued only
Periodic) after induction

4. Reporting

4.1 Safety Statistics Monthly Monthly NA NA Monthly Monthly

4.2 Weekly First Aid and Weekly Weekly W Weekly Once a Week R
Illness Reports

4.3 Labour Report with Work Daily Daily Daily Daily Daily R Summary at the end of
hours month

4.4 Incident Reports As applicable As NA W W R


applicable

4.5 Investigation Reports As applicable As NA W W R


applicable

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HSE ASSURANCE PLAN


SR ACTIVITY FREQUENCY EXTENT OF CHECKING REMARKS

NO OPERATING CHECKING SUB CONTRACTOR LSTK CONSULTANT


/OWNER
Area Engr Safety Safety Officer CONTRACTOR
Supervisor

5. Statutory requirements Regular Once in 3 NA NA Monthly R Once in Quarter


(Registration, Records of months
Payment, Licenses)

6. Facilities

i. First Aid Regular R NA W R R Once in a Month

ii. Emergency care services Advance R NA Daily Periodic S Once in a Month


(Doctor, Ambulance) arrangement.

iii. Medical examination (Pre & Regular Periodic N.A. N.A. Periodic S Once in a Month
Periodic)

iv. Temporary accommodation In the beginning R N.A. R R R R

v. Drinking Water tank Filling everyday, Through R N.A. R S R


cleaning once a Records
week

vi. Urinals & Latrines Daily sweeping R N.A. R R R R If applicable


arrangement.

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HSE ASSURANCE PLAN


SR ACTIVITY FREQUENCY EXTENT OF CHECKING REMARKS

NO OPERATING CHECKING SUB CONTRACTOR LSTK CONSULTANT


/OWNER
Area Engr Safety Safety Officer CONTRACTOR
Supervisor

vii. Septic tank/disposal system In the beginning S N.A. W R R R If applicable

viii. Mosquito control Once a week, Through records N.A W R R R If applicable


disinfecting
arrangement

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


6 yrs. more females
employed at site

x. Canteen Required if more R N.A. Daily Monthly R R If applicable


than 250 workers
are employed.

xi. Waste disposal Daily R N.A. Daily monthly R R

7. Fire fighting system S Once in a month N.A. W R R R

8. Traffic rules Daily Daily N.A. W R R R

9. Use of PPE Daily Daily By all, regular basis.

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HSE ASSURANCE PLAN

SR ACTIVITY FREQUENCY EXTENT OF CHECKING REMARKS


NO
OPERATING CHECKING SUB CONTRACTOR LSTK CONSULTANT
CONTRACTOR /OWNER
Area Engr Safety Safety Officer
Supervisor
10. Work permit system S W W R R As applicable
11. Safety publicity Continuous Periodic N.A. N.A. W R
12. Excavation S NB W W R R S
13. Cutouts/openings S NB W W R R S
14. Barricading S Daily W W R R
15. Scaffolds S Regularly W W W R
16. Ladders S Regularly R R R R
17. Welding/cutting M/C S Once in 3 W W W R S
months
18. Elect. Hand tools & S Once in 3 W W R R
Distribution Boards month
19. Mechanical Equipment S Once in 6 W W Rw R S
months
20. LOAD TESTS FOR Heavy lifts W N.A. Rw Rw S Formal procedure
required for heavy lifts

Legends: W Witness
Rw Review of Sub-Contractors document
R Random verification
S Surveillance
NA Not applicable

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Site Safety Organisation Chart


Owner
Owners/PMCs Project Owner/PMCsSafety Representative
/PMC Representative

EIL
Resident Construction Manager

Safety officer

Resident Construction Manager


Contractor

Safety Manager

Safety Engineer

Safety Supervisor Safety Supervisor Safety Supervisor

Safety Observer Safety Observer Safety Observer Safety Observer Safety Observer

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Client: Weekly Safety Meeting


Safety Committee
Project:
Meeting
Project Number Meeting Number:

Confirmation of Meeting Telephone Talk


Date Held : Location :
Date Issued : Recorded by:
Issued By : Distribution:
Subject:
Participants:
Client Consultant Contractor/
EIL

Agreed date
Sl. Target
Remarks in Previous Action by
No Date
meeting

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SAFETY OBSERVATION REPORT (SOR) SUMMARY SHEET

Project Contractor Date From: To:

P - Positive; AR - At Risk: UA - Unsafe Act; UC - Unsafe Condition; LB - Lack of Belief; LT - Lack of Training; LI - Lack of Interest; LR - Lack of Resource; C - Closed; O-Open
SOR
Direct
Observation Indirect Cause SOR SOR Status Closed
Date Time Observer Location Description Cause Corrective Action
category on
P AR UA UC LB LT LI LR C O

Contractors RCM Name Contractors Safety Manager Name


Signature Signature
Date Date
1.7.7.1

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Safe Plan of Action

Contractor Date: From: To: Doc no:


Activity/ Task Work area/ location Rev 0
Job description:
PPE Required
Full body double lanyard Hand gloves
Helmet Safety shoes/ Gumboot Safety goggles
safety harness
Nose mask Ear plug Hard hat with welding Shield Grinding visors/ face shield Others

Safety Devices
Caution tape/ Barricading Sign/Display boards Fluorescent jackets Lifeline/Fall Arrestor Safety net
pipes
Flash back Arrestor Fire extinguisher Fire blanket Warning lights
Others

Steps of Activity/Task Hazard/Reaction to Change Safe Plan Resources

Description Performer (Team members) Approved by Reviewed by


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

Supervisors Signature: Date


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

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General Inspection Report (Safety Walk Around)


Project Contractor
Location Date Time

Name of team members involved in inspection


Sl.No Observation Hazard Identified Corrective Action Remarks

Signature of team members

Contractor shall complete the corrective action and submit the compliance report to EIL/ owner/consultant

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Attachment 9

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Attachment 9

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Monthly Safety Audit Checklist


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

Sl. Possible Obtained


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

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Page 2 of 6

Project Date Location


Contractor Audit No. Audit Team members:

Sl. Possible Obtained


Description Observation
No Score Score
D Work at height 20
17 Edge protection & floor opening protection provided? 5

18 Fully planked working platform with handrails, mid rails & toe- 5
guards with secured access ladder extending 1 m from
19 Fall arrestors, lifelines & safety nets in use wherever 5
necessary?
20 Ensuring everyone anchoring the safety harness when 5
exposed to a fall of 2m and above
E Scaffolds & ladders 40
21 Scaffold designed & erected by trained personnel 5

22 Scaffolding checklist prepared and displayed? Scaffold 5


tags displayed?
23 Scaffold erected on a level surface with base plate / sole plate? 5

23 Appropriate scaffold materials are used & installed 5


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

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Page 3 of 6
Project Date Location
Contractor Audit No. Audit Team members:

Sl. Possible Obtained


Description Observation
No Score Score
G Electrical 50

33 Electrical Inspection register maintained? 5


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

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Page 4 of 6

Project Date Location


Contractor Audit No. Audit Team members:

Sl. Possible Obtained


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

51 Flash Back Arrestors installed in the cutting set (both at 5


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

61 All rigging tools and lifting equipment are in good 5


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

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Page 5 of 6

Project Date Location


Contractor Audit No. Audit Team members:

Sl. Possible Obtained


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

Safety Performance Rating Indicator (Score %) Contractor's Safety Performance


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

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Page 6 of 6
Project Date Location
Contractor Audit No. Audit Team members:

Sl. Responsible Completion


Observation Corrective Action Target date
No Person date

Contractors RCM Endorsement


Date

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

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AT DCU,CPCL CHENNAI

Safety Induction Induction Number


Project Name Project Number
Contractor Date of Induction
Inductee Name Designation
Age Blood Group Experience in Role:

1.0 Introduction about site

2.0 Safety Policy of Owner, Consultant & Contractor

3.0 Alcohol policy, Drugs, No smoking

4.0 Gate pass procedure

5.0 First aid facilities

6.0 Emergency procedure

7.0 Incident Reporting

8.0 Welfare facilities

9.0 Personal Hygiene

10.0 Good housekeeping

11.0 Fire preventions and protections

12.0 Safe Plan of Action (SPA)

13.0 Personal Protective Equipment (PPE)

14.0 Working at height (Ladders, Scaffolding, Safety harness)

15.0 Fall prevention and protection (Open edges, floor cut outs)

16.0 Safe use of hand and power tools

17.0 Material handling

18.0 Electrical safety

19.0 Gas cutting, welding and Gas Cylinders

20.0 Traffic rules

21.0 Movement on site


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

Name of Inductor Name of Inductee


Signature Signature/ Thumb Impression
Date Emergency Contact Number

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Safety Induction Attendance Register (Required only for two or more attendees)
Date of Induction: Total Number of Attendees: Induction Number:
Emergency Signature/
Gate Pass Blood Experience
Sl.No Full Name Designation Age Contractor Permanent Address Contact Thumb
Number Group in Role
Number impression

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Safety Training Matrix


Project Number Project Name
Contractor Training Matrix for the Month of

Supervisor

Electrician
Strength

Bar binder

Operators
Carpenter
Planned

Unskilled

Scaffold

operato
Sl.No Training Topic

Grinder

Vehicle
Painter

erector

Welder
worker

Rigger
Mason

mover
Date

Crane

Earth
Fitter
1. Safety Induction
2. Personal Protective Equipment
3. Housekeeping
4. Work permit
5. First-aid
6. H2S
7. Mock drill
8. Excavation
9. Manual handling
10. Driving Safety
11. Working at Height
12. Scaffold
13. Hot work
14. Heavy lifting and Rigging
15. Fire prevention and protection
16. Electrical Safety
17. Hand and power tools
18. Confined Space Entry
19. Pre-commissioning Safety
20. Lock-out and Tag-out
Contractors Endorsement Date

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Attendance Register for Safety Training


Project Project No

Contractor Topic

Date Location

Time Conducted by

Signature/ Thumb
Sl.No Name Designation Organisation
Impression
1

10

11

12

13

14

15

16

17

Facultys Signature
Date

1.

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Weekly Safety Report

Project Name Name of the Contractor


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

Recordable

Medical Aid
Incidents

Days away from work


Restricted Workday case
First-aid case
Near miss
Property Damage
Environmental Damage
Motor Vehicle Incident
Brief description of the incident during the week (if any):

Safety Metrics
Safety Induction
Tool Box Talks
Safety Training
Positive SOR
Other SOR
Safety Inspection
Safety Audit
Safe Plan of Action (SPA)
Safety Meeting

Contractors RCM endorsement Contractors Safety Manager Endorsement


Date of Submission

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

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MONTHLY HEALTH, SAFETY & ENVIRONMENT (HSE) REPORT

Actual work start Date: Project: For the Month of


Name of the Contractor Name of Work Report No
Job No : Status as on
Contractor in consultation with EIL shall generate the reports through web based package (www.eil.co.in/conthse)

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

To : - OWNER & RCM EIL (2 copies)

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MANAGEMENT AT DCU,CPCL CHENNAI

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MANAGEMENT AT DCU,CPCL CHENNAI

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MANAGEMENT AT DCU,CPCL CHENNAI

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MANAGEMENT AT DCU,CPCL CHENNAI

Incident Reporting Chain and Emergency Contact Numbers

Project: Contractor:

Incident (First Witness)

Immediate Supervisor

Contractors RCM Emergency Services


(Name and Contact Number to be updated) (First-aid centre, Fire Services)

Consultants RCM
(Name and Contact Number to be updated)

Head Office Client


(Name and Contact Number to be updated)

Emergency Contact Numbers


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

Fire Station (To be updated) (To be updated)


Project Security (To be updated) (To be updated)
Police Station (To be updated) (To be updated)
Consultants Safety Department (To be updated) (To be updated)
Contractors RCM (To be updated) (To be updated)
Contractors Safety Manager (To be updated) (To be updated)
Contractors First-aid centre (To be updated) (To be updated)
Consultant RCM (To be updated) (To be updated)
Client (To be updated) (To be updated)

Note:
First witness shall attend the injured person.
Supervisor shall inform emergency services and also the contractors RCM.
All incidents and near miss incidents shall be reported immediately.
Detail report shall be submitted within 24 hours irrespective of Sundays and holidays if any.

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CONTENTS OF A FIRST-AID
BOX

A sufficient number of eye wash bottles filled with distilled water or suitable liquid clearly indicated
by a distinctive sign which shall be visible at all times.
4 per cent xylocaine eye drops, and boric acid eye drops and soda by carbonate eye drops.
Twenty-four small sterilised dressings.
Twelve medium size sterilised dressings.
Twelve large size sterilised dressing.
Twelve large size sterilised burn dressings.
Twelve (fifteen cm) packets of sterilised cotton wool.
(Two hundred ml) bottle of certimide solution (1 per cent) or suitable antiseptic solution.
One (two hundred ml) bottle of mercurochrome (2 per cent) solution in water.
One (one hundred twenty ml) bottle of salvolatile having the doses and mode of administration
indicated on the label.
One pair of scissors.
One roll of adhesive plaster (six cm X one metre).
Two rolls of adhesive plaster (two cms X one metre).
Twelve pieces of sterilised eye pads in separate sealed packets.
A bottle containing hundred tablets (each of three hundred twenty-five mg) of aspirin or any
other analgesic.
Twelve roller bandages ten cms wide.
Twelve roller bandages five cms wide.
One tourniquet.
A supply of suitable splints.
Three packets of safety pins.
Kidney tray.
A snake bite lancet.
One (thirty ml) bottle containing potassium permanganate crystals.
One copy of first-aid leaflet issued by the Directorate General.
Six triangular bandages.
Two pairs of suitable, sterilised, latex hand gloves.

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MANAGEMENT AT DCU,CPCL CHENNAI

Bureau of Indian Standards for PPE

IS : 1179 - 1967 Equipment for eye and face protection during welding.

IS : 1989 -1986 (Part - I & III) Leather safety boots and shoes.

IS : 2925 -1984 Industrial Safety Helmets.

IS : 3521 - 1983 Industrial Safety belts and harness.

IS : 3778 -1975 Rubber knee boots.

IS : 4770 -1968 Rubber gloves for electrical purposes.

IS : 5424 - 1969 Rubber mats for electrical purposes.

IS : 5557 -1969 Industrial and Safety rubber knee boots.

IS : 5983 -1978 Eye protectors.

Code of practice for selections, care and repair of Safety


IS : 6519 -1971
footwear.
IS : 6994 -1973 (Part - I) Industrial Safety Gloves.

Guide for selection of industrial safety equipment for


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

Recommendations for the selection, use and


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

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CHENNAI

Project: Contractor
Personal Protective Equipment Issue Register

Personal Protective Equipment Signature/


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

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AT DCU,CPCL CHENNAI

Personal Protective Equipment & Safety Equipments Stock Register

Date as on: Contractor:


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

Name of Stores In-charge Name of Safety Manager


Signature Signature
Date Date

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AT DCU,CPCL CHENNAI

Diesel Generator Set Checklist

Project Contractor

Inspection Date : Inspected By:

Location: DG ID:

DG Rating Output Current

Sl.No Particulars Observations Remarks

1 Whether DG is acoustic type


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

Name of Electrical Engineer


Signature
Date

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AT DCU,CPCL CHENNAI

Excavation Checklist
Project Contractor
Description of work: Dimension of the pit/ trench:
Sl. Day Mon Tue Wed Thu Fri Sat Sun
ITEMS
No Date

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

Date: Comments

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AT DCU,CPCL CHENNAI

Hot Work Activity Checklist


Project Contractor

Description of work: Hot work permit no:


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

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AT DCU,CPCL CHENNAI

ARC WELDING MACHINE CHECKLIST


Project Contractor:
Site supervisor: Welding m/c ID
Date: Location
No Items Observation Remarks
A WELDING SETS
1 Connections are proper and effectively insulated.
2 ON / OFF switch in good working condition?
3 Voltmeter/ Ammeter connected & working properly?
4 Regulator working properly
5 Welding machine completely covered and no loose
connections?
6 Good earthing and grounding.(Double earthing)
7 Wheels freely rotating?
Compatible Fire extinguisher available for the welding set
8
B CABLE AND JOINTS
1 Supply cable's length exceeding 5m?
2 Connection taken through ELCBs?
Welding cables of proper rating and in proper
3
condition without any damages?
4 Connecting lugs tightened properly?
5 Well insulated and no exposed parts?
6 Size of cable used are proportional to voltage supply
Return earth cable of sufficient length? Are electrical
7
conductors prohibited from being used to complete
8 Any overloading, whereby cables become hot?
9 Any contact with oil / sharp edges or water?
Are cables properly placed to prevent tripping
10
hazards?
C ELECTRODE HOLDERS
Electrode holders used are in good working
1
condition?
2 Properly insulated and no exposed metal parts?
Holders are kept dried and properly hung up after use?
3

4 Not in contact with metal parts.


5 Electrodes are detached after welding.
Name of Electrical Manager Name of Safety Manager
Signature Signature

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AT DCU,CPCL CHENNAI

Gas Cutting Set Checklist


Project Contractor:

Site supervisor: Gas cutting set ID

Date: Location

No Items Observation Remarks


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

6 Are regulators, hoses & fittings free from oil &


grease?
7 Any kinked or tangled hoses?
8 Hoses protected from being run-over?
Are approved flash back arrestors installed at both
9
cylinder and torch ends?
C OTHERS
1 Cylinder keys readily available on cylinder?

2 Proper lighter is used to light the torch?

3 Fire extinguisher & fire blanket readily available?

Name of Safety Manager


Signature

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AT DCU,CPCL CHENNAI

Grinding Machine Checklist


Project Contractor:

Site supervisor: Machine ID

Date: Location

No Items Observation Remarks


A GRINDING MACHINE
1 Any physical damages to the machine?
2 RPM punched/ marked?

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

Name of Safety Manager

Signature

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AT DCU,CPCL CHENNAI

Fire Extinguisher Monthly Inspection

Project

Contractor:

Inspected by:

Visual Inspection
Sl.NO Date Identification No. Result Location Date of Refill Date of Expiry
OK NOT OK

Checklist for Inspection


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

Comments/Remarks

Name of the Inspector


Signature
Date

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CHENNAI

Slings and Lifting Gear Register


Project Contractor
Inspected by: Date: Signature:

Manufacturers Date into service Remarks


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

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CHENNAI

Monthly Wire Rope Inspection Report


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

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CHENNAI

Monthly Synthetic Web Sling Periodic Inspection Report


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

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CHENNAI

Crane Register
Project Contractor
Third Party
Capacity Certificate Date into service Remarks
Sl.No Crane Type Manufacturer Model Year Current Owner
Rating (SWL) Reference
Number

Name of Contractors P& M Manager Name of Contractors Safety Manager


Signature Signature
Date Date

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AT DCU,CPCL CHENNAI

Mobile Crane Inspection

Date Time

Contractor Make

Owner Operator

Load Rating Registration No

Sl.No Description Observation Hazards Identified Remedial Measure


Condition of wire rope
1
(Visual Inspection)
2 Safety latch
3 Tyres Condition
4 Reverse horn
5 Limit Switch

Operator
6 License
Competency Certificate

7 Certificate from third party


8 Hook Condition
9 SWL Marked
10 Load Chart Displayed
11 Any oil leakage
12 Wind Screen
13 Out Riggers

Name of Contractors P&M Manager Name of Contractors Safety Manager

Signature Signature

Date Date

1.7.7.1

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AT DCU,CPCL CHENNAI

Pre-Lift Checklist
Project: Date:

Contractor

Lift Description:
Yes No
1. Crane Operator minimum qualification requirements?

2. Lift calculations and rigging plan completed?

3. Are all required approvals/permits signed?

4. Crane inspections up to date (Monthly/Daily)?

5. Weather conditions and wind speed acceptable?

6. Has the stability of the ground been assured?

7. Matting and/or outrigger pads inspected and approved?

8. Electrical equipment and power lines at required distance?

9. Rigging inspected for defects?

10. Connecting/disconnecting means have been developed?

11. Have the safety precautions been reviewed?

12. The total lifted weight is below 95% of crane capacity capacity?

13. Signal person(s) assigned?

14. Safe Plan of Action (SPA) Completed?

15. Pre-Lift Meeting/SPA talk held?

16. Hoist area & load path cleared of non-essential personnel?

17. Crane set up per the lift plan (radius, configuration, etc)?

18. Rigging equipment and tag line(s) installed per plan?


19. Emergency/Contingency plan in place for power failure, plant upset,
power line contact, lifting over operating equipment, etc.

Name of rigging coordinator:

Signature: Date:

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AT DCU,CPCL CHENNAI

Checklist for Construction Vehicles


Date of Inspection Inspected by

Registration No. Make

Driver Name License type

License No License valid up to

PUC Certificate No and Valid up to RC No and Valid up to

3. Sl.No Description Observation Remarks

1. Operator with valid driving permit


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

Name of Contractors RCM Name of Contractors Safety Manager


Signature Signature

Date Date

Format No. 8-00-0001-F1


Page 195 of 564 Rev. 0
Copyright EIL All rights reserved
SAFETY MEASURES FOR STANDARD No.
alf-ar_Jek ENGINEERS
kVieg INDIA LIMITED ELECTRICAL INSTALLATIONS 7-51-0332 Rev. 2
r222.. ofnok: Unde, tnkir70)
DURING CONSTRUCTION Page 1 of 2

ELECTRICAL POWER IS THE MAINSTAY OF ANY CONSTRUCTION ACTIVITY. AT THE SAME TIME IT REQUIRES
UTMOST CARE IN IT'S UTILISATION TO AVOID ACCIDENTS DUE TO ELECTRICAL SHOCK, FIRE INCIDENTS OR
ELECTRIC SHORT CIRCUITS. EXPOSURE OF ELECTRICAL INSTALLATION TO ADVERSE ENVIRONMENTAL
CONDITIONS INCREASE THE RISK OF SUCH ACCIDENTS. HENCE IT IS NECESSARY TO TAKE EXTRA
PRECAUTIONS FOR SUCH INSTALLATIONS TO ENSURE SAFETY OF PERSONNEL AND EQUIPMENT. THIS
STANDARD ADDRESSES THE SAFETY MEASURES REQUIRED TO BE ADOPTED FOR THE ELECTRICAL
INSTALLATIONS BY ALL CONTRACTORS DURING CONSTRUCTION PHASE.

ALL ELECTRICAL CONNECTIONS/WORK FOR ELECTRICAL INSTALLATIONS SHALL BE CARRIED OUT AS PER
PROVISIONS OF THE LATEST REVISION OF THE FOLLOWING CODES AND STANDARDS IN ADDITION TO THE
REQUIREMENTS OF STATUTORY AUTHORITIES AND IE RULES:
OISDSTD-173 : FIRE PREVENTION AND PROTECTION SYSTEM FOR ELECTRICAL INSTALLATIONS.
SP-30 (BIS) : NATIONAL ELECTRIC CODE.
THE INSTALLATION SHALL HAVE APPROVAL FROM CONCERNED STATUTORY AUTHORITIES.

ALL ELECTRICAL CONNECTIONS SHALL BE DONE BY AN ELECTRICIAN WITH VALID LICENCE AND TO THE
SATISFACTION OF ENGINEERINCHARGE.

ONE COMPETENT LICENCED ELECTRICIAN SHALL BE MADE AVAILABLE BY CONTRACTOR AT SITE ROUND
THE CLOCK TO ATTEND TO THE NORMAL/EMERGENCY JOBS.
ALL SWITCH BOARDS/WELDING MACHINES SHALL BE KEPT IN WELL VENTILATED & COVERED SHED.
THE SHED SHALL BE ELEVATED TO AVOID WATER LOGGING. NO FLAMMABLE MATERIALS SHALL BE
USED FOR CONSTRUCTING THE SHED. ALSO FLAMMABLE MATERIALS SHALL NOT BE STORED IN AND
AROUND ELECTRICAL EQUIPMENT/SWITCHBOARD. ADEQUATE CLEARANCES AND OPERATIONAL SPACE
SHALL BE PROVIDED AROUND THE EQUIPMENT.

FIRE EXTINGUISHERS AND INSULATING MATS SHALL BE PROVIDED IN ALL POWER DISTRIBUTION CENTERS.
TEMPORARY ELECTRICAL EQUIPMENT SHALL NOT BE EMPLOYED IN HAZARDOUS AREAS WITHOUT OBTAINING
SAFETY PERMIT.

PROPER HOUSE KEEPING SHALL BE DONE AROUND THE ELECTRICAL INSTALLATIONS.

ALL TEMPORARY INSTALLATIONS SHALL BE TESTED BEFORE ENERGISING, TO ENSURE PROPER


EARTHING, BONDING, SUITABILITY OF PROTECTION SYSTEM, ADEQUACY OF FEEDERS/CABLES ETC.

ALL WELDERS SHALL USE HAND GLOVES IRRESPECTIVE OF HOLDER VOLTAGE.


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

OPERATION OF EARTH LEAKAGE DEVICE SHALL BE CHECKED REGULARLY BY TEMPORARILY CONNECTING


SERIES TEST LAMP (2 BULBS OF EQUAL RATING CONNECTED IN SERIES) BETWEEN PHASE AND EARTH.

12. THE FOLLOWING DESIGN FEATURES SHALL BE ENSURED FOR ALL ELECTRICAL INSTALLATIONS DURING
CONSTRUCTION PHASE.

12.1 EACH INSTALLATION SHALL HAVE A MAIN SWITCH WITH A PROTECTIVE DEVICE, INSTALLED IN AN
ENCLOSURE ADJACENT TO THE METERING POINT. THE OPERATING HEIGHT OF THE MAIN SWITCH
SHALL NOT EXCEED 1.5 M. THE MAIN SWITCH SHALL BE CONNECTED TO THE POINT OF SUPPLY
BY MEANS OF ARMOURED CABLE.

12.2 THE OUTGOING FEEDERS SHALL BE DOUBLE OR TRIPLE POLE SWITCHES WITH FUSES/MCBs. LOADS
IN A THREE PHASE CIRCUIT SHALL BE BALANCED AS FAR AS POSSIBLE AND LOAD ON NEUTRAL
SHOULD NOT EXCEED 20% OF LOAD IN THE PHASE.

2 02.03.12 REAFFIRMED & ISSUED );t46#14C UAP/JMS DM


1 26.09.06 REVISED & ISSUED AS STANDARAD BP RKS/UAP JMS VC
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Page 196 of 564
Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved
SAFETY MEASURES FOR STANDARD No.
Of=a-ael ENGINEERS
INDIA LIMITED ELECTRICAL INSTALLATIONS 7-51-0332 Rev. 2
015leg, n di o Undertoking;
DURING CONSTRUCTION Page 2 of 2

12.3 THE INSTALLATION SHALL BE ADEQUATELY PROTECTED AGAINST OVERLOAD, SHORT CIRCUIT AND EARTH
LEAKAGE BY THE USE OF SUITABLE PROTECTIVE DEVICES. FUSES WHEREVER USED SHALL BE HRC TYPE.
USE OF REWIRABLE FUSES SHALL BE STRICTLY PROHIBITED. THE EARTH LEAKAGE DEVICE SHALL HAVE
AN OPERATING CURRENT NOT EXCEEDING 30 mA.

12.4 ALL CONNECTIONS TO THE HANDTOOLS/WELDING RECEPTACLES SHALL BE TAKEN THROUGH PROPER
SWITCHES, SOCKETS AND PLUGS.

12.5 ALL SINGLE PHASE SOCKETS SHALL BE MINIMUM 3 PIN TYPE ONLY. ALL UNUSED SOCKETS SHALL BE
PROVIDED WITH SOCKET CAPS.

12.6 ONLY 3 CORE (P+N+E) OVERALL SHEATHED FLEXIBLE CABLES WITH MINIMUM CONDUCTOR SIZE OF
2
1.5 MM COPPER SHALL BE USED FOR ALL HAND TOOLS.

12.7 ONLY METALLIC DISTRIBUTION BOXES WITH DOUBLE EARTHING SHALL BE USED AT SITE. NO WOODEN
BOXES SHALL BE USED.

12.8 ALL POWER CABLES SHALL BE TERMINATED WITH COMPRESSION TYPE CABLE GLANDS.
LUGS SHALL BE USED FOR MULTISTRAND WIRES/CABLES.

12.9 CABLES SHALL BE FREE FROM ANY INSULATION DAMAGE.

12.10 CABLES SHALL BE LAID IN UNDERGROUND AT A MINIMUM DEPTH OF 750 MM, FOR LV & CONTROLS
AND 900MM FOR HV CABLES COVERED WITH SAND, BRICK AND SOIL FOR ENSURING MECHANICAL
PROTECTION. CABLES SHALL NOT BE LAID IN WATER LOGGED AREA AS FAR AS PRACTICABLE
CABLE ROUTE MARKERS SHALL BE PROVIDED AT EVERY 25 M OF BURIED TRENCH ROUTE. WHEN
LAID ABOVE GROUND, CABLES SHALL BE PROPERLY CLEATED OR SUPPORTED ON RIGID POLES OF
ATLEAST 2.1 M HIGH. MINIMUM HEAD CLEARANCE OF 6 METERS SHALL BE PROVIDED AT ROAD CROSSING.

12.11 UNDER GROUND CABLES SHALL NOT BE ALLOWED TO CROSS THE ROADS WITHOUT PIPE SLEEVE

12.12 ALL CABLE JOINTS SHALL BE DONE WITH PROPER JOINTING KIT. NO TAPED/TEMPORARY JOINTS SHALL
BE USED.

12.13 AN INDEPENDENT EARTHING FACILITY SHOULD PREFERABLY BE ESTABLISHED WITHIN THE TEMPORARY
INSTALLATION PREMISES. ALL APPLIANCES AND EQUIPMENT SHALL BE ADEQUATELY EARTHED. IN CASE
ARMOURED CABLES ARE USED, THE ARMOUR SHALL BE BONDED TO THE EARTHING SYSTEM.

12.14 ALL CABLES AND WIRE ROPE USED FOR EARTH CONNECTIONS SHALL BE TERMINATED THROUGH TINNED
COPPER LUGS.

12.15 IN CASE OF LOCAL EARTHING, EARTH ELECTRODES SHALL BE BURIED NEAR THE SUPPLY POINT AND
EARTH CONTINUITY WIRE SHALL BE CONNECTED TO LOCAL EARTH PLATE FOR FURTHER DISTRIBUTION
TO VARIOUS APPLIANCES. ALL INSULATED WIRES FOR EARTH CONNECTION SHALL HAVE INSULATION OF
GREEN COLOUR.

12.16 SEPARATE CORE SHALL BE PROVIDED FOR NEUTRAL. EARTH/STRUCTURES SHALL NOT BE USED AS A
NEUTRAL IN ANY CASE.

12.17 ON/OFF POSITION OF ALL SWITCHES SHALL BE CLEARLY DESIGNATED/PAINTED FOR EASY ISOLATION
IN EMERGENCY.

13. ALL INSULATIONS SHALL BE INSPECTED BY ENGINEERINCHARGE ATLEAST ONCE IN A MONTH.

X--S('S/ 9Th .1
2 02.03.12 REAFFIRMED & ISSUED BP *- - C UAP/J MS DM
1 26.09.06 REVISED & ISSUED AS STANDARD BP RKS/UAP J MS VC
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Page 197 of 564 Approved by
Format No. 8-00-0001-F4 Rev.0 Copyright EIL - All rights reserved
SPECIFIC PROJECT REQUIREMENTS Part A - Section: III
DISTRIBUTED CONTROL SYSTEM A133-000-16-51-SP-1503 Rev. B
RESID UPGRATION PROJECT
CPCL, CHENNAI Page 1 of 4

SECTION-III
(SPECIFIC PROJECT REQUIREMENTS)

B 11-03-2014 REVISED & Issued with MR RK NZ AR

A 17-01-2014 Issued with MR RK NZ AR


Rev. Prepared Checked Approved
Date Purpose
No by by by

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved


Page 198 of 564
SPECIFIC PROJECT REQUIREMENTS Part A - Section: III
DISTRIBUTED CONTROL SYSTEM A133-000-16-51-SP-1503 Rev. B
RESID UPGRATION PROJECT
CPCL, CHENNAI Page 2 of 4

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

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved


Page 199 of 564
SPECIFIC PROJECT REQUIREMENTS Part A - Section: III
DISTRIBUTED CONTROL SYSTEM A133-000-16-51-SP-1503 Rev. B
RESID UPGRATION PROJECT
CPCL, CHENNAI Page 3 of 4

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

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved


Page 200 of 564
SPECIFIC PROJECT REQUIREMENTS Part A - Section: III
DISTRIBUTED CONTROL SYSTEM A133-000-16-51-SP-1503 Rev. B
RESID UPGRATION PROJECT
CPCL, CHENNAI Page 4 of 4

5.2.1 The DCS along with other systems shall be installed in Main Control Room normally maintained at
231C. Bidder must furnish the total ventilation and air-conditioning requirement as per the enclosed
form (Annexure-IV) for MCR.
5.3 Air Quality Requirement
5.3.1 Bidder must fill complete information in the form enclosed (Annexure-V) to indicate the allowable air
quality requirements for the systems i.e. DCS, PLC or any other system as indicated for MCR. In
addition bidder to note that the control room may not have any air quality control. Limitations if any
must be indicated in the same form.
Bidder to note that Chemical filters will be provided in the HVAC system of purchaser to limit the
concentration of contaminants as below:
S02: Less than 0.05 ppm by Volume
NOX: Less than 0.05 NO2 by Volume
H2S: Less than 0.01 ppm
NH3: Less than 0.1 ppm
SPM: Less than 100 micro gram/NM3
CL2: Less than 0.001 ppm by volume
Bidder shall confirm suitability of offered system for the same.
6.0 PROVEN TRACK RECORD
6.1 Bidder shall fill the Proven Track Record (PTR) form enclosed (Annexure-VI) in this section with
information as asked for the system proposed and shall comply with the proven track record
requirement specified in clause no: 4.2.1.2 of PMC job specification for instrumentation ( 44NC-
4600-0000/J.02//0101/A4) attached with MR without exception
6.2 Bidder to note that proven record must be available for the offered console/ controller combination as a
minimum. Accordingly, information must be provided in the form.
6.3 Proposal received without properly filled PTR form not, or incomplete form, or the proposed system/
subsystem(s)/ agency responsible for any activity/ activity location not meeting basic qualification
specified in clause no. 6.4 shall not be evaluated. Activities shall be as defined in Para 8.5 of Proven
Track Record format.
6.4 The system should be supplied, engineered, integrated, tested, etc. from a factory from where the
system/ sub-systems as offered/ supplied have already been supplied, engineered, integrated tested, etc.
6.5 Over and above requirements specified in clause no. 2.3 and 2.4, for system confirming to Safety
Integrity level (SIL) certified by statutory authorities like TUV, etc., the basic engineering of the
system comprising of system configuration diagram, system loading calculation, system scan time
calculation, system network design shall be carried out by the agency on whose name TUV/ SIL
certificate has been issued. Application engineering should be carried out by the agency meeting the
proven-ness requirements as a minimum.
6.6 The system should be supplied by the manufacturer in the fully engineered condition or by the
manufacturers representative/ subsidiary who have proper infrastructural facilities.
Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved
Page 201 of 564
ANNEXURE-I

(SECTION-III)
TO DCS MR A133-000-YE-MR-1500

Page 202 of 564


Page 203 of 564
Page 204 of 564
Page 205 of 564
Part A - Section: III
DISTRIBUTED CONTROL SYSTEM
RESID UPGRADATION PROJECT Annexure II to
A133-000-16-51-SP-1503 Rev. A
CHENNAI PETROLEUM CORPORATION LTD
Page 1 of 7

SECTION-III
ANNEXURE II
(RESPONSIBILITY CHART)

B 11-03.2014 Revised & ISSUED with MR RK NZ AR

A 17-01.2014 ISSUED with MR RK NZ AR


Rev.
Date Purpose Prepared by Checked by Approved by
No

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved


Page 206 of 564
Part A - Section: III
DISTRIBUTED CONTROL SYSTEM
RESID UPGRADATION PROJECT Annexure II to
A133-000-16-51-SP-1503 Rev. A
CHENNAI PETROLEUM CORPORATION LTD
Page 2 of 7

NAME OF VENDOR:
NAME OF THE PRINCIPAL:
SL. DESCRIPTION RESPONSIBILITY ACTIVITY REMARKS
NO OWNED BY OWNED BY OWNED BY LOCATION
BIDDER PRINCIPAL SUB
(YES/NO) (YES/NO) VENDOR
(YES/NO)

A SOURCE OF SUPPLY

1 Controller And Data Acquisition Subsystem

i. Processor Modules
ii. I/O Modules
iii. Communication Modules
iv. Power Supply Modules
v. Any Other (Please specify)

2 Operator Console Subsystem And Engineering Console

i. CPU cabinet including Processor Modules,


Memory Modules, Power Supply Modules and
Communication Modules
ii. Keyboards
iii. Monitors
iv. Any Other (Please specify)

3 Hardwired Instruments

i. PB / SS / Lamps
ii. Interposing relays
iii. Signal Isolators

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved


Page 207 of 564
Part A - Section: III
DISTRIBUTED CONTROL SYSTEM
RESID UPGRADATION PROJECT Annexure II to
A133-000-16-51-SP-1503 Rev. A
CHENNAI PETROLEUM CORPORATION LTD
Page 3 of 7

SL. DESCRIPTION RESPONSIBILITY ACTIVITY REMARKS


NO iv. Safety Barriers LOCATION
v. Line fault detector
vi. FieldBus junction boxes
vii. FieldBus power supplies
viii. Fieldbus Surge Protector
ix. Any Other (please specify)

4 Programmable Logic Controller (PLC) -ESD

i. Processor Module
ii. I/O Modules
iii. Communication Modules
iv. Power Supply Modules
v. Remote I/O Modules
vi. PLC SOE Console
vii. PLC Programming Terminal
viii. Any Other (please specify)

5 Programmable Logic Controller (PLC) F&G

i. Processor Module
ii. I/O Modules
iii. Communication Modules
iv. Power Supply Modules
v. Remote I/O Modules
vi. PLC SOE Console
vii. PLC Programming Terminal

Any Other (please specify)

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved


Page 208 of 564
Part A - Section: III
DISTRIBUTED CONTROL SYSTEM
RESID UPGRADATION PROJECT Annexure II to
A133-000-16-51-SP-1503 Rev. A
CHENNAI PETROLEUM CORPORATION LTD
Page 4 of 7

SL. DESCRIPTION RESPONSIBILITY ACTIVITY REMARKS


NO LOCATION
6 Printers and Hard copier unit

7 Instrument Asset Management System (IAMS)

8 Hardwired Console, Racks and Other System Racks

9 Documentation Node (DON)

10 Unit History Node (UHN)

11 Giant Screen

12 Alarm Information and Management System (AIMS)

13 OPC Server with Firewall

B SYSTEM ENGINEERING

1 Distributed Control System (DCS)

i. Basic System Design


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

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved


Page 209 of 564
Part A - Section: III
DISTRIBUTED CONTROL SYSTEM
RESID UPGRADATION PROJECT Annexure II to
A133-000-16-51-SP-1503 Rev. A
CHENNAI PETROLEUM CORPORATION LTD
Page 5 of 7

SL. DESCRIPTION RESPONSIBILITY ACTIVITY REMARKS


NO vi. System Software Loading and Debugging LOCATION
vii. Fieldbus engineering including segment design
viii. Any Other (Please specify)

2 Programmable Logic Controller (PLC) - ESD

i. Basic System Design


ii. Detailed System Engineering including Finalizing
Worksheets
iii. Standard Configuration and Generation
iv. Logging and Report Generation
v. Foreign Device Interface
vi. Special Software
vii. System Software Loading and Debugging
viii. Any other (please specify)

3 Programmable Logic Controller (PLC) F&G

i. Basic System Design


ii. Detailed System Engineering including Finalizing
Worksheets
iii. Standard Configuration and Generation
iv. Logging and Report Generation
v. Foreign Device Interface
vi. Special Software
vii. System Software Loading and Debugging

Any other (please specify)

4 OPC Server with Firewall

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved


Page 210 of 564
Part A - Section: III
DISTRIBUTED CONTROL SYSTEM
RESID UPGRADATION PROJECT Annexure II to
A133-000-16-51-SP-1503 Rev. A
CHENNAI PETROLEUM CORPORATION LTD
Page 6 of 7

SL. DESCRIPTION RESPONSIBILITY ACTIVITY REMARKS


NO LOCATION
5 Instrument Asset Management System (IAMS)

6 Documentation Node (DON)

7 Unit History Node (UHN)

8 Giant Screen

9 Alarm Information and Management System (AIMS)

C System Integration And Factory Testing

i. Factory Testing of PLC.


ii. Integration of complete system including PLC,
IAMS, OPC server, DON, Giant Screen, AIMS
and DCS.
iii. Integrated Factory acceptance testing
iv. Interface of CCTV with Giant Screen

D Installation, Field Testing & Commissioning

E Training

i. DCS including IAMS, DON, AIMS etc


ii. PLC ESD
iii. PLC F&G

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved


Page 211 of 564
Part A - Section: III
DISTRIBUTED CONTROL SYSTEM
RESID UPGRADATION PROJECT Annexure II to
A133-000-16-51-SP-1503 Rev. A
CHENNAI PETROLEUM CORPORATION LTD
Page 7 of 7

SL. DESCRIPTION RESPONSIBILITY ACTIVITY REMARKS


NO LOCATION
F Post Warranty Maintenance Contract for 5 years

i. DCS
ii. PLC ESD
iii. PLC F&G
iv. Instrument Asset Management system (IAMS)
v. Foundation Field Bus interface Devices
vi. Alarm Information and Management System
(AIMS)
vii. Any Other bought out items supplied by bidder
(Please Specify)

G Any Other (Please Specify)

NOTES:
1. Bidder must fill the form completely.
2. Information filled in this form shall be unambiguous and without any qualification.
3. In case vendor does not have any proven record, it must be backed by the collaborator and accompanied by the letter from the collaborator for the back up
guarantee.
4. While filling this format Bidder must ensure that the prime responsibility shall be owned by the original equipment manufacturer of the equipment, while
overall responsibility shall be owned by the bidder.

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved


Page 212 of 564
Part A - Section: III
DISTRIBUTED CONTROL SYSTEM
RESID UPGRADATION PROJECT Annexure III to
A133-000-16-51-SP-1503 Rev. A
CHENNAI PETROLEUM CORPORATION LTD
Page 1 of 5

SECTION-III
ANNEXURE III
(POWER CONSUMPTION AND UPS REQUIREMENT)

B 11-03-2014 Revised & ISSUED with MR RK NZ AR


A 17-01-2014 ISSUED with MR RK NZ AR
Rev.
Date Purpose Prepared by Checked by Approved by
No

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved


Page 213 of 564
Part A - Section: III
DISTRIBUTED CONTROL SYSTEM
RESID UPGRADATION PROJECT Annexure III to
A133-000-16-51-SP-1503 Rev. A
CHENNAI PETROLEUM CORPORATION LTD
Page 2 of 5

Sl Item description Unit Total Power factor Inrush current Duration


No consumption Consumption (A) (ms)
(VA) (VA)

Location: MCR

1 DCS Controller/ Controller File

2 DCS Data acquisition I/O Modules


i. Fieldbus Interface Module
ii. 4-20mA
iii. Digital input
iv. Digital Output
v. Serial Interface
vi. Any other Module ( Please specify)

3 DCS Controller & Data Acquisition Cabinet


with maximum loading

4 DCS Marshalling Cabinets

5 DCS Operator console, with electronics &


monitor only

6 DCS Engineering station, with electronics


&monitor only

7a ESD PLC Processors

7b F&G PLC Processors

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved


Page 214 of 564
Part A - Section: III
DISTRIBUTED CONTROL SYSTEM
RESID UPGRADATION PROJECT Annexure III to
A133-000-16-51-SP-1503 Rev. A
CHENNAI PETROLEUM CORPORATION LTD
Page 3 of 5

8a ESD PLC I/O Modules


i. 4-20mA
ii. Digital input
iii. Digital Output
iv. Any other Module (Please specify)

8b F&G PLC I/O Modules


i. 4-20mA
ii. Digital input
iii. Digital Output
iv. Any other Module (Please specify)

9a ESD PLC processor and I/O cabinet with


maximum loading

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


maximum loading

10a ESD PLC Marshalling Cabinets

10b F&G PLC Marshalling Cabinets

11a ESD PLC Engineering Station, with


electronics & TFT only

11b F&G PLC Engineering Station cum Operator


Station, with electronics & TFT only

12a ESD PLC SOE station, with electronics & TFT


only

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved


Page 215 of 564
Part A - Section: III
DISTRIBUTED CONTROL SYSTEM
RESID UPGRADATION PROJECT Annexure III to
A133-000-16-51-SP-1503 Rev. A
CHENNAI PETROLEUM CORPORATION LTD
Page 4 of 5

12b F&G PLC SOE station, with electronics & TFT


only

13 Hardwired consoles, with instruments installed

14 Hard copier unit

15 Multi-purpose color printer

16 Instrument Asset Management System

17 Foreign device interface, if mounted separately


and as applicable
i. Machine Monitoring system
ii. Governor control system
iii. Anti surge control system
iv. Any other ( Please specify)

18 OPC Servers

19 Documentation Node

20 Alarm Information & Management System

21 Network Components

22 Giant Screen

23 CCTV System with detail break up

24 Unit History Node

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved


Page 216 of 564
Part A - Section: III
DISTRIBUTED CONTROL SYSTEM
RESID UPGRADATION PROJECT Annexure III to
A133-000-16-51-SP-1503 Rev. A
CHENNAI PETROLEUM CORPORATION LTD
Page 5 of 5

25 C & M Printer

26 Training Kit

27 Any other ( Please indicate)

TOTAL POWER CONSUMPTION IS _________ VA @ _______ LEAD/ LAG POWER FACTOR


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

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved


Page 217 of 564
Part A - Section: III
DISTRIBUTED CONTROL SYSTEM
RESID UPGRADATION PROJECT Annexure IV to
A133-000-YE-SP-1503 Rev. A
CHENNAI PETROLEUM CORPORATION LTD
Page 1 of 7

SECTION-III
ANNEXURE IV
(VENTILATION & AIR CONDITIONING REQUIREMENTS)

A 17-01-2014 ISSUED with MR RK NZ AR


Rev.
Date Purpose Prepared by Checked by Approved by
No

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved


Page 218 of 564
Part A - Section: III
DISTRIBUTED CONTROL SYSTEM
RESID UPGRADATION PROJECT Annexure IV to
A133-000-YE-SP-1503 Rev. A
CHENNAI PETROLEUM CORPORATION LTD
Page 2 of 7

NAME OF VENDOR:

Temp. Limits Humidity Temp. Humidity Operating time


Sl. Unit load Total load limits for Limits for limits for without air-
Item description for operation
No. (kcal/hr) (kcal/hr) operation storage storage conditioning
(oc) (%) (oc) (%) (s)
Location: Main Control Room
Console Area

A DCS Operator console, with electronics & monitor


only
1
Hardwired consoles, with instruments installed

2 Giant Screen

3 Network Components

4 CCTV Monitor

5 Printer
6 Any other ( Please indicate)
TOTAL HEAT LOAD _______________ kCAL/h

Temp. Limits Humidity Temp. Humidity Operating time


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

B Engineering Room Area

1 DCS Engineering station, with electronics &


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

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Page 3 of 7

Temp. Limits Humidity Temp. Humidity Operating time


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

3 PLC SOE Station

4 Hard Copier Unit

5 Multipurpose printer

6 C&M printer

7 Instrument Asset Management System

8 OPC Servers

9 Documentation Node (DON)

10 Alarm Information & Management System

11 Network Components

12 CCTV Programming Unit & Printer

13 Any other ( Please indicate)

TOTAL HEAT LOAD _______________ kCAL/h

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Page 4 of 7

Temp. Limits Humidity Temp. Humidity Operating time


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

C Rack Room

1 DCS Controller/ Controller File

2 DCS Data acquisition I/O Modules


i. Fieldbus Interface Module
ii. 4-20mA
iii. Digital input
iv. Digital Output
v. Serial Interface
vi. Any other Module ( Please specify)

3 DCS Controller & Data Acquisition Cabinet


with maximum loading

4 DCS Marshalling Cabinets

5 PLC Processors (ESD)

6 PLC I/O Modules (ESD)


i. 4-20mA
ii. Digital input
iii. Digital Output
iv. Any other Module ( Please specify)

7 PLC processor (ESD) and I/O cabinet with


maximum loading

8 PLC (ESD) Marshalling Cabinets

9 Foreign device interface, if mounted

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CHENNAI PETROLEUM CORPORATION LTD
Page 5 of 7

Temp. Limits Humidity Temp. Humidity Operating time


Sl. Unit load Total load limits for Limits for limits for without air-
Item description for operation
No. (kcal/hr) (kcal/hr) operation storage storage conditioning
(oc) (%) (oc) (%) (s)
separately and as applicable
i. Machine Monitoring system
ii. Governor control system
iii. Anti surge control system
iv. Wireless Gateway
v. Any other ( Please specify)

10 PLC Processors (F&G)

11 PLC I/O Modules (F&G)


i. 4-20mA
ii. Digital input
iii. Digital Output
iv. Any other Module ( Please specify)

12 PLC processor (F&G) and I/O cabinet with


maximum loading

13 PLC (F&G) Marshalling Cabinets

14 Network Components

15 CCTV System

16 DCS Engineering work stations with monitor

17 PLC engineering work stations with monitor

18 SOE PLC PC

19 SOE PLC PRINTER

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Page 6 of 7

Temp. Limits Humidity Temp. Humidity Operating time


Sl. Unit load Total load limits for Limits for limits for without air-
Item description for operation
No. (kcal/hr) (kcal/hr) operation storage storage conditioning
(oc) (%) (oc) (%) (s)
OPC SERVER
20
19 Any other ( Please indicate)
TOTAL HEAT LOAD _______________ kCAL/h

Temp. Limits Humidity Temp. Humidity Operating time


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

D OPC Server Room

1 OPC server

2 Client PC

3 OPC server Printer

4 Any other ( Please indicate)

E TRAINING ROOM

1 Training System with break up

2 Operator Work Station

3 Any other ( Please indicate)

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RESID UPGRADATION PROJECT Annexure IV to
A133-000-YE-SP-1503 Rev. A
CHENNAI PETROLEUM CORPORATION LTD
Page 7 of 7

Temp. Limits Humidity Temp. Humidity Operating time


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

TOTAL HEAT LOAD _______________ kCAL/h

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Part A - Section: III
DISTRIBUTED CONTROL SYSTEM
RESID UPGRADATION PROJECT Annexure V to
A133-000-YE-SP-1503 Rev. A
CHENNAI PETROLEUM CORPORATION LTD
Page 1 of 2

SECTION-III
ANNEXURE V
(AIR QUALITY REQUIREMENTS)

A 17-01-2014 ISSUED with MR RK NZ AR


Rev.
Date Purpose Prepared by Checked by Approved by
No

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Part A - Section: III
DISTRIBUTED CONTROL SYSTEM
RESID UPGRADATION PROJECT Annexure V to
A133-000-YE-SP-1503 Rev. A
CHENNAI PETROLEUM CORPORATION LTD
Page 2 of 2

NAME OF VENDOR:
SYSTEM: DCS Vendor / Sub Vendor: ..
All consoles including All Disks & Disk
Sl. No Maximum Allowable Concentration of All cabinets All Printers
Keyboards Drives

1 CORROSIVE GASES (in ppm)


i. Hydrogen Sulphide
ii. Sulphur Dioxide
iii. Chlorine
iv. NO/ NO2/ NOx
v. Any Other (Please Specify)

2 i. Maximum Dust concentration (in g/m3)


ii. Dust Particle Size

SYSTEM: PLC Vendor / Sub Vendor: ..


All consoles including All Disks & Disk
Sl. No Maximum Allowable Concentration of All cabinets All Printers
Keyboards Drives

1 CORROSIVE GASES (in ppm)


i. Hydrogen Sulphide
ii. Sulphur Dioxide
iii. Chlorine
iv. NO/ NO2/ NOx
v. Any Other (Please Specify)

2 i. Maximum Dust concentration (in g/m3)


ii. Dust Particle Size

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Part A - Section: III
DISTRIBUTED CONTROL SYSTEM
RESID UPGRADATION PROJECT Annexure VI to
A133-000-YE-SP-1503 Rev. A
CPCL LTD
Page 1 of 5

SECTION-III
ANNEXURE VI
(PROVEN TRACK RECORD)

A 17-01-2014 ISSUED with MR RK NZ AR


Rev.
Date Purpose Prepared by Checked by Approved by
No

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Part A - Section: III
DISTRIBUTED CONTROL SYSTEM
RESID UPGRADATION PROJECT Annexure VI to
A133-000-YE-SP-1503 Rev. A
CPCL LTD
Page 2 of 5

Sl. Description As offered for System as installed System as installed System as installed System as installed
No this project @ site 1 @ site 2 @ site 3 @ site 4
1 Name of the Plant

2 Name, Address, Telephone No./ Fax No.


& E-mail of the contact person in the
Plant

3 Name, Address, Telephone No./ Fax No.


& E-mail of the contact person of the
Consultant

4 Month & Year of System Supply

5 Month & Year of System commissioning

6 Any major breakdowns till date

7 If Yes, Cause of Breakdown

8.1 System details & Model No. for


i. DCS system with all operational
and engineering data base

8.2 System Used for:


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

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Part A - Section: III
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RESID UPGRADATION PROJECT Annexure VI to
A133-000-YE-SP-1503 Rev. A
CPCL LTD
Page 3 of 5

8.3 Major Subsystems


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

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CPCL LTD
Page 4 of 5

ix. PLC interface with the DCS:


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

8.4 System Details


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

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DISTRIBUTED CONTROL SYSTEM
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CPCL LTD
Page 5 of 5

vi. MIS Reports


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

8.5 Scope of Vendor Responsibility


i. Design & Supply
ii. System Engineering
iii. Installation
iv. Testing
v. Commissioning
vi. Training

8.6 Salient Features of the offered System over


the earlier installed

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PROJECT SPECIFICATION Part A - Section: IV
DISTRIBUTED CONTROL SYSTEM A133-000-16-51-SP-1504 Rev. B
RESID UPGRATION PROJECT
CPCL , CHENNAI Page 1 of 2

SECTION-IV
(PROJECT SPECIFICATION)

B 11-03-2014 Revised & Issued with MR RK NZ AR

A 17-01-2014 Issued with MR RK NZ AR


Rev. Prepared Approved
Date Purpose Checked by
No by by

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PROJECT SPECIFICATION Part A - Section: IV
DISTRIBUTED CONTROL SYSTEM A133-000-16-51-SP-1504 Rev. B
RESID UPGRATION PROJECT
CPCL , CHENNAI Page 2 of 2

TABLE OF CONTENTS

S. DESCRIPTION DOCUMENT No. No of Sheets


No.

1 PROJECT INFORMATION A133-000-16-51-SP-1507 4

2 SPECIAL INSTRUCTIONS TO VENDOR A133-000-16-51-SIV-1500 25

3 ADDITIONAL REQUIREMENTS OF DCS / ANNEXURE-A 22


PLC SYSTEM

4 SPECIFICATIONS FOR F&G SYSTEM ANNEXURE-B 12

5 TAGGING PHILOSOPHY FOR JUNCTION ANNEXURE-C 7


BOXES, PANELS AND CABLES

6 CABLES AND JUNCTION BOX ANNEXURE-D 3


REQUIREMENTS

7 PMC JOB SPECIFICATIONS 44NC-4600- 32


(INSTRUMENTATION) 0000/J.02/0101/A4

8 INSTRUMENT CABLE DUCT 20


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

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PROJECT INFORMATION Part A - Section: IV
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CPCL , CHENNAI Page 1 of 4

SECTION-IV
(PROJECT INFORMATION)

A 17-01-2014 Issued with MR RK NZ AR


Rev. Prepared Approved
Date Purpose Checked by
No by by

1.0 INTRODUCTION

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PROJECT INFORMATION Part A - Section: IV
RESID UPGRATION PROJECT A133-000-16-51-SP-1507 Rev. A
CPCL , CHENNAI Page 2 of 4

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

2.0 Plant Description:


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

2.4 Dedicated monitoring/ control systems which are provided for some units, packages by respective
contractor / package vendor are as follows. Interface with those shall be provided with DCU Main
Control Room as defined in the MR.

Sr. Unit/ Package Type of Type of Connection TO DCS


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

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CPCL , CHENNAI Page 3 of 4

System
2. Coke Un-heading Package PLC based Serial Serial
System

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

2.6.2 Then approximate cable distance between process units and Main Control Room are as given below.
Approx.
distance from
Unit/ Area TRAINS/UNITS/SYSTEM respective
units to MCR
(Meters)
Delayed Coker Unit Unit No: 086 550
Composition analyzer in DC Unit No: 086 500
Heater Package Unit No: 086 700
Analyser Shelter in Heater Pkg. Unit No: 086 800
LPG-CFC Unit Unit No: 087 350
Instrument Air Compressor 1250

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PROJECT INFORMATION Part A - Section: IV
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CPCL , CHENNAI Page 4 of 4

Package
Cooling Water System Package 1250

2.7 Site location


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

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SPECIAL INSTRUCTIONS TO Part A - Section: IV
VENDOR A133-000-16-51-SIV-1500 Rev. B
RESID UPGRATION PROJECT
CPCL , CHENNAI Page 1 of 25

SECTION-IV
(SPECIAL INSTRUCTIONS TO VENDOR)

B 11-03-2014 REVISED & ISSUED with MR RK NZ AR

A 17-01-2014 ISSUED with MR RK NZ AR


Rev. Prepared Approved
Date Purpose Checked by
No by by

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SPECIAL INSTRUCTIONS TO Part A - Section: IV
VENDOR A133-000-16-51-SIV-1500 Rev. B
RESID UPGRATION PROJECT
CPCL , CHENNAI Page 2 of 25

1.0 General
1.1 Bidder shall read this Special Instruction to Vendor (SIV) in conjunction with PMC job
specifications(44NC-4600-0000/J.02/0101/A4), Annexure-A (Additional requirements for DCS/PLC) ,
Annexure-B(Specification for fire and gas system), Standard Specification for DCS 44NC-4600-
0000/J.SS/0102/A4),Standard Specification for Programmable Logic Controllers( 44NC-4600-
0000/J.SS/0103/A4) other specifications attached with MR.
1.2 Bidder shall note that in the PMC/Owner specification attached with MR, wherever, it is mentioned as
Contractor, the same shall be replaced and considered as Bidder ( DCS Vendor) for complying to the
requirements specified in the documents.
1.3 All the instruments/equipments/items shall be procured from the approved vendor list attached with
MR without exception. For any specific item/instrument , not in approved vendor list in the MR, bidder
shall obtain prior approval from Purchaser before ordering.
1.4 Bidder shall note that pre-bid meeting clarifications necessitate the revision of MR( wherever required)
had been considered in the revised MR. Bidder shall refer the revised MR for the scope and detail
specifications and pre-bid clarifications resolution and shall comply in accordance with revised MR
specifications.
1.5 Bidder shall be responsible for the submission of all the applicable statutory certification for all the
instrumentations items including the certification from PESO/CCOE as applicable.
1.6 Bidder shall be fully responsible to comply with the total scope of work indicated in this MR on turnkey
basis and meeting all functional requirements specified in this requisition through hardware and
software during detail engineering. Bidder shall be fully responsible for the Bill of Material submitted
by them.
Bidder shall note that evaluation shall be carried out on the bottom line (lump sum) basis of complete
DCS system including UPS and CCTV system.
Bidder shall be fully responsible for proper engineering, integration, installation, performance and
operation of all equipments including I/O and marshalling racks and bought out items supplied by
them as per the requirement.
Further the following are bidders scope/ responsibility:
a) All Serial interface cables/ connectors from purchasers supplied system located within MCR shall
be in DCS vendor scope.
b) All fibre optic cables , convertors and connectors with HDPE conduits for Serial communication
between analyzer shelter to MCR shall be in DCS vendors scope
c) Spares as specified in this MR
d) Bidder shall be responsible to involve sub-vendors of major items like Giant Screen, AIMS, DON,
UPS, CCTV for all engineering, engineering reviews, system definitions and software definition
meeting, drawing/ document review meetings without any exception as per responsibility chart..
1.7 In case of conflict, SIV and its attachments shall override in general, however it shall be obligatory on
the bidder part to bring to the notice of the Purchaser all such conflicts, wherein the purchases
decision shall be final. However, in case of conflict with respect to specifications and any other
engineering requirement or legal regulation, bidder shall consider the most stringent requirement by
default while selecting the DCS and PLC.
1.8 System Modification/ Change Management :
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SPECIAL INSTRUCTIONS TO Part A - Section: IV
VENDOR A133-000-16-51-SIV-1500 Rev. B
RESID UPGRATION PROJECT
CPCL , CHENNAI Page 3 of 25

Refer to Annexure-A - Additional requirements for DCS/PLC system attached with MR. The
changes/modification specified in the above referred document in clause no: 1.3 shall be carried out
by vendor without any time and cost implications as long as the I/O quantities specified in the I/O
summary table including installed spares does not increase.
1.9 Bidder to note that purchaser reserve the right to associate their personnel at any or all stages of
project execution. Further, Bidder shall not proceed without getting prior approval from
purchaser/Owner/PMC for the documents required to be approved under Vendor Data Requirement.
1.10 Bidder is required to get prior approval from Purchaser, in case he plans to sub-contract a part of
their site activities job to any other Vendor.
1.11 The handling and storage of the equipment at site shall be Bidders responsibility for all equipments
supplied by them. No ware house shall be provided for storage of system at site and only open
space shall be provided. Bidder shall be responsible for the storage of bidder supplied
equipments/items including bought-out items at their risk and cost. The open storage space
requirement shall be intimated by vendor during detail engineering. The delivery schedule of
complete system shall be in accordance with time schedule and requirements specified in
commercial section.
1.12 Loop checking : Shall be carried out by DCS vendor in accordance with requirement specified in
Annexure-A( Additional requirements for DCS/PLC system), PMC job specifications(44NC-4600-
0000/J.02/0101/A4) and standard specifications.
1.13 Bidder shall note that exceptions to PMC job specifications(44NC-4600-0000/J.02/0101/A4),
Annexure-A (Additional requirements for DCS/PLC system) , Annexure-B (specification for fire and
gas system) which are not applicable for the MR are deleted in the respective specifications. Other
requirements specified and considered in above referred documents and attached with MR shall be
mandatorily complied by bidder.
1.14 P&IDs and other licensor documents will be given to the successful bidder after order, which will be
used for preparing functional schematics, network/ segment diagrams, graphic diagrams etc. Vendor
shall be required to sign confidentiality and secrecy agreements for non disclosure and limited use of
licensor documents/information.
1.15 Power Supply
1.15.1 110V AC UPS power supply voltage shall be used for DCS/PLC and F&GS system.
The UPS for F&GS system shall be dedicated and separate from UPS of DCS/PLC system. For
specification, quantities load, rating and other details refer to Part-B UPS system.
The duration after main power supply failure shall be 60 mins for DCS/ESD UPS system and 48
Hours for F&GS UPS system.
In addition to Part-B( UPS specifications), bidder shall also refer to refer to PMC job
specifications(44NC-4600-0000/J.02/0101/A4), Annexure-A ( Additional requirements for DCS/PLC
system)
1.15.2 All types of power supply distribution ( UPS and Non-UPS) to DCS and Non-DCS equipments and
purchasers free issued items within control room shall be in DCS vendors scope . The supply of all
Power supply cables, cables glands, cable lugs including installation , glanding and termination and
testing at both ends for distribution of power supply from UPS ACDB to bidder supplied PDB to all

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CPCL , CHENNAI Page 4 of 25

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

2.1 Foundation Fieldbus system is considered for monitoring open loops in non-critical applications. For,
the transmitters in critical open loops, closed loops and inputs for PLC shall be based on SMART type
with HART protocol . The PLC system shall be SIL 3 , TUV certified with Triple Modular Redundant
(TMR) with hot stand-by without I/O or QMR (Quad Modular Redundant) with hot stand-by with I/O
configuration for ESD system & F&GS system. The DCS/PLC for each unit shall be sized
considering I/Os and other sizing requirements like scan time, CPU loading etc as per MR. The sizing

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

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

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

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


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

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

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

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

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


layout developed by bidder.
Supply and installation of consoles (Similar design of operator console) for housing
the HMI/ operator console in the console area of MCR.
Furniture for the PC, Printers for the other vendor supplied items. ( Design similar to
Bidder supplied DCS items)
Power supply (110VAC UPS and 230VAC Non-UPS) for all bought-out items
including supply, laying and glanding and termination of cables.
Supply, installation of cable trays/conduits in rack room area, console area and
engineering room of MCR.
Glanding, ferruling and termination of all the interface cables ( serial
communication/special cables/hardwired cables) in the bidder supplied cabinets.
Earthing of cabinets/equipments including supply of cables, installation and
termination of earthing cables at both ends.

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

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

2.19 Earthing Requirement


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

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

3.0 Training requirement


Bidder shall provide different type of training for Owners personnel at manufactures works and at
site. The courses shall be offered for in hardware and software aspects of various system in the field
of engineering, operation and maintenance for operation/ process engineers and operators,
instrument maintenance engineers and technician. For details of training days and its requirement,
refer to clause no: 15.0 PMC job specifications(44NC-4600-0000/J.02/0101/A4) attached with MR .
Training for following system are applicable and shall be considered by bidder.
Distributed Control System
Programmable Logic Controllers
IAMS system
AMS system
CCTV system
UPS system.

For Site Training for all above systems, following shall be considered
2 days for 10 persons : 20 Man days
For details of training for UPS system ( number of days, personnel and its courses its location) refer
to Part-B of this MR.

4.0 POST WARRANTY MAINTENANCE AND SPARES MANAGEMENT CONTRACT


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

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved


Page 260 of 564
SPECIAL INSTRUCTIONS TO Part A - Section: IV
VENDOR A133-000-16-51-SIV-1500 Rev. B
RESID UPGRATION PROJECT
CPCL , CHENNAI Page 24 of 25

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

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SPECIAL INSTRUCTIONS TO Part A - Section: IV
VENDOR A133-000-16-51-SIV-1500 Rev. B
RESID UPGRATION PROJECT
CPCL , CHENNAI Page 25 of 25

o) Network Switches.
p) Fibre optic cable.
q) Special cables ( System cables) of each type
r) Termination assemblies
s) Operator Work Station( single)
t) Engineering work station
u) Analog Barriers
v) Digital Barriers
w) Non-IS isolators
x) Interposing relays SIL-3
y) Interposing relays Non-SIL certified
z) Each type of push buttons, selector switches, lamps in Aux. console
aa) Annuniciator ( each type with number of rows/column offered)
bb) Blank cabinet with power socket, receptacle and lighting
cc) Blank Hardwired console with power socket and receptacle
dd) Blank Operator console with power socket and receptacle
ee) OPC server
ff) CCTV-DVR
gg) CCTV-32 LED monitor
hh) Giant Screen of cube size 70 minimum in 2x2 configuration

6.0 TEST EQUIPMENTS

Bidder shall supply the test equipments consists of multimeter, calibrators, pneumatic test
bench, dead weight tester, temperature bath etc. in accordance with clause no: 16 of job
specification ( 44NC-4600-0000/J.02/0101/A4) attached with MR. The make and quantities
shall be as per above referred clause in the specification. These items shall be supplied as
loose supplied items with valid test certificates.

7.0 TAKE-OFF PRICE

Bidder shall furnish take-off price for dedicated SIL-3 PLC controller subsystem indicated in
the System Configuration Diagram (Doc. No. A133-086-16-51-MD08) for interlock operation
of overhead pressure monitoring for equipment 086-C-07 & 086-C-10 respectively.

Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved


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

ANNEXURE-A
ANNEXURE-IV

ADDITIONAL REQUIREMENT FOR DCS & PLC

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CPCL Chennai Additional Requirement for PART III Section B 8.2
44NC-4600 DCS & PLC PAGE 2 OF 22
LSTK-1 Coker Block Annex. IV to 44NC-4600-0000-/J.02/0101/A4 Rev. 0

1.0 SPECIAL INSTRUCTIONS 0

1.1 The additional requirements for DCS &PLC shall read in conjunction with Job Specification,
standard specification for DCS, PLC & any other specifications and other requirement as
specified in feed documents

1.2 Contractor to note that they shall be fully responsible for the Bill of Material submitted by
them to meet all hardware and functional requirements as indicated in tender document. In
addition, contractor shall be fully responsible for the total scope of work indicated in the
document on turnkey basis and meeting all functional requirements through hardware and
software during detail engineering

1.3 In case of conflicts with respect to specifications, and any other engineering requirement or
legal regulations, the contractor shall consider the most stringent requirement by default while
selecting the DCS and PLC system, however it shall be obligatory on the contractor's part to
bring to the notice of the owner/PLC all such conflicts, wherein the PMC/ OWNERS decision
shall be final.

1.3 System Modification / Change Management.

a) Contractor shall carry out all the modifications/changes/revisions necessary to be


incorporated and pointed out at the time of FAT including graphic changes, wiring
changes, I/O assignments, logic changes etc.

b) Contractor shall carry out all changes/modifications/revisions which are to be carried out
during installation including additional inputs for sub-package items, configuration of new
tags, termination changes, incorporation of cable schedule connections, modification and
addition of new graphics, modification of group trend history etc.

c) Contractor shall carry out any changes required during loop checking and
precommissioning activities such as range change, graphic display changes,
reassignment of I/O, termination changes etc. shall be performed by contractor.

d) Contractor shall carry out changes/modifications required in the system during


commissioning and start up due to operational requirements like graphic changes, tag
reassignment, tags new assignment, history trend and grouping, format changes, set point
range changes, logic modifications etc. Contractor scope shall include incorporation of all
such software/hardware configuration, engineering changes that may occur for normal
engineering project execution.

1.4 Contractor to note that Owner/PLC reserve the right to associate their personnel at any or
all stages of project execution. Further, contractor shall not proceed without getting prior
approval from Owner/PLC for the documents required to be approved under Contractor
Data Requirement.

1.5 The storage of items / equipment at site shall be contractors responsibility for all the
items / equipments supplied by them. Handling of material at site is contractors
responsibility.

1.6 The loop checking shall be carried out in co-ordination with other package contractors,
owner/PMC in accordance with Job specification & standard specification and the
requirements given in this document. It is essential that dedicated team of skilled
personnel from contractors side shall be provided at site for each package item so that
the execution activities such as installation, loop checking, commissioning, SAT are
independently and conveniently done as required.

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CPCL Chennai Additional Requirement for PART III Section B 8.2
44NC-4600 DCS & PLC PAGE 3 OF 22
LSTK-1 Coker Block Annex. IV to 44NC-4600-0000-/J.02/0101/A4 Rev. 0

1.7 POWER SUPPLY


0
1.7.1 110 VAC UPS

1.7.1.1 110 VAC UPS systems shall be provided for New DCU units by contractor as per
specification the Electrical part of this document. In general Min two Nos of UPS one for
Coker Unit along with sub packages ,utility packages, like IA compressor Package,
cooling water Package & another UPS dedicated for F & G system which shall have 48
Hrs Back Up.

1.7.1.2 UPS system shall be Part of DCS/PLC system & supplied by DCS vendor.

1.7.1.3 For Utility and other package contractor supply items, separate Power supply distribution
cabinet (by LSTK-1) shall be provided in Rack room.

1.7.1.4 For Non-DCS loads, major loads above 1.0 KVA, the feeder shall be provided from UPS
AC Distribution Board (UPS ACDB) located at UPS room and for smaller loads, the
distribution shall be provided from power supply distribution cabinet (by contractor) in
Rack Rooms.

1.7.1.5 UPS feeders except for field Instruments & Analyser shelter shall be redundant.

1.7.1.6 20% or minimum one no. Spare feeder shall be provided by the contractor for each feeder
rating.

1.7.2 The Size of UPS shall be arrived at after considering system and user loads. The system
load shall be calculated considering:
a) Expandability of I/Os including installed spares and installed future spare space.
b) In rush current and PF for system/user load shall be considered.

1.7.3 The UPS sizing shall be arrived at after considering additional 10% capacity over and
above the total of both system and user load.

1.7.4 230V AC

The contractor shall provide 230V AC feeders with power distribution cabinet at Rack
Room for the 230V AC power supply for cabinet / Panel lighting, utility sockets and fans
other load requirement. Similar arrangement shall be provided for field local panel
requirements with necessary isolation transformers.

1.7.5 24 VDC

1.7.5.1 24 VDC power supply required for interrogation voltage, solenoid valve supply, lamp,
pushbutton, etc and for other packages shall be supplied by contractor using dual
redundant Bulk Power Supply (BPS). Such redundant BPS shall be fed from two separate
AC feeders. Power looping In & looping Out shall be avoided.
1.7.5.2 Each redundant bulk power supply shall be sized for 35% loading of its capacity in normal
time; the maximum loading is to be 70% of its capacity of BPS.

1.7.5.3 All bulk power supply (BPS) shall be provided with surge protection capability. BPS shall
also provide with cooling fans and with fan failure alarm indications in DCS. In the event of
one BPS failure the second BPS shall take the complete load.

1.7.5.4 BPS Failure alarm shall be provided on Hardwired console & in DCS with highest
priority.

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CPCL Chennai Additional Requirement for PART III Section B 8.2
44NC-4600 DCS & PLC PAGE 4 OF 22
LSTK-1 Coker Block Annex. IV to 44NC-4600-0000-/J.02/0101/A4 Rev. 0

1.7.6 The system Power cables from PDB at rack room to DCS contractor supply items
including cabinets etc. within control room shall be of copper only and shall be supplied by
Contractor. The supply and laying of all incoming and pout going cables is in contractor
scope.

1.7.7 110 VAC UPS Power supply feeder failure alarm before PDB shall be provided in DCS by
using double pole MCB in PDB. One contact of these MCBs shall be wired to DCS for 0
alarm purpose.

1.7.8 Fan failure alarm shall be provided in DCS for each cabinet. RTD for cabinet temperature
monitoring from DCS

1.7.9 Separate PDB cabinet shall be provided for primary & redundant feeders in Rack Room.

1.7.10 The power distribution schemes shall be submitted for review and approval bt PMC /
Owner.

2.0 SPECIFIC REQUIREMENTS FOR DCS/PLC 0


2.1 The PLC system shall be Triple Modular redundant (TMR) or Quadruplicated Modular
redundant (QMR) SIL-3, TUV certified PLC as a minimum.

2.2 The DCS / PLC for each unit shall be sized considering I/Os and other sizing requirements
like scan time, CPU loading etc as per PR. The sizing calculations shall be reviewed during
detail engineering. Contractor shall be fully responsible to supply number of DCS/ PLC as
required meeting above requirements and approved sizing calculations.

2.3 The main PLC processor and I/O cards replacement should be possible on line without
compromising the plant safety and TUV guidelines. The PLC system shall have high
availability.

2.4 In case of two out of three voting inputs in PLC, the inputs shall be wired in three different
cards. Also the I/O shall be segregated equipment wise and redundant equipment shall be
configured in different rack.

2.5 All PLC I/O signals shall be two wired, with no looping or common sharing of power supply or
negative points.

2.6 Maintenance over ride switches (software switches) shall be implemented from PLC console.

2.7 Interposing relays, Power Supply unit for TUV, SIL-3 Certified PLC shall be TUV, SIl-3
certified. However For IS barriers for PLC, both SIL-3 and SIL-2 certified barriers are
acceptable.

2.8 Instrumentation shutdown and interlock shall be de-energizing to trip.

2.9 All Intrinsically safe DI / DO shall be provided with barrier. All MCC Digital inputs / output,
Field input / output (Non IS, if any) shall be connected through external interposing relay.

2.10 Hardwired switches, pushbuttons, lamps in Aux. Consoles shall be powered in 24 VDC circuit
through external relays.

2.11 Contractor shall provide touch screen facility for the bottom tier TFT monitor of the dual tier
operator console. Touch screen facility shall also be provided for Engineering station as well
as Operator cum engineering station.

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CPCL Chennai Additional Requirement for PART III Section B 8.2
44NC-4600 DCS & PLC PAGE 5 OF 22
LSTK-1 Coker Block Annex. IV to 44NC-4600-0000-/J.02/0101/A4 Rev. 0

2.12 IAMS System shall be considered and provided by contractor for all (SMART and Field Bus)
for all analog signals to DCS and PLC. All Non-Field Bus signals to DCS and PLC shall be
SMART type with HART protocol. The I/O cards for DCS (for Non field Bus section) shall be
HART protocol compatible.

2.13 For PLC analog inputs only, if HART pass through card is not available as standard from the
PLC manufacturer, bidder shall provide necessary HART multiplexer, as required, for
communicating to IAMS.

2.14 The offered IAMS system shall be suitable for running / loading advance diagnostic software
of following makes of SMART Positioner: Metso, Fisher, and Dresser.

2.15 The plugin advance diagnostic / valve signatures software of Smart positioner, shall loaded
on the IAMS station. However proper loading, integration and compatibility checking with the
DCS vendors IAMS system shall be the complete responsibility of Contractor. Any other
specific software other than plug-in software, if required by for implementing advanced
diagnostics features in IAMS shall be supplied by Contractor / DCS vendor.

2.16 The time synchronization with external clock i.e. GPS shall be provided by DCS vendor for
DCS, PLC, IAMS, OPC, PSA PLC and other third party devices like VMS etc.

2.17 For Analog output of DCS, the barriers shall be provided with line fault detector.

2.18 All proximity probe input to PLC / DCS shall be provided with IS barrier cum pre-amplifier.

2.19 Fan failure alarm shall be provided in DCS individually for all cabinets.

2.20 For all split range applications the controller shall provide two independent output signals one
for each control valve.

2.21 For fieldbus loop repeat indication shall be a part of fieldbus segment and not through the
DCS.

2.22 Separate cabinet shall be provided for analog, Digital, FF signals separately for DCS and
PLC as applicable. Similarly separate cabinet with interposing relays shall be provided for
MCC inputs and output.

2.23 Type of report generation shall be finalized during detail engineering by operation/process
department of client.

2.24 Screw less terminals shall be considered by contractor for all terminations. All terminals shall
be sourced from reputed make like WAGO.

2.25 Repeat indication in field shall be separate DCS non-redundant AO with IS output barrier for
signal transmission to IS local indicator.

2.26 For control systems where the architecture necessitates that the transmitter power supply be
segregated from controller power supply and the input/output power supply, the system shall
be designed with capability to discriminate between transmitter failure and zero signal value.
The detection of the transmitter failure shall be alarmed and shall cause the controller output
to be held at the prior valid signal output value until the operator takes action by transferring
the control to manual.

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CPCL Chennai Additional Requirement for PART III Section B 8.2
44NC-4600 DCS & PLC PAGE 6 OF 22
LSTK-1 Coker Block Annex. IV to 44NC-4600-0000-/J.02/0101/A4 Rev. 0

2.27 Expandability Philosophy


All the spares shall be calculated based on various requirements specified in the tender
document, including I/O summary, power supply etc.

2.28 Communication Sub-system

2.28.1 The communication subsystem cable shall be secured in G.I. / HPDE conduit. The
communication subsystem, in each case must perform to the offered specifications for error
rate, signal attenuation, noise immunity, etc. No other cable (signal, alarm, power) should
be kept in conduit.

2.28.2 All communication cables, data highway cable routed outside (i.e. between Contro