Plant Client Contract Code Document ID tkIS Contract No.

BS-VI IOCL BS-VI PDR 25284124‐8551‐PH‐000‐0003 66-6699

TECHNICAL SPECIFICATIONS FOR

MACHINE CONDITION MONITORING SYSTEM (MCMS)
Rev 00 Page 1 of 22

00 Issued For Enquiry 17.07.19 PSK 17.07.19 NVE 17.07.19 NVE -

Rev. Status Description Date Prepared Date Checked Date Approved AC
Category Code: -

Barcode
© thyssenkrupp Industrial Solutions (India) Private Limited 2016
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8551-PH-000-0003 66-6699

TECHNICAL SPECIFICATIONS FOR

MACHINE CONDITION MONITORING SYSTEM(MCMS)
Rev 00 Page 2 of 22

Contents:

1.  GENERAL .............................................................................................................................................. 4 

2.  APPLICABLE CODES AND STANDARDS ................................................................................................... 4 

3.  SCOPE OF WORK AND RESPONSIBILITIES: ............................................................................................. 5 

Erection and Commissioning .............................................................................................................................. 6 

4.  HARDWARE: ......................................................................................................................................... 7 

5.  SOFTWARE: .......................................................................................................................................... 8 

6.  DESIGN & SYSTEM ENGINEERING: ........................................................................................................ 10 

6.1  DESIGN: ........................................................................................................................................... 10 

6.2  SYSTEM ENGINEERING:................................................................................................................ 11 

7.  TRAINING............................................................................................................................................ 12 

8.  INSPECTION AND TESTING .................................................................................................................. 12 

9.  FINAL ACCEPTANCE AND WARRANTY ................................................................................................... 12 

10.  COMPREHENSIVE POST WARRANTY ANNUAL MAINTANENCE CONTRACT ............................................... 13 

11.  PACKING ............................................................................................................................................ 14 

12.  INSTALLATION & COMISSIONING ......................................................................................................... 15 

13.  LABELING & CABLE IDENTIFICATION .................................................................................................... 15 

14.  INFORMATION REQUIRED WITH THE BID: .............................................................................................. 16 

14.1  Technical Details .............................................................................................................................. 16 

14.2  Commercial Details .............................................................................................................................. 16 

15.  DOCUMENTATION ............................................................................................................................... 17 

 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8551-PH-000-0003 66-6699

TECHNICAL SPECIFICATIONS FOR

MACHINE CONDITION MONITORING SYSTEM(MCMS)
Rev 00 Page 3 of 22

DOCUMENTS ATTACHED:

NO. DESCRIPTION NO. OF DOCUMENT NO. LATEST

PAGES REV.

1. List of Equipment’s 1 Annexure-1

Machine Monitoring System(MMS)

2. and Condition Monitoring System 32 PDRP4200-8550-FS-1004 F3
(CMS) functional requirements
Control/Marshalling cabinet 13 PDRP4200-8550‐SP‐0005 F3
3.
specifications
Inspection and Testing of Electronic 31 PDRP4200-8550‐SP‐0011 F3
4.
Control Systems

5. Requirements for Spare Parts 75 PDRP4200-8550‐SP‐0008 F2

6. Vendor Documentation Procedure 16 25284124-8820-PI-000-0002 01

HSE Design Requirements for 16 PDRP4200-8150‐SP‐1003 F1

7.
Vendors and Contractors
Packing, Marking, Documentation 13 25284124-8610-PI-000-0001 00
8.
and Dispatch Instructions

9.
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8551-PH-000-0003 66-6699

TECHNICAL SPECIFICATIONS FOR

MACHINE CONDITION MONITORING SYSTEM(MCMS)
Rev 00 Page 4 of 22

1. GENERAL

Paradip Refinery is the latest refinery of Indian Oil Corporation Limited (IOCL). To make
Paradip refinery BS-VI compliant, there is need for installation of new units along with offsite
Tankfarm and also revamp of old units to produce 100% BS-VI MS and HSD compliant
products. This specification defines design, supply, testing integration requirements for a
Machine Condition Monitoring System (MCMS) for IOCL-Paradip BS-VI project.
Individual compressor package vendor will supply Bentley Nevada 3500 series system
with Bentley Nevada vibration / temperature probes and sensors. The Rack
Configuration of these packages unit wise are listed in Annexure.1 of this document.
MCMS vendor’s scope is to integrate these BN 3500 systems with Condition monitoring
Software being supplied by them as per Annexure-1. Vendor to clearly indicate all
necessary hardware and software required to implement the same.

2. APPLICABLE CODES AND STANDARDS

Instrument Codes/Reference standards for design and installation of instrumentation system

shall comply with the standards and codes for the specific subject. Refer attached documents
for complete list of codes and standards to be followed for the project. In case of conflict
between specified documents, the more stringent requirement shall have precedence. The
vendor shall, nevertheless, draw to the attention of tkIS-India any unacknowledged conflicting
requirements that he considers may affect his supply.
The related standards referred to herein and mentioned below shall be of the latest edition prior
to the data of purchaser’s enquiry.
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8551-PH-000-0003 66-6699

TECHNICAL SPECIFICATIONS FOR

MACHINE CONDITION MONITORING SYSTEM(MCMS)
Rev 00 Page 5 of 22

3. SCOPE OF WORK AND RESPONSIBILITIES:

Scope of work and responsibilities of MCMS Vendor and others is summarized as given in
following Table.

Sr. DESCRIPTION E S ER COM

No.

1 Vibration probes, proximitors, axial displacement probes, key phase M M M V, M

probes, Radial Bearing RTD, Thrust bearing RTDs, Temperature
probes, Rod drop probes, Cylinder pressure Monitors etc. as
applicable for package compressors.
(MCMS vendor shall co-ordinate with individual compressor/pump
vendor for integration of compressor/pump MMS with MCMS
system during Commissioning)
2 Fully wired MCMS Server Cabinet consisting of MCMS Servers V V V V

3 MCMS server Monitor 22” TFT color, laser printer and keyboard. V V V V

4 MCMS Maintenance PC along with necessary furniture. V V V V

5 Fully Wired Network Component Cabinet (NCC) consisting of V V V V

Ethernet switches & FO converters for following
a. Simplex communication with MMS Rack & MCMS cabinet as
per Annexure-1.
b. For Plant Information Network(PIMS) via Firewall
c. DCS (OPC) server via Firewall.
6 All communication Cables between MCMS server cabinet, Monitor, V V V V
maintenance PC, MMS racks, Printers, and NCC etc. inside Rack
Room/ shelter.
7 Redundant Armored Fiber optic cable between Network Component U U U U
Cabinet (NCC) in SRR -823 Rack Room and following unit
1. Existing CMS Server in main Control Room
2. HGU MMS Shelter
Required FO converters at both side ,Cable Splicing and
termination of FO cable at both side by MCMS Vendor)
8 LIUs, patch cables, connectors required for Fiber Optic V V V V
communication at NCC, LNC. Also all type of cable glands required
for LNC, NCC, etc. to be provided by MCMS Vendor.
9 Necessary tool kit for fiber optic cable splicing and connection with - V - -
all accessories shall be supplied by MCMS Vendor.

Sr. DESCRIPTION E S ER COM

 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8551-PH-000-0003 66-6699

TECHNICAL SPECIFICATIONS FOR

MACHINE CONDITION MONITORING SYSTEM(MCMS)
Rev 00 Page 6 of 22

No.

10 Condition monitoring Software like application software, includes V V V V

MCMS configuration, building of operator graphics, tags linking,
screen display configuration, database & report creation, OPC data
base creation ,Alarms & events handling, Diagnostic Display
software licenses, DAQ licenses, OPC data export/ import, Alarm
and Events and Historian licenses, Rule Packs, licenses for CMS
servers and display PCs plus further minimum of a 10 licenses for
the IOCL client PCs, The minimum number of OPC licenses for data
transfer shall be 4 (four), user management configuration, system
hardening, Operating systems , Antivirus software (till the end of
warranty period), Firewall hardware and software etc.
Accessories and site services:

11 Integration, Testing, and Commissioning of all MCMS Vendor V - V,M V,M

supplied items and interface communication with MMS Racks
supplied by package vendors.
12 Trouble shooting if required of MCMS loops by MCMS Vendor during - - - V
commissioning period
13 Optimization and fine-tuning of overall system during warranty V - - V
period, which include visits by MCMS vendor, engineer to IOCL site
for fine-tuning and optimization by MCMS vendor.
Other Services:

14 Shop Inspection Tests (FAT) – By MCMS vendor V - - -

Shop inspection is applicable for NCC, Server cabinet along with
monitor & verification of all hardware & software as per BOM,
Communication interface with MMS racks, DCS, PIMS and
Application software etc.
Inspection charges shall be borne by Vendor. TPI is applicable for
all items.
15 SAT and Training by MCMS vendor. Training shall be both at Site & V - V V
Vendors facility
16 Complete technical manual and as built documentation in electronic V - - -
form as well as hardcopy by MCMS vendor
Spare Parts :

17 Mandatory Spares - Electronic modules / cards : 10% or minimum 1 V V - -

no. of each type,
18 Commissioning ( other than those in mandatory spares) - V - -

19 Two Years operation ( other than those mentioned in Mandatory - V - -

Spare Parts List)

Erection and Commissioning

 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8551-PH-000-0003 66-6699

TECHNICAL SPECIFICATIONS FOR

MACHINE CONDITION MONITORING SYSTEM(MCMS)
Rev 00 Page 7 of 22

Sr. Description E S ER COM

No.
20 Unloading of system at site and shifting to site stores U

21 Transport of system from site stores to actual location/s U

22 Unpacking the system, inspection of the same for damages, and U

preparation of damage assessment report
23 Fabrication of base frames for cabinet / console mounting U U U

24 Installation of system at site U

25 Laying and termination of power supply cables from PDBs to U U U

different MCMS cabinets
26 Laying and termination of inter-panel cables of MCMS V V V V
system/switches
27 Laying, termination, jointing of FO cables, incl. OTDR testing U U U U

28 Laying and termination of all earthing cables from respective bus U U U U

bars to cabinets within control room
29 System power up, loading of configuration, application software V V V V

30 Internal loop checking from MMS racks up to MCMS Server/PC. V V V V

31 Integrated Site Acceptance Test (SAT) V V V V

32 Providing commissioning assistance V V V V

E : Engineering

S : Supply, packing, forwarding

I : Inspection

ER : Erection at site : Supervision by vendor

COM : Testing, calibration & commissioning at site

M : Original Equipment Manufacturer / Supplier (including local panel MMS vendor)

V : By MCMS vendor.

C : By clients

U : By tkIS (including DCS / ESD vendor) / Erection contractor (Supervision by MCMS vendor
(Integrator))

4. HARDWARE:
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8551-PH-000-0003 66-6699

TECHNICAL SPECIFICATIONS FOR

MACHINE CONDITION MONITORING SYSTEM(MCMS)
Rev 00 Page 8 of 22

4.1 Supply of fully wired MCMS server cabinet consisting of :

a. MCMS Servers of RAID 5 configuration with multiple drives configured in redundant mode- Qty as
per requirement.
b. Display work station 22” LCD screen(Color)

c. Ports for connecting to existing CMS network, PIMS and DCS. The CMS interface to DCS shall be
directional and shall be via OPC, through a firewall to the DCS network to collect historical data
from the DCS, which will be required by the CMS for further analysis. Interface to PIMS shall be
through firewall. Vendor to consider all required firewall in scope of supply.
d. The CMS shall communicate with MMS panels within SRR over dedicated Ethernet LAN
Communication. For other details, refer document PDRP4200-8550-FS-1004.
4.2 Supply of MCMS Maintenance PC along with necessary furniture. Maintenance PC shall have minimum
configuration as follows:
a. PC of latest model / configuration, table Top Mounted
b. Memory-8 GB RAM
c. Hard Disk Drive-500 GB or Higher
d. DVD / CD R/W ROM Drive-50X
e. 22” TFT color monitor with resolution 1280 x 1024 pixels minimum & anti-glare, anti-reflection
feature.
4.3 Supply of fully wired Network Component Cabinet (NCC) consisting of :
a. Ethernet Switch & FO converters for communications interface as indicated in system
architecture.
b. Ethernet Switch, Firewall for Communication with Maintenance PC and DCS.
c. Power supply Unit & Required necessary hardware items.
d. All components shall be of reputed make with required no. of ports including at least 20%
spare ports for future.
4.4 Supply of Firewall with latest hardware and software along with antivirus software recommended by
OEM & it shall be System appliance firewall (PIX) and software IOS firewall. Firewall shall be required
for connection to DCS and PIMS.

5. SOFTWARE:

Vendor shall supply latest software for machine data gathering and presentation and to be
installed on the Server supplied by the vendor along with the latest operating system meeting
various requirements. Vendor to list down all features of MCMS software in technical offer.
The MCMS vendor shall provide software licenses with at least 20% spares for all the machines
probes and sensors supplied as part of vendor packages specified as per Doc. No. PDRP4200-
Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8551-PH-000-0003 66-6699

TECHNICAL SPECIFICATIONS FOR

MACHINE CONDITION MONITORING SYSTEM(MCMS)
Rev 00 Page 9 of 22

8550-FS-1004. The MCMS application software shall be of latest version & shall be compatible for
latest version of MS operating system. Vendor to provide support for the supplied software for at
least ten years from the date of installation & commissioning.
Vendor to provide all other necessary software’s like MS office for database editing & application
usage. For other details, refer document PDRP4200-8550-FS-1004.
DCS / Historian Tags: Specify approximate number of DCS points, which needs to be imported.
(Consider additional 20% spare points in addition to I/Os indicated in Annexure-I of this
specification.)
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8551-PH-000-0003 66-6699

TECHNICAL SPECIFICATIONS FOR

MACHINE CONDITION MONITORING SYSTEM(MCMS)
Rev 00 Page 10 of 22

6. DESIGN & SYSTEM ENGINEERING:

6.1 DESIGN:

a) The MCMS System provided by the MCMS vendor shall allow monitoring, analysis of data and
predictive fault analysis of the rotating as well as reciprocating equipment’s as listed in
Annexure-I from Machine Monitoring console in Rack room.
b) Configuration diagram for MCMS System attached with this specification indicates the generic
and minimum requirements of Machine Monitoring System. MCMS vendor shall develop
actual system configuration showing all the components and include the same in their offer.
c) MCMS vendor shall be responsible for selecting proper networking topology and networking
equipment, including networking cables, converters and PCs based on the actual
requirement.
d) Incoming 110 VAC + 10% VAC grounded UPS feeder and 230 VAC grounded NON-UPS
feeder for lighting load shall be supplied at one point location within the cabinet. Termination
of the incoming UPS & NON-UPS cable inside the cabinet & internal power supply distribution
shall be by MCMS vendor. Panel shall be with bottom side cable entry. MCMS vendor shall
provide all cable glands.
e) MCMS network shall be synchronized with the DCS Network Time. MCMS Vendor will provide
all necessary Hardware & software is required.
f) Documents to be referred are listed in this document. Wherever a conflict arise between this
specification and any other or requiring national, state and local government regulation and
laws, then the same shall be brought to the notice of tkIS/ IOCL for further clarification. In
general, more stringent specifications shall be followed.
g) Vendor shall take necessary measure & supply required hardware & software for Cyber
Security of MCMS System considering following requirements –

i. System Hardening
ii. Perimeter Protection
iii. Account management
iv. Coding Practices
v. Flaw Remediation
vi. Malware Detection & Protection
vii. Host name Resolution
viii. End Devices
ix. Remote Access
x. Physical Security
xi. Network Partitioning
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8551-PH-000-0003 66-6699

TECHNICAL SPECIFICATIONS FOR

MACHINE CONDITION MONITORING SYSTEM(MCMS)
Rev 00 Page 11 of 22

6.2 SYSTEM ENGINEERING:

a) Complete system engineering including network engineering, application engineering

including configuring the software to the specified application with actual tag numbers.
Software loading & debugging shall be in the vendor’s scope.
b) System Architecture drawing indicates the overall connectivity of MCMS system.
c) Vendor shall interact with machine manufacturers through tkIS to obtain all necessary
information for machine health analysis.
d) Vendor shall act as single point responsible for design, detail engineering, supply of all
components needed, installation & commissioning, as detailed below: -
 During engineering stages (to approve all applications related issues) for
Networking, Cabling, electrical design, etc.
 During order execution stages (in order to participate in the Machinery FAT / SAT
and to oversee timely supplies of various components of the system envisaged).
 During installation and commissioning of the package MCMS, Vendor to verify all
the transducers indications and monitoring systems in MCMS server and
documentation of the complete installation.
 To optimize the overall systems in terms of appropriate integration and optimal
information provision for plant wide management system. Such optimization
services will include the visit of the Machinery Management System vendor’s
specialist to site every month to review fine-tuning that will be necessary during the
warranty period. This period is expected to be twelve-month.
e) OPC server shall have compliance with OPC foundation standards. Firewall shall be provided
on the OPC server PC and the same shall be the latest CISCO (System appliance firewall (PIX)
and software IOS firewall. Vendor shall provide necessary hardware/software.
f) Testing, integration and commissioning of LNC/LIU cabinets in field and NCC/NIU cabinet in
Rack room.
g) Supply of complete technical and as built documentation in electronic form as well as
hardcopy as per documentation requirements.
h) Bill of Material and MCMS vendor’s responsibility. In addition, any hardware/software apart
from those indicated in BOM to make system fully functional is MCMS vendor’s responsibility.
Approval on any document does not absolve the vendor of his responsibility of supplying
what is required to meet the specification or meeting the functional requirements.
i) FAT at MCMS vendor’s works and integrated SAT at site for all hardware and software
supplied by MCMS vendor with package vendor supplied vibration / temperature probes
supplied with equipment as defined in the Annexure-I.
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8551-PH-000-0003 66-6699

TECHNICAL SPECIFICATIONS FOR

MACHINE CONDITION MONITORING SYSTEM(MCMS)
Rev 00 Page 12 of 22

j) FAT of all hardware / software (indigenous and imported) and system participation /
demonstration and integration during SAT with DCS for interfacing with DCS / ESD and
providing all assistance as required by the DCS vendor.

7. TRAINING

Training of IOCL personnel in MCMS software shall be as follows:

MCMS vendor’s works: 2 batches for 3 days each for 5 persons per batch.
At site: 2 batches for 3 days each on functional, operational and maintenance aspects for 5 persons
per batch.

8. INSPECTION AND TESTING

Inspection shall be carried out by TPI / Client / tkIS India on the panels, cabinets, servers, etc.
in fully assembled and wired condition exactly as it would be erected finally at site as per
document PDRP4200-8550‐SP‐0011.
a. For any of the above, clients/tkIS/third party reserve the right to carry out stage wise inspection
as and when deemed necessary.
b. The vendor shall be responsible for completing the in-house testing and test reports for the
same shall be ready before inspection by the clients/tkIS/third party. The vendors shall arrange
for all the test instruments and provide all the facilities/assistance for inspection and testing.
All the test instruments shall be calibrated in a standard laboratory and the vendor shall
produce valid calibration documents for the purposes of verification. The calibration shall be
traceable to any of the approved national laboratories.

9. FINAL ACCEPTANCE AND WARRANTY

Clients/tkIS-India shall take over the system from vendor after final Site Acceptance Test (SAT)
as given below.
The integrated system shall run uninterruptedly for four weeks from the date of commissioning
of the whole plant. Any loss of time due to reasons like power failures, forced shutdowns of the
plant, etc.; which are due to no fault of the vendor shall also be counted as run time. However if
any major software / hardware failure of the system occurs due to which the system or a part
thereof has to be shutdown the test shall be carried out afresh on the system. As soon as four
weeks of uninterrupted run of the system is completed successfully, the SAT is deemed to be
complete.
For the purpose of warranty the above definition of SAT shall prevail.
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8551-PH-000-0003 66-6699

TECHNICAL SPECIFICATIONS FOR

MACHINE CONDITION MONITORING SYSTEM(MCMS)
Rev 00 Page 13 of 22

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 vendor for a
period of 36 months from the date of final commissioning or 42 months from the date of last
supply whichever is earlier.

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 malfunctions is
revealed even during on line operation after taking over within the warranty period.
Vendor shall also provide the total maintenance of the system during warranty period. The cost
of warranty maintenance if any shall be included in the offer.
In the event of any malfunction of the system hardware/ system software during warranty
period, experienced service engineer shall be made available at site within 48 hours of the
receipt of such information from owner.

10. COMPREHENSIVE POST WARRANTY ANNUAL MAINTANENCE CONTRACT

Vendor shall include an AMC for 5 years after the completion of the warranty period. Vendor
shall propose 5 years maintenance contract and shall exclusively mention the services to be
provided, methodology, and scope of work and vendors responsibility with year-wise
breakup.

In the event of any malfunction of the system hardware / software, experience service
engineer shall be made available at site within 24 hours on the receipt of such information
from IOCL.

The contract shall include supply of maintenance spares, tools and tackles as required;
travel, boarding and lodging of the service engineer. The quote shall be made year-wise up
to 5 years.

Vendor can use these spares during the AMC. Vendor shall replace the spares used within 7
days with no cost to Owner. Vendor shall maintain a record of all faults during the AMC.

The service order under the AMC including supply of spare parts and services shall broadly
encompass-

a. Preventive Maintenance
Once a year, involving complete overhaul of the system, inspection of hardware and
software, fault prediction, inspection of power supply quality, environmental and operating
condition checks, major repairs / replacements and detailed reporting. This visit is in addition
to visit required for periodic maintenance.
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8551-PH-000-0003 66-6699

TECHNICAL SPECIFICATIONS FOR

MACHINE CONDITION MONITORING SYSTEM(MCMS)
Rev 00 Page 14 of 22

b. Periodic Maintenance

Site visits, minimum four times in a year, inspection of general healthiness of the system,
study and advice on daily maintenance, inspection of hardware. If any problem is reported,
running of test programs, on-line servicing and solving reported problems. Checks shall be
conducted on running system i.e. a) on-line sub-systems and b) others (vendor to state).

c. Emergency Service

Any failure shall be on system supplier’s account. The engineer must report at site within 24
hours of first intimation through telephone/email/fax of report of failure, with necessary
spares. The system must be brought back within 24 hours after reporting at site.

d. Shutdown Visit

During annual shutdown of the plant, vendors Engineer shall visit and carry out all the
checks required. Each visit shall not be part of periodic /preventative maintenance visit.

e. Software Maintenance / Support

Vendor is to maintain existing operating and application software to improve upon

performance of system. Software modification and upgradation and when required shall also
be covered under this scope at no extra cost.

Notes:
Vendor to note that while carrying out the AMC activities IOCL engineers may associate with
system engineers. On-job training of these associated engineers shall be covered under this
scope. The Vendor must list all financial aspects of the AMC clearly.

11. PACKING

For packing, following special requirements shall be taken care of by the vendor prior to
dispatch:
a) All lamps, push buttons shall be covered with thermocole/packing foam.
b) Items/ components susceptible to break during transportation and similar other items
shall be removed from panel, suitably identified and packed separately.
c) Panel shall be unbolted into suitable shipping sections after disconnecting necessary
wiring, tubing etc. Number of sections which can be shipped together and shall be
confirmed with tkIS before dispatch.
d) The panel shall then be covered with polyethylene sheet and bolted firmly to the crate
at the bottom. Necessary thermocole/packing foam shall be placed on sides and top
to ensure that panel does not move within the crate.
e) Packing and forwarding / transportation to IOCL Paradip Refinery site and unloading at
site.
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8551-PH-000-0003 66-6699

TECHNICAL SPECIFICATIONS FOR

MACHINE CONDITION MONITORING SYSTEM(MCMS)
Rev 00 Page 15 of 22

12. INSTALLATION & COMISSIONING

a) Installation and commissioning of MCMS as per Clause 3.0 scope of work will be in
vendor’s scope.
b) Installation and commissioning of the MCMS will be in staggered period, depending on
availability of equipment at site & Machine manufacturer. Accordingly vendor to
estimate no. of days and quote for installation and commissioning.
c) Vendor shall offer the services of the installation team, which would install the
equipment in the Rack Room and in field, laying & termination of the interconnecting
cabling inside the Rack Room, termination of FO cables inside the LNC’s in field, check
out, test and commission the system.
d) Vendor shall inspect all equipment’s thoroughly 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
intimation to Engineer-in-charge. Vendor must document all observations including
details of malfunctions observed, if any. Items/equipment is requiring total
replacements must document reasons for the same.
Material after receipt at site will be kept in project warehouse / storage at IOCL facility.
It is vendor’s responsibility to unpack & check for completeness of hardware proper to
installation.
e) Vendor shall arrange all necessary tools & equipment’s for cable glanding &
termination. TkIS erection contractor under supervision of Vendor will do erection of
cabinet.
f) All erection hardware and consumables like nuts & bolts; primers, paints, cable glands,
grommets etc. shall be supplied by vendor.

13. LABELING & CABLE IDENTIFICATION

a) 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.
b) 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.
c) All cabinets / enclosures shall be labeled in front and rear for easy identification.
d) All internal 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. Tag plate shall be provided for the cable no.
identification on the top of the related terminal strip in the marshalling cabinet.
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8551-PH-000-0003 66-6699

TECHNICAL SPECIFICATIONS FOR

MACHINE CONDITION MONITORING SYSTEM(MCMS)
Rev 00 Page 16 of 22

14. INFORMATION REQUIRED WITH THE BID:

Following information is required to be submitted with the bid:

14.1 Technical Details

a) Point-wise compliance/deviation from specifications.

b) Tentative G.A. Drawings with complete BOM of all components, modules, power
supplies, PB’s, Switches, Lamps etc.
c) Proven Track Record (PTR). Vendor shall indicate installations of similar systems
in India and abroad and the period for which they are in continuous operation for
more than 2 years.
d) Complete bill of material of the system offered including all spares. This shall be
properly segregated sub-system wise.
e) List of all licensed software proprietary and bought out along with the quantity.
f) Catalogues, technical specifications for all hardware.
g) Power consumption calculations (VA Rating) for the entire Panel
h) Mandatory spares as per list and two years commissioning spares
i) Complete architecture drawing with details of all hardware & software.
j) Earthing requriements

14.2 Commercial Details

a) Cost of hardware and software including lumpsum cost for erection up to Site
Acceptance Test (SAT) and pre-commissioning and commissioning assistance
b) All taxes duties as applicable.
c) Man-day rates applicable after end of the period stipulated for pre-commissioning and
commissioning.
Rates quoted for above activities shall consider 6 day working per week with an average of 10
working hours per day.
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8551-PH-000-0003 66-6699

TECHNICAL SPECIFICATIONS FOR

MACHINE CONDITION MONITORING SYSTEM(MCMS)
Rev 00 Page 17 of 22

15. DOCUMENTATION

Refer 25284124-8820-PI-000-0002 rev-01 for Vendor Documentation Procedure.

Documentation requirements are as below.
FOR INFORMATION FOR APPROVAL FINAL
AFTER PO/LOI AFTER PO/LOI COPIES

SR.
DOCUMENT TIME COPIES (PRINTS) TIME
NO. COPIES (PRINTS) S P
SCH. SCH.
CLIENTS TKIS - CLIENTS TKIS - (1) (1)
WEEK WEEK
India India
1. Architecture (one line diagram of the 2 1 1 1 6
offered system
2. Detailed bill of material 3 1 1 1 6
3. Bill of material with part nos., catalogues 3 1 1 1 6
for bought out items
4. Statutory Certificates 8 1 1 1 6
5. Proposed organization chart for project 2 1 1 1 6
execution
6. Detailed project schedule 2 1 1 1 6
7. Standard dimensional and layout drawings 4 1 1 1 6
for:
 Operator consoles
 All cabinets
8. Calculation of total power requirements at 2 1 1 1 6
different voltage levels
9. Calculation of heat dissipation 2 1 1 1 6
10. Earthing scheme 4 1 1 1 6
11. Hardware & Software Specifications 4 1 1 1 6
12. Internal Wiring Diagram 16 1 1 1 6
13. FAT procedure 8 1 1 1 6
14. SAT Procedure 12 1 1 1 6
15. Inspection Test Reports 12 1 1 1 6
16. Standard system documentation available 16 1 1 1 6
like:
 Installation and instruction manual
 Software ref. manual
 Algorithm library
 Any other
ABBREVIATIONS:
S : SOFT COPIES (.PDF FILES)
P : PRINTS
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8551-PH-000-0003 66-6699

TECHNICAL SPECIFICATIONS FOR

MACHINE CONDITION MONITORING SYSTEM(MCMS)
Rev 00 Page 18 of 22

2. NOTES:
a. Drawings to be submitted for approval shall be submitted as per timeline indicated above and
in line with order specifications. Any deviations with respect to order specifications shall be
listed separately. In absence of same, order specification will be governing document. It is
vendor responsibility to get drawings approved and if required vendor to visit tkIS office to get
drawings approved. Delivery period shall be as per terms and conditions of Purchase order and
any delay in drawing approval will not be considered as reason for delay in delivery.
b. Drawings submitted for information shall not be approved by tkIS - India. Vendor to note that
documents prepared for the purpose of manufacturing shall not be sent to tkIS - India for
approval. tkIS - India shall not be responsible for any mistakes / omissions in these documents
as well as any delays due to the same. Specifications of instruments ordered shall be strictly as
per tkIS - India data sheets which shall also form the basis for inspection
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8551-PH-000-0003 66-6699

TECHNICAL SPECIFICATIONS FOR

MACHINE CONDITION MONITORING SYSTEM(MCMS)
Rev 00 Page 19 of 22

COMPLIANCE DECLARATION & PTR

Please note that vendor shall indicate his replies to the following points without which the offer shall be
liable for rejection.
Deviations, if any, from tkIS-India specifications, shall be listed in the enclosed format (List of Deviations)
indicating the applicable specification clause. The vendor will be made liable for full compliance with the
specification requirements, if deviations are not listed in ‘List of Deviations’, as it will be deemed as ‘No
deviation’.

SR. EXPECTED CONFIRMATION

DESCRIPTION REMARKS
NO. REPLY BY VENDOR
1. Confirm that all deviations against tkIS-India No Deviation
specifications are consolidated under “List
of Deviations”. Deviations mentioned
elsewhere will not be taken into
consideration.
2. Confirm that a soft copy of the technical bid, Yes
as per the attached format, is submitted
with the technical offer.
3. Confirm that there is no discrepancy in the No
technical details outlined in the hard and Discrepancy
soft copy of the offer.
4. Relevant Catalogues / literature giving Yes
specifications for all models offered
including sizing data is enclosed with the
offer.
5. Relevant Catalogues/specifications of all Yes
bought out items is enclosed with the offer.
6. Quoted for Spare parts recommended for 2 Quoted
years continuous trouble-free operation
along with listing.
7. Quoted and offered recommended Quoted
Commissioning spares along with listing.
8. Quoted for ‘Mandatory spares’ if specified in Quoted
tkIS-India specifications along with listing.
9. Confirm that PTR form, as per attached format, Yes
is submitted with the technical offer in any of the
following cases:
a) Vendor has not supplied the item to tkIS-India
or to projects where tkIS-India is EPCM
Contractor.
b) Items/ part items not supplied to tkIS-India or
to projects where tkIS-India was EPCM
contractor.
c) tkIS-India Enquiry specifically asks for PTR.
(Signature of Vendor)
Name:
Designation :
Date : (Company Seal)
Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8551-PH-000-0003 66-6699

TECHNICAL SPECIFICATIONS FOR

MACHINE CONDITION MONITORING SYSTEM(MCMS)
Rev 00 Page 20 of 22

LIST OF DEVIATIONS

Sr. Doc. No:

Subject / Description Deviation
No. Clause No. Page No.

(Signature of Vendor)
Name:
Designation:
Date : (Company Seal)
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8551-PH-000-0003 66-6699

TECHNICAL SPECIFICATIONS FOR

MACHINE CONDITION MONITORING SYSTEM(MCMS)
Rev 00 Page 21 of 22

PROVEN TRACK RECORD

I) Vendor to submit the filled PTR form as part of the initial offer itself in the following cases:

(a) The instruments/System selected / offered / supplied for the units shall be rugged in
design and should have been operating satisfactorily in hydrocarbon industry like
Refinery, Petrochemical and Gas Processing Plant under similar process conditions for
at least 8000 hours.
(b) For cryogenic services, instruments meet the proven track record criteria mentioned
above for use in similar cryogenic service.
(c) Prototype design or equipment of experimental nature or design undergoing testing
etc. shall not be selected and supplied.
(d) Vendor has not supplied the item to tkIS-India or to projects where tkIS-India was
EPCM contractor.
(e) The vendor offer contains items / part items not supplied by vendor to tkIS-India or to
projects where tkIS-India was EPCM contractor e.g. accessory like Solenoid valve,
limit switch, I/O card, control valve body etc.
(f) PTR form is specifically required as per the tkIS-India enquiry specification.

II) PTR form, when required to be filled in, shall be submitted by vendor as part of the initial
offer failing which their offer shall not be processed further.

III) Vendor to fill the respective clause in the 'Compliance Declaration' form correctly.

IV) Vendor shall confirm work load data for next 2 years and current commitments with each
quote.

V) Vendor to submit the PTR details in the format given below. All entries shall be for items
which have been commissioned for more than a year. Vendors are required to fill out the
contact details of the person (from End customer) from whom feedback regarding
operation of item can be taken.

PTR FORM

Plant / End customer contact details

Sr. Product / End Date of Date of
Country Project
No. Accessory Customer Supply Comm.
Name Tel Mobile
Name E-mail id
No. No.

5
Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8551-PH-000-0003 66-6699

TECHNICAL SPECIFICATIONS FOR

MACHINE CONDITION MONITORING SYSTEM(MCMS)
Rev 00 Page 22 of 22

ANNEXURE-I

LIST OF EQUIPMENTS
SNO EQPT NO EQPT TYPE

1 016-K-001A Reciprocating

2 016-K-001B Reciprocating

3 057-K-001A Reciprocating

4 057-K-001B Reciprocating

5 057-K-002A Reciprocating

6 057-K-002B Reciprocating

7 057-K-003A Reciprocating

8 057-K-003B Reciprocating

9 057-K-006 Reciprocating

No. and type of probes shall be as per document PDRP4200-8550-FS-1004.

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SPECIFICATION

Machinery Monitoring System (MMS) and PDRP4200-8550-FS-

Condition Monitoring System (CMS) 1004
Functional Requirements PAGE 2 OF 32
REV F3

12. Section 5.4: transfer of configuration data to CMS servers added

13. Section 5.6: temperature 4-20mA repeat module aded
14. Section 5.9: local displays shall be certified Intrinsically Safe
15. Section 5.11: new paragraph Battery Backup
16. Section 6.1: size of colour monitors changed to 22”.
17. Section 6.1: the data transfer shall be bi-directional added
18. Section 6.1: display of CMS server data across CMS servers added
19. Section 6.2: new paragraph Network Requirements
20. Section 6.10: new section Portable Data Collection
21. Section 7.0: new section for local control panels added
22. Appendix B: new section for local panels

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SPECIFICATION

Machinery Monitoring System (MMS) and PDRP4200-8550-FS-

Condition Monitoring System (CMS) 1004
Functional Requirements PAGE 3 OF 32
REV F3

CONTENTS

1. INTRODUCTION ....................................................................................................................... 5
1.1 Purpose of the MMS/CMS .................................................................................................. 5
1.2 Structure of the MMS .......................................................................................................... 6
1.3 Structure of the CMS .......................................................................................................... 6
2. DEFINITIONS AND ABBREVIATIONS ...................................................................................... 7
2.1 Definitions ........................................................................................................................... 7
2.2 Abbreviations ...................................................................................................................... 8
3. APPLICABLE DOCUMENTS ..................................................................................................... 9
4. GENERAL REQUIREMENTS FOR MMS/CMS ........................................................................ 11
4.1 Environment ..................................................................................................................... 11
4.2 Availability......................................................................................................................... 11
4.3 SIL Implementation ........................................................................................................... 12
4.4 Redundancy ..................................................................................................................... 12
4.5 Security............................................................................................................................. 12
4.6 Spare Capacity & System Loading.................................................................................... 13
4.7 Time Related Functions .................................................................................................... 13
4.8 System Communications .................................................................................................. 13
4.9 Earthing Requirements ..................................................................................................... 14
4.10 Electromagnetic Compatibility (EMC) ................................................................................ 15
5. MACHINE MONITORING SYSTEM REQUIREMENTS ........................................................... 15
5.1 Machine Monitoring Philosophy ........................................................................................ 15
5.2 Operator Interfaces ........................................................................................................... 16
5.3 I/O Structure ..................................................................................................................... 16
5.4 System Hardware ............................................................................................................. 16
5.5 Cabinets ........................................................................................................................... 16
5.6 Monitoring Racks .............................................................................................................. 17
5.7 MMS Power Supplies........................................................................................................ 18
5.8 System Wiring................................................................................................................... 18
5.9 Remote Displays ............................................................................................................... 18
5.10 System Configuration........................................................................................................ 19
5.11 Battery Backup ................................................................................................................. 19
6. CONDITION MONITORING SYSTEM (CMS) REQUIREMENTS............................................. 19
6.1 Operator Interfaces ........................................................................................................... 19
6.2 Network Requirements ..................................................................................................... 20
6.3 Basic System Software ..................................................................................................... 20
6.4 Specialist System Software............................................................................................... 22
6.5 Condition monitoring Function .......................................................................................... 22
6.6 Predictive Fault/Failure Functions ..................................................................................... 23
6.7 Performance Monitoring Functions ................................................................................... 23
6.8 System Data Storage ........................................................................................................ 23
6.9 Historian ........................................................................................................................... 24
6.10 Portable Data Collection ................................................................................................... 24
7. LOCAL CONTROL PANELS .................................................................................................... 24
8. GENERAL INSPECTION AND TESTING FOR MMS/CMS ...................................................... 24

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SPECIFICATION

Machinery Monitoring System (MMS) and PDRP4200-8550-FS-

Condition Monitoring System (CMS) 1004
Functional Requirements PAGE 4 OF 32
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8.1 Factory Acceptance Tests (FAT) ...................................................................................... 25

8.2 Site Testing ....................................................................................................................... 25
9. DOCUMENTATION FOR MMS/CMS ....................................................................................... 26
10. APPENDIX A - MONITORING INSTRUMENTATION GUIDELINES .................................... 27
11. APPENDIX B – LOCAL CONTROL PANEL GUIDELINES ................................................... 32

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SPECIFICATION

Machinery Monitoring System (MMS) and PDRP4200-8550-FS-

Condition Monitoring System (CMS) 1004
Functional Requirements PAGE 5 OF 32
REV F3

1. INTRODUCTION
This specification defines the minimum functional requirements for the Machinery
Monitoring System (MMS) and Condition Monitoring System (CMS) as required for
the Paradip refinery at Paradip, Orissa State, India.
Each item of rotating equipment such as Gas Turbine Generator, Compressor etc
shall be equipped with its own dedicated Machinery Monitoring System, all of which
shall be connected to a common Condition Monitoring System platform.
The above protection and condition monitoring systems shall be designed &
configured to provide an effective “Health Care Package” that shall help in
maintaining the integrity, availability & reliability over the entire life of the critical asset.
The MMS & CMS shall provide and integrate the following: -
• Machine protection
• Online Condition Monitoring (data acquisition, trending, analysis & storage)
• Process Control System Data for DCS and Rotating Equipment Control
System.
• Facilities for Remote Monitoring & Analysis,
• Online performance monitoring.

1.1 Purpose of the MMS/CMS

The MMS shall provide operational information, as well as alarms and trip signals,
relating to the condition and protection of the mechanical rotating machinery in the
process plant areas.
The MMS shall automatically collect and process data during both steady state and
transient (start-up and coast down) operations. The system shall be designed for
standalone operation. This operational data shall be transmitted to the DCS via a
redundant Modbus serial connection. Trip signals shall be hardwired to the ESD.
The MMS shall also provide for transmission of monitored data to local panel
mounted displays located adjacent to machines being monitored.
The CMS shall include Server/Engineering Workstations with 22’’ TFT colour
monitors and laser printers which shall provide the diagnostic and analytical data of
machinery condition, as well as the long-term storage of machine information. Its
uses shall include predictive maintenance, and the calculation of aerodynamic and
thermodynamic performance and efficiency.
The CMS servers shall be provided with necessary ports for connecting to CMS
network, PIMS and DCS. The servers should be of RAID5 configuration with multiple
drives configured in redundant mode.
The CMS interface to the DCS shall be directional and shall be via OPC, through a
firewall to the DCS network to collect historical process data from the DCS, which will
be required by the CMS for further analysis.
The CMS interface to the PIMS shall be through a firewall.

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SPECIFICATION

Machinery Monitoring System (MMS) and PDRP4200-8550-FS-

Condition Monitoring System (CMS) 1004
Functional Requirements PAGE 6 OF 32
REV F3

1.2 Structure of the MMS

The MMS shall be installed in the respective SRR in dedicated cabinets. Each MMS
will have a dedicated PC/Workstation located in the engineering room of the SRR, on
which the rack configuration software will be installed. After installation and during
the SIT the configuration data will be transferred to the CMS display workstations.
Each plant MMS shall interface with other systems as follows:
• The CMS within the local SRR by means of a communication network utilising
Ethernet connections.
• The Distributed Control System (DCS), within the local SRR by means of
redundant MODBUS communications.
• The Emergency Shutdown System (ESD), by means of hardwired I/O. All
voting related to trip logic is to be implemented in the ESD.
• Local panel mounted displays by means of serial communications.
The MMS shall be responsible for the monitoring of their respective package.
The MMS shall be a microprocessor-based system of high reliability and availability,
equipped with self-test and self-diagnostic capabilities. The MMS shall be supplied
with configuration facilities locally within the respective SRR.
Machinery monitors shall be provided as part of the MMS cabinets. These shall
convert signals from machine-mounted transducers in the field into data, alarms and
trips for use by the CMS, DCS and ESD, as required.
The maximum data transfer time between MMS and DCS display unit shall not
exceed 5 seconds.

1.3 Structure of the CMS

The CMS servers shall be installed in the engineering rooms of the respective control
buildings. They shall communicate over a dedicated Ethernet LAN to the CMS
display workstations and the MMS equipment in the SRR’s. The communications
outside of buildings shall be via fibre optic cable. The condition monitoring data for all
the machine packages shall be available to the operators at the control building DCS
consoles via connections through OPC servers and firewalls from the CMS servers.
All CMS servers and displays shall be tower type suitable for under desk mounting.
The CMS servers shall also be connected to the PIMS through a firewall so that
maintenance personnel can perform monitoring, diagnostics and analysis of critical
rotating machines through the IOCL client PC’s connected to PIMS.
Any software that is required to be loaded on to an IOCL client PC to achieve the
above functionalities is in the scope of CMS VENDOR. Additionally a common CMS
display workstation with 22” TFT colour screen shall be installed in the Mechanical
Maintenance and Planning Office complete with all hardware and software facilities to
access the CMS servers via the PIMS.

DSN 11660
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SPECIFICATION

Machinery Monitoring System (MMS) and PDRP4200-8550-FS-

Condition Monitoring System (CMS) 1004
Functional Requirements PAGE 7 OF 32
REV F3

CMS software shall be capable of data monitoring functionality in client-server

configuration so that monitoring, diagnostic, analysis and configuration changes are
possible from both main control room CMS servers and Mechanical Maintenance and
Planning Office IOCL client PCs. Therefore, the software offered by CMS VENDOR
should support Client/Server Architecture.
It shall be possible to monitor all parameters; trend alarms, etc., and change
configuration, rule set, from the CMS servers and the IOCL client PCs. All rule sets
shall be fully engineered, tuned and appended based on actual machine, site
condition, suppliers and Owner’s input.
Licenses for the CMS Software shall be provided for all the CMS servers and display
PCs plus a further minimum of a 10 licenses for the IOCL client PCs.
For diagnostic and decision support software, the process data necessary for proper
analysis should be imported from the DCS. The interface with DCS should be at the
‘OPC level’ via a firewall.
Smart Notifier shall be supplied as part of the offered CMS together with all the
Software required for data import in OPC format.
The minimum number of OPC licenses for data transfer shall be 4 (four).
Following design data must be considered by CMS VENDOR, while designing the
network:
a) Maximum number of nodes shall not exceed 50% of the total capacity of the
network.
b) Update of Network Data shall be as follows:
• Monitoring Display, less than 2 sec.
• Monitoring and Diagnostic Display, less than 5 sec.
The data update shall be the time taken by the CMS to update the data on the screen
when data changes on the respective MMS monitor.
c) Network speed shall be decided by the VENDOR based on above Data.

2. DEFINITIONS AND ABBREVIATIONS

2.1 Definitions
The following defines the meaning of specific words used in this specification:
CONTRACTOR Shall mean the parties which have contractual responsibility for
the design, engineering, procurement and construction
management of the plants.
VENDOR Shall mean any person, firm or company having a purchase
order with IOCL/ CONTRACTOR for the performance of any
item of work.

DSN 11660
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SPECIFICATION

Machinery Monitoring System (MMS) and PDRP4200-8550-FS-

Condition Monitoring System (CMS) 1004
Functional Requirements PAGE 8 OF 32
REV F3

IOCL Shall mean the owner, any assignee of the owner, and any
designated representative of the owner.
Plant Shall mean Paradip refinery at Paradip, Orissa State, India.
Shall Refers to a requirement.
Should Refers to a recommendation.
May Refers to one acceptable course of action.

2.2 Abbreviations
ASCS Anti-Surge Control System
CMS Condition Monitoring System
CPU Central Processing Unit
DCS Distributed Control System
EGT Exhaust Gas Temperature
ESD Emergency Shutdown System
FAT Factory Acceptance Test
FGS Fire and Gas System
GTG Gas Turbine Generator
GUI Graphical User Interface
HMI Human Machine Interface
HVAC Heating, Ventilation and Air-Conditioning
IFAT Integrated Factory Acceptance Test
I/O Input/ Output
IS Intrinsically Safe
LAN Local Area Network
MCB Main Control Building
MMS Machinery Monitoring System
MPV Machine Package VENDOR
MTBF Mean Time Before Failure
MTTR Mean Time To Repair
NPSH Net Positive Suction Head
OPC Object Linking and Embedding for Process Control
PC Personal Computer

DSN 11660
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SPECIFICATION

Machinery Monitoring System (MMS) and PDRP4200-8550-FS-

Condition Monitoring System (CMS) 1004
Functional Requirements PAGE 9 OF 32
REV F3

PIMS Plant Information Management system (IOCL Plantwide

LAN)
RAID Redundant Array of Independent Disks
RAM Random Access Memory
RTU Remote Terminal Unit
SAT Site Acceptance Test
SER Sequence of Events Recorder
SIL Safety Integrity Level
SIT Site Integration Test
SRR Satellite Rack Room
TCS Turbine Control System
TMR Triple Modular Redundant
VDU Visual Display Unit

3. APPLICABLE DOCUMENTS
The equipment covered in this specification shall comply with the following
documents:

3.1.1 FWEL Specifications

Number Title

PDRP-8550-SP-0006 Instrumentation for Packaged Units

PDRP4200-8550-FS-1001 Functional Specification for Distributed

Control System

PDRP4200-8550-FS-1002 Functional Specification for Emergency

Shutdown System

PDRP-8550-SP-0005 Specification for Control/ Marshalling

Cabinets
PDRP-8550-SP-0011 Inspection and Testing of Electronic
Systems

3.1.2 FWEL Drawings

Number Title

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Machinery Monitoring System (MMS) and PDRP4200-8550-FS-

Condition Monitoring System (CMS) 1004
Functional Requirements PAGE 10 OF 32
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PDRP4200-8550-63-1001 Instrument Earthing Philosophy Drawing

PDRP4200-8550-64-1004 DCS Architecture Diagrams

SHTS 001 TO 013

PDRP4200-8550-64-1005 ESD Architecture Diagrams

SHTS 001 TO 013

PDRP4200-8550-64-1009 CMS/MMS Architecture Diagrams

SHTS 001 TO 014

TBA Conceptual Layout Main Control Building

PDRP4200-8550-64-1050 Equipment Layout Satellite Instrument

Buildings

3.1.3 Codes and Standards

Number Title

89/ 336/ EEC European Union EMC Directive

EN 50081-2 Emission, Industrial Environment
EN 50082-2 Immunity, Industrial Environment
IEC-144/ BS-5420 (1977) Ingress Protection for Dust and Water Jets

IEC 60079 Electrical apparatus for explosive gas

atmospheres
IEC 60227 PVC Insulated Cable
IEC 60502 Power Cables
IEC 61000 Electromagnetic Compatibility For
Industrial-Process Measurement and
Control Equipment

IEC 61511 Functional Safety- Safety instrumented

systems for the process industry sector.
Part 1-2004

IEEE 802.3 Information Processing Systems – Local

Area Networks

ISA – RP-55.1/ BS-588 Hardware Testing of Digital Process

Computers (Codes of Practice for Testing
Computer Based Systems)

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SPECIFICATION

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Condition Monitoring System (CMS) 1004
Functional Requirements PAGE 11 OF 32
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ISBN 086341 2335 IEE Guidelines for the Documentation of

Computer Software Real Time and
Interactive

NEMA 250-1991 Enclosures for Electric Equipment (1000

Volts Maximum)

MIL-STD-217E Military Handbook – Reliability Prediction

of Electronic Equipment

4. GENERAL REQUIREMENTS FOR MMS/CMS

4.1 Environment
The MMS/CMS equipment shall be installed in the air-conditioned, non-hazardous
environments within the control buildings and SRRs, with a normal ambient
temperature of 25oC, RH of 45% + / - 5%.
The MMS/CMS equipment shall be capable of operating under air-conditioning failure
conditions, when the following ambient conditions shall apply:
Outside ambient temperature (max) 48 oC
Design temperature (for air cooler areas) 31.0 oC
Relative Humidity 75%
Normal dust filters shall be used for HVAC equipment.
All transducers are assumed to be located in Zone 0 or Zone 1 classified hazardous
areas. IS barriers and/or Galvanic Isolators shall be supplied as part of the MMS
cabinets and in accordance with Project specifications or standards to be followed in
the design and implementation of Control Systems for the Paradip Project and shall
be selected with advice from the CMS VENDOR to ensure compatibility.

4.2 Availability
The MMS shall be designed to achieve availability between 99.9% and 99.99 % with
an assumed MTTR of 8.0 hours. The system availability shall be submitted as part of
the design documents.
The availability of the CMS data acquisition systems may be lower than 99.9%,
subject to the prior approval of the CONTRACTOR and IOCL.
The mean time to spurious trip/ alarm shall be greater than 10 years.
The MTBF of the system shall be submitted as part of the design documents.
The system availability data may be based on both MIL-HDBK-217 analysis and
historical data for comparable systems. In qualitative terms, the overall system
availability shall be “high”.

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SPECIFICATION

Machinery Monitoring System (MMS) and PDRP4200-8550-FS-

Condition Monitoring System (CMS) 1004
Functional Requirements PAGE 12 OF 32
REV F3

4.3 SIL Implementation

SIL reviews shall be carried out by others for each MMS safety function to determine
the system integrity requirements in accordance with international standards and the
system shall be designed to satisfy the defined requirement.
The MMS shall be based on fault tolerant redundant architecture and shall be capable
of implementing SIL 3 safety functions in accordance with IEC 61508 and IEC 61511.
All MMS hardware shall be safety function certified as standard.

4.4 Redundancy
In order to meet the required system availability, redundant and/or fault tolerant
technology shall be incorporated.
However, the following equipment shall be redundant:
• MODBUS Communication Network between MMS and DCS
• Control Processors
• Mass data storage devices
• Power Supplies
The redundant system shall be designed so that, on failure of an operating unit,
automatic changeover to the redundant unit shall occur. The system design shall
permit the replacement and testing of the failed unit without disrupting the control of
the process.
Within the MMS, at least two self-checking channels are required for all trip-initiating
modules.

4.5 Security
Adequate system security shall be provided through password protection for various
functionalities. Each user of the MMS/CMS shall have a unique User ID and
password to gain access to the system. Security passwords shall be user-
configurable. User-definable access levels with assignable privileges shall be
provided. Each user shall belong to one or more User Groups that shall restrict both
the operations that can be carried out and the plant areas that he can control. User
Groups shall be defined as follows:
Operator - This level shall typically be used by non-specialist personnel to
view MMS information that is not available to the DCS.
Engineering - This level shall give access to all analysis and diagnostic tools. It
shall also allow changes to the MMS configuration.
Administrator - This level shall allow the creation of new users and assignment to
User Groups.

DSN 11660
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SPECIFICATION

Machinery Monitoring System (MMS) and PDRP4200-8550-FS-

Condition Monitoring System (CMS) 1004
Functional Requirements PAGE 13 OF 32
REV F3

4.6 Spare Capacity & System Loading

After commissioning, all system cables terminating in the MMS cabinets shall include
at least:
• 20% unused pairs which shall be connected to spare Elco plug pins or
terminals.
• 20% spare terminal blocks shall be provided in cabinets containing terminal
blocks.
• 20% spare capacity over and above the required loadings (including the spare
capacities).
The MMS shall be designed and engineered to include wired and available rack slots
to enable an increase of 20% in capacity after commissioning. The spare cards shall
not be fitted.
These slots shall be distributed across the racks such that an increased requirement
associated with any machine can be accommodated.
The final projected loading of the MMS/CMS servers, CPUs, RAM and
communications shall not exceed 60% of capacity. Should the recommended
maximum loading be less than this figure then the system shall not exceed 60% of
this lower figure following plant commissioning.
All power supply units shall include 25% spare capacity when all specified (including
sparage) loads are utilised.
After commissioning, the MMS/CMS communications networks shall not exceed 60%
of the maximum allowable loading.
The MMS/CMS shall be designed so that 20% future expansion can be
accommodated without any modification or replacement of existing equipment,
communication systems or software.

4.7 Time Related Functions

All MMS/CMS subsystem clocks shall be synchronised to the DCS clock at regular
intervals via the network time protocol or other method.
Sequence of events recording shall be implemented by the ESD system SER.

4.8 System Communications

The MMS shall interface to the following systems:
• Condition Monitoring System (CMS)
• Distributed Control System (DCS)
• Emergency Shutdown System (ESD)
• Local panel mounted displays

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The MMS shall connect to the CMS via a simplex Ethernet LAN in the same SRR.
The LAN will also connect the local CMS display PCs to the primary CMS server(s)
located in the control buildings.
The CMS LAN switches shall support both Ethernet copper and fibre optic
communication cable types. All outdoor communication cables between SRRs and
control buildings shall be fibre optic cables via diverse routes.
The responsible parties for the design of the CMS LAN shall develop the architecture
to ensure correct functioning of the communication links between the systems.
The CMS LAN shall not be used to pass critical safety and/or control signals between
systems, i.e. signals whose failure could directly prejudice either plant control or
safety. Critical signals shall instead be exchanged via hardwired I/O connections.
The MMS to DCS communication shall comprise of dedicated, redundant MODBUS
communication lines to the respective unit DCS node within the same SSR.
Differences between the primary and secondary communication cable lengths shall
be minimised so as not to affect the DCS communication system operation. The
MAC shall advise maximum allowable length discrepancy.
MMS shall transmit to the DCS all signals for the Operator to monitor, control and/or
alarm through the DCS HMI. Details of the DCS System are described in PDRP-
8550-FS-0001.
All signals between the MMS and ESD shall be hardwired. The MMS shall provide a
separate volt-free contact to the ESD System so that the latter can initiate shutdown
of Plant items outside the scope of the MMS. Details of the ESD System are
described in PDRP-8550-FS-0002.
Each MMS rack shall be provided with modules to provide serial communications to
local panel mounted displays, which will repeat monitored data for operators.
Connection from the CMS to the DCS shall be achieved at the higher network level
via a suitable gateway (typically an OPC server) and firewall.
The LAN shall not electrically connect different systems together i.e. galvanic isolation
techniques shall be incorporated into the system design.
Loss of data communications shall not result in trips or status changes of the data
point.

4.9 Earthing Requirements

System earthing requirements shall be in accordance with drawing PDRP-8550-63-
0001.
Any special earthing requirements for the MMS shall be specified by the MMS
VENDOR and subject to approval by the appropriate CONTRACTOR and IOCL.

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4.10 Electromagnetic Compatibility (EMC)

The MMS equipment shall comply with the European Union EMC Directive and in
particular to IEC 61000-4 as follows:
Part 1 – General Introduction
Part 2 – Electrostatic Discharge Requirements
Part 3 – Immunity to Radiated Electromechanical Field
Part 4 – Immunity against Fast Transients/ Bursts
Part 5 – Surge Immunity Requirements
Part 6 – Immunity to Conductive Radio Frequency Disturbances

5. MACHINE MONITORING SYSTEM REQUIREMENTS

The provision and implementation of machinery protection shall satisfy the
requirements defined in API Standard 670, ‘Machinery Protection Systems’.

5.1 Machine Monitoring Philosophy

The following classifications may be used in determining the monitoring and
protection equipment required. The classifications are described more fully in
APPENDIX A:

5.1.1 Class A
Applicable to large rotating equipment that may be spared or unspared and has the
potential to cause plant shutdown, personnel fatality or multiple injuries, large
environmental release, or a large fire or explosion.

5.1.2 Class B
Applicable to major rotating equipment, whose failure would result in lost throughput,
acute health risk, local fire risk, local environmental release or high maintenance cost.

5.1.3 Class C
Applicable to rotating equipment, whose failure would significantly impact operations
and/or safety.

5.1.4 Class D
Applicable to non-critical rotating equipment where intermittent collection of condition
monitoring by off-line equipment is acceptable. Vibration data is collected by portable
equipment connected to permanently installed probes.

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5.2 Operator Interfaces

For the normal operational activities such as the monitoring of vibration amplitude,
axial displacement levels, temperature measurement, and alarms the operator
interface shall be the DCS workstation.
Local panel mounted displays shall be connected to the MMS to provide information
of monitored data to field operators.

5.3 I/O Structure

Volt-free output contacts from the MMS, which interface with other systems, shall be
powered by the receiving-end system.
Where TMR trip logic for vibration and temperature is required, then three slots in
each direction for X and Y proximity probe inputs shall be provided.
Trip signals from the MMS to the ESD shall be fail-safe i.e. normally energised relay
contacts; these relays shall be de-energised in the case of a trip, causing the trip to
open.
No trip voting logic shall be conducted within the MMS. Instead, there shall be
dedicated outputs to the ESD for each trip sensor.
Logic for control interlocks may be conducted within the MMS, by provision of relay
modules.

5.4 System Hardware

The MMS system hardware shall consist of system cabinets containing instrument
racks housing power supply units, communication modules to CMS, DCS and local
displays, monitoring modules and relay modules; IS barriers/galvanic isolators; wiring
ducts; circuit breakers; cooling fans; termination strips. All equipment shall be fully
installed and prewired.
Each major item of rotating equipment such as a GTG or compressor shall be
equipped with a dedicated MMS with discrete output signals for “Alarm & Trips”.
Alarms and trips may also be implemented in separate control systems such as
turbine control systems (TCS) and compressor anti-surge control systems (ASCS).
Each MMS will be provided with a PC/workstation loaded with software for the
configuration of the rack modules. After installation of MMS and CMS the rack
configuration software and configuration data will be transferred from this
PC/workstation to the associated CMS server.

5.5 Cabinets
The MMS system cabinets shall be located in each of the SRR’s and control building
rack rooms and local Machinery Control Shelters (where required) and shall be
supplied in accordance with the requirements of PDRP-8550-SP-0005,
‘Control/Marshalling cabinet specification’.

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Cabinet layouts shall be of a standard design for each type of cabinet.

5.6 Monitoring Racks

The monitoring racks for the conversion of the raw transducer signals into
electronically processed formats, shall be located within the MMS system cabinets.
These racks shall typically consist of, but are not limited to a combination of the
following:
• Power supplies (main and redundant)
• Transient data interface modules (for signals to CMS)
• Keyphasor monitors
• Radial vibration monitors (multi-channel)
• Axial vibration monitors (multi-channel)
• Accelerometer monitors (multi-channel)
• Temperature monitors (multi-channel)
• Temperature 4-20mA repeat modules (multi-channel)
• Relay output modules (for signals to the ESD system)
• Communication interface modules (DCS)
• Remote display interface modules
The front plate of all modules shall be equipped with comprehensive LED indications
to enable all operating, diagnostic, test and fault conditions to be identified.
All racks shall be arranged logically, relating to the machinery being monitored, taking
into account the segregation requirements between the equipment trains.
Each equipment train shall have a dedicated power supply, I/O cards and
terminations etc that are separate from those of other equipment trains.
The MMS shall be designed so that it shall be possible to remove and replace, test
and configure any of the modules dedicated to a particular equipment train, without
affecting the operation of the others.
To prevent faults within a rack affecting the performance of the bus or any other rack,
the electronics of each rack shall be optically or galvanically isolated from the system
communication bus.
The communication interface modules shall transmit alarm and status information to
the DCS. These devices shall be capable of collecting the data from all signals in
parallel, and they shall be a separate hardware component from the machinery
monitoring system. The communication interface module of the MMS should be fully
programmable and communicate with the DCS via MODBUS Protocol.
The communication interface module shall have on board memory sufficient to collect
all transient data from all machines simultaneously without deterioration of sample
density, in the event of a complete plant shutdown.

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The MMS shall be connected to the CMS via a communications processor capable of
transmitting online transient & steady state data.
The interconnection between the MMS cabinets and the CMS Server/Display
workstation shall be via an Ethernet LAN with associated hubs, or equal, to convert to
fibre optic cable for building to building connections. Refer to Block diagrams
PDRP4200-8550-64-1009, sheets 001 to 014, “CMS/MMS Architecture Diagrams”.

5.7 MMS Power Supplies

Each rack/cabinet/system shall be provided with redundant 24 VDC power supply
units, each sized and networked so that a system shutdown shall not be caused by
the failure of one of these supplies. Any power supply failure shall generate an alarm
at the DCS.
The power supply modules shall operate in auto-changeover mode. The system shall
be designed such that the removal and replacement of a power supply module can be
completed while the rack is on-line (i.e. hot insertion) without affecting the system’s
monitoring or protection functionality.
The primary 110 VAC, 1 phase, 50 Hz required for the 24 VDC MMS Power Supplies
shall be taken from the main UPS of the Plant, available in all the SRR’s.
Power supplies and distribution shall be rated to accommodate the maximum rack
capacity available within each cabinet.
Field devices connected to the MMS shall be powered from the MMS system
cabinets.

5.8 System Wiring

System wiring shall be supplied in accordance with the requirements of PDRP-8550-
SP-0005, ‘Control/Marshalling Cabinet Specification’.
All MMS marshalling needs and field cable terminations shall be satisfied within the
MMS system cabinets.
Wiring between monitor racks and field devices shall be supplied in accordance with
the requirements of PDRP-8550-SP-0002, ‘Instrument Cabling Standard’.
The shielding shall be earthed in only one location, preferably at the monitor rack.
Sufficient space shall be allowed for the termination, marking off, installation and
looming of field cables in the MMS system cabinets. Suitably sized trunking shall be
provided for this purpose.

5.9 Remote Displays

For each Machine Monitoring System to be supplied by the MPV, a local display unit
(LCD Type) shall be provided in the field Local Control Panel, which shall be serially
interfaced with the corresponding Machine Monitoring System located in the SRR.
This display shall repeat all the monitored variables (vibration, bearing temperature,

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speed) in bar graph form. This facility shall be used by the field operator to start the
machine in the field as well as for the indication of detected abnormalities in the
Machine.
The local display units shall be suitable for location in hazardous areas and be
certified Intrinsically Safe.

5.10 System Configuration

Each MMS shall include configuration and diagnostic tools loaded on a Laptop.
These tools shall be suitable for configuring the monitors and displayed data with
respect to the raw data, measured values, monitor health status, alarm and trip
settings and status etc.
Each MMS sub-system/rack in the SRRs and control buildings shall be provided with
an interface port to allow connection of the portable configuration tool/Laptop.
Suitable password protection shall be included for configuration of the monitors.
Each monitoring point shall be fully configured with all appropriate software alarms,
mode of analysis, predictions, correlations and trending.

5.11 Battery Backup

Any backup batteries required for the MMS/CMS shall have a minimum operational
life of two years based on an operating temperature of 25°C. Short excursions of up
to eight hours above operating temperature conditions shall not reduce the life of the
battery.

6. CONDITION MONITORING SYSTEM (CMS) REQUIREMENTS

6.1 Operator Interfaces

The operator interfaces to the CMS shall be via the CMS Servers located in the
engineering rooms of the control buildings. Each CMS server will have a CMS
display unit consisting of PC workstation and 22” industrial grade TFT type colour
monitor located in the associated SRR, which is to be interfaced to the MMS to
indicate all monitor racks status, alarm and event history, trend plots and bar charts.
This interface shall be used for historical trending, machinery diagnostics and
predictive maintenance purposes and the storage, analysis and archival of condition
and performance data and the diagnosis of machinery problems.
The system shall operate such that graphics/displays are accessed with minimal
keystrokes in a hierarchical arrangement from overview to detail graphics.
The following graphics as a minimum shall be provided:
• Graphics containing measured variables, setpoints, alarms and outputs.
• Group displays of similar data/information.

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• Individual detail displays that provide additional information of items in the

Group displays.
• Real-time trend graphics.
All CMS data shall be accessible from every point of CMS network i.e., CMS servers
and CMS displays as well as from CMS display at Mechanical Maintenance Office.
A dedicated Laser colour printer shall be provided for the CMS Server and CMS
display workstation for the purpose of producing screen displays, reports, alarms,
events and trends.
The DCS shall transmit to the CMS via firewall and OPC server all process values
required by the CMS for performance monitoring of Class A rotating equipment. (See
Appendix A). The data transfer shall be bi-directional.
CONTRACTOR shall develop a detailed list of signals to be exchanged between the
systems.

6.2 Network Requirements

The CMS network shall consist of communications equipment located in the rack
rooms of the control buildings and SRRs. The equipment shall include, but not be
limited to the following:
• Network Cabinets with power distribution, lighting etc. The power distribution
shall be designed such that multiple power feeds may be provided if the
cabinet contains equipment serving more than one CMS network. The power
shall be then distributed so that all equipment connected to one CMS network
is separate from that of other networks.
• Network switches. Switches shall be provided with both copper and fibre optic
network connections.
• Firewalls. For cabinets interfacing with the DCS and PIMS.
• System cables, Ethernet and fibre optic
• Interface cables

6.3 Basic System Software

The system shall employ standard software configured to meet the stated
requirements. The software shall be the latest commercially released version at the
time of order placement.
The system’s standard operating software shall not be modified to meet the project
requirements.
All necessary software licences shall be provided enabling the right to exercise the
use of all relevant and applicable software.
The CMS shall be configured using “open” packages and shall be Microsoft Windows
based, with IOCL having source code ownership.

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The system shall include the following features:

• Microsoft Windows GUI to enable a common interface across all compatible
systems.
• Menu driven displays.
• Capability to provide a structured database to enable logical data retrieval.
• Capability to provide a structured event listing on a machine basis including
protection signal details.
• Capability to accept standard tag numbering without abbreviation.
• Print out of screen graphics, reports, alarm listings etc.
The software shall meet the following functional requirements as a minimum:
1. Acquisition of machine raw data from the different monitoring systems
installed in the SRR’s along the Plant.
2. Storage of base line data and conditional base line data for comparison.
3. Alarm and event management, including continuous and transient data, alarm
level settings, modifications etc.
4. Real Time and historical trending of raw and deduced data.
5. Multivariable trending including X-Y plot, Bode Plot, Polar Plot etc.
6. VENDOR should also indicate other data display and presentation features
available as standard in the System supplied.
7. Real-Time Database DCS Data (Tag) Integration is to be the responsibility of
the CONTRACTOR.
8. Configured Plant Hierarchy shall be at least 3 levels deep, including: Site
level, Plant Area, and machine train level. GUI graphics must be configured,
with primary monitoring parameters shown at the lower hierarchy level
(typically direct or overall amplitude). Basic machinery information is to be
configured into the data fields where relevant.
9. Two levels of software alarms shall be configured for each Management
Variable monitored.
10. CONTRACTOR shall pre-configure diagnostic and trend plots to cover all
machine groups and key monitoring measurements types. As a minimum the
following plots shall be pre-configured for each machine covered by the MMS
as applicable:
• Bar Charts and multivariable trend plots, showing direct amplitudes for all
sensors.
• Diagnostic vibration plots: Shaft orbits. Bode & Polar, Spectrum, Waterfall &
Cascade, Rod position (for reciprocating compressors), Electrical Current
Spectrum/ Harmonic Analysis, Electrical Phasor Plots.
• Steam Turbine performance plots: Heat rate, specific steam consumption,
heat drop efficiency and overall thermal efficiency.

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• Gas Turbine and Compressor section performance plots; Heat rate,

compression ratio overall thermal efficiency, EGT plots.
• Centrifugal Compressor performance plots: Polytropic Head, Polytropic
Efficiency, Gas/ Shaft Power, and Discharge Pressure vs. Suction pressure
(pressure ratio) and Volume Flow vs. Speed.
• Reciprocating Compressor performance plots: Suction & Discharge
Volumetric Efficiency, Indicated Power, and Theoretical Discharge
Temperature, Capacity at Suction Valve and Discharge Valve, Median
Capacity, Theoretical Capacity at Discharge Valve, Cylinder Flow Balance &
Theoretical Flow Balance, Power Median Capacity Ratio, Theoretical
Clearance Volume, Suction and Discharge Power Loss.
• Pump performance plots: Pump design performance characteristic curves
showing actual compared to expected performance, NPSH and operation
margin (NPSH required and NPSH available) at current operating suction
conditions.

6.4 Specialist System Software

Software specific to predictive and diagnostic functions shall include as a minimum
the following functionality:
• Sampling and historic functions.
• Decision Support Software Module
• Analysis tools to provide long-term condition predictions, including expert
systems for automatic diagnosis. Fault Diagnostic Analysis and Decision
Support software modules when integrated should have the capability of:
a) Diagnostics and root causes analysis
b) Supporting development, configuration, and modification of machine specific
rule sets for decision supports based on machine manufacturer and owner
requirements.
c) Supporting change management by providing audit trail for all changes
made in system configuration, rule set, etc.
• A facility to compare historic data with any present or past event data.
• A facility to compare data from different machines.

6.5 Condition monitoring Function

The CMS’s Software shall provide, as a minimum, the following real time and trend
graphic displays and reports of machinery condition:
• Current values including bearing temperatures and absolute vibration levels.
• Scalar history points.
• Historical spectrum plots.

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• Bode plots.
• Polar plots.
• Nyquist plots.
• Transient spectrum plots.
• Average shaft position.
• Scalar v speed plots (transient).
• Shaft orbit plots.
• Shaft X-Y position history plots.
• Shaft vector plots.
• Spectrum plots.
The system shall be capable of banded trending for both temperature and vibration.

6.6 Predictive Fault/Failure Functions

The CMS shall provide as a minimum, the following predictive fault/failure analysis
graphic displays and reports, and alarm outputs:
• Historic comparison of present data with base line data and previous analysis
data.
• Historic trending to evaluate changes.
• Correlation of vibration with machine geometry and plant variables.
• Vibration analysis to categorise vibration frequency elements, amplitude and
vibration form.
• Amplitude and phase angle.
• Shaft centre line position.

6.7 Performance Monitoring Functions

The system shall provide but not be limited to, performance monitoring graphic
displays/reports as follows:
• Efficiency comparison of Turbine/Motor power with computation for
Generator/Compressor.
• Compressor polytropic head vs flow.
• Compressor discharge pressure and/or compression ratio vs. volumetric flow
rate.
• Diagnostic Vibration Plots
• Pump performance plots

6.8 System Data Storage

The system shall have a real time and historical data (such as process values,
conditions and operator actions) collection facility to support machine condition

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analysis, performance analysis, fault diagnosis system trends, logs and reports as
required.
The data storage system shall be sized sufficiently to handle all historical data
collection requirements. The data storage system shall be able to store all volatile
system data (such as operating programs, process information, graphics,
configuration and programs).
The system shall include facilities to enable selected real-time and historical data to
be saved onto removable mass media; e.g. CD-R or Zip drive, for long-term storage
and/or archiving.
Complete system configuration shall be stored on a bulk storage device with
capability of being removed for backup and subsequently restored.

6.9 Historian
For those signals which are continuously monitored it shall be possible to retain a
history leading up to an event occurrence such as a trip.
A permanent storage shall exist for:
• Monthly readings per machine
• Start-up and shutdown readings
• Trip and deviations outside the current operating parameters
The system shall include the hardware to load data to and read from the long-term
mass storage system.

6.10 Portable Data Collection

There shall be a common licence for portable data collection. The number of points,
eg 5000 data points, shall be shall be distributed across all units of the project.
Portable data collected by hand held device shall be uploaded at any location in the
CMS network or Mechanical Maintenance Office and shall be accessible by any CMS
server or CMS display including that in the Mechanical Maintenance Office.

7. LOCAL CONTROL PANELS

Local control panels shall be based on the details given in Appendix B. Components
and internal wiring shall be in accordance with Project Specifications.

8. GENERAL INSPECTION AND TESTING FOR MMS/CMS

All Inspection and Testing of the MMS/CMS shall be carried out in accordance with
specification PDRP-8550-SP-0011, “Inspection and Testing of Electronic Control
Systems”.

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8.1 Factory Acceptance Tests (FAT)

The MMS/CMS shall undergo a FAT at the Vendor’s works. All cabinets,
components, and sub-assemblies shall be assembled in one area at one time.
Simulation and loading equipment devices shall also be connected.
The purpose of the FAT is to verify that the MMS/CMS and their sub-components
function correctly. It shall be demonstrated that the MMS/CMS conforms to the
specification, and that the configuration and application software accurately reflects
the required functionality.
Inspections and tests shall include demonstrations of all system functions, including
service functions and configuration/diagnostic equipment.
Documentation and drawings shall be available which detail the entire system
requirement. Any errors that are identified during the FAT shall be incorporated into
these documents after the completion of the FAT.

8.2 Site Testing

8.2.1 Site Installation Test (SIT)

The SIT shall be carried out on the MMS/CMS equipment when it is installed in the
SRRs and the control buildings but prior to connection of field inputs. The test will
confirm the correct operation of the links from the MMS to the CMS in both locations,
as well as identifying equipment damaged during transportation and installation and
punch list clearance from FAT.
The SIT shall include, but not be limited to the following:
• Verification of calibration of sensors and monitors for all machinery supplied
by MPVs, LSTK Contractors and EPCm Contractors.
• After applying power to the system verification of factory configured data shall
be undertaken. In cases of any mismatch, reconfiguration/reloading shall be
undertaken.
• The decision support software shall be verified for its base configuration with
Rule Sets/Heuristics supplied by the machine manufacturer.

8.2.2 Loop Checking

The loop check shall be carried out when the MMS is connected to the field detectors
on the rotating equipment. Detector signals will be simulated and the response
monitored in the CMS, DCS and in the ESD, proving correct operation of field wiring,
CMS, communication links to the DCS and hard wiring to the ESD. This shall be
done for each machine and each sensor. In case of any discrepancy the data shall
be re-verified after calibration.
All loop checking data shall be recorded machine wise for acquisition and shall be
verified for its presentation on the MMS monitoring consoles. All the data shall be
fully recorded and signed by the representative of the Engineers in-charge.

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8.2.3 Commissioning
During commissioning the rule sets and decision support software will be tuned to
arrive at the correct and logical decisions. All scenarios shall be verified at site.

8.2.4 Site Acceptance Testing

The MMS/CMS shall be accepted after the entire integrated system is commissioned
and placed in continuous operation for an agreed period (Site Acceptance Test) with
all machines in operation.
The test shall demonstrate complete system functionality and performance. In cases
of non-satisfactory functioning or mismatch in the data between the probe signal,
monitor indication and workstation indication shall under take recalibration as
required.

9. DOCUMENTATION FOR MMS/CMS

Documentation requirements are detailed in the ‘Material Requisition for MMS/CMS’,
PDRP-RQ-4301-1617G-001.

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10. APPENDIX A - MONITORING INSTRUMENTATION GUIDELINES

Machinery monitoring and protection equipment shall be determined by
CONSULTANTS Mechanical Engineers in conjunction with the equipment vendor and
finalised on vendor selection.
The following classifications may be used in determining the monitoring and
protection equipment required:

10.1.1 Class A
Applicable to large rotating equipment that may be spared or unspared and has the
potential to cause plant shutdown, personnel fatality or multiple injuries, large
environmental release, or a large fire or explosion.
Equipment in this class requires continuous on-line condition and performance
monitoring together with safeguarding facilities.
Class A equipment includes but is not limited to:
• Centrifugal Compressors to API 617
• Packaged integrally geared, centrifugal plant and instrument air compressors
to API 672
• Reciprocating compressors to API 618
• Steam turbines API 612
• Gear boxes, special purpose to API 613
• Electric Motors driving critical machinery and electric motors 1000 kW and
above
• High pressure pumps (barrel pumps) to API 610 and their driver
• Steam and gas turbine driven generator sets, continuous duty
The following table summarizes the required sensors for critical machines. In some
cases, the MPV will not propose nominated sensors for a minimal safe
instrumentation level, however where available, they must be supplied according to
this Plan. Such points are marked with an asterix (*) below.
Machine Monitoring Point Transducer
Shaft speed & phase ref. Keyphasor transducer ( proximity probe)
Tachometer (incl. zero speed) Keyphasor transducer (two probes)
Overspeed protection-SIL 3 Proximity Probe, TMR
Thrust Position – SIL 3 Proximity Probes, TMR
Steam Turbine Shaft radial vibration Proximity Probes
Bearing Housing Vibration (*) Piezo-electric velocity sensor
Bearing Temperature RTD (1 active, 1spare)
Shaft Eccentricity (*) Proximity Probe
Differential Expansion (*) Proximity Probe

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Machine Monitoring Point Transducer

Valve Position LVDT
Shaft Speed and Phase ref. Keyphasor transducer (proximity probe)
Combustor Dynamic Pressure (*) High temperature dynamic pressure sensor
Exhaust Gas Temperature RTD (installed to MPV’s recommendation)
Hazardous Gas accumulation Heated catalytic-bead gas sensor
Overspeed protection-SIL 3 Proximity Probe, TMR
Gas Turbine Thrust Position – SIL 3 Proximity Probes, TMR
Tachometer (incl. zero speed) Keyphasor transducer (two probes)
GG Casing Vib. Protection SIL 3 High Temp. Seismic Transducer , TMR
GG Aux. Gearbox vibration Piezo-electric Accelerometer
PT Shaft Radial Vibration Proximity Probe (Extended Temperature)
Bearing Housing Vibration (*) Piezo-electric Velocity sensor
Shaft speed & phase ref. Keyphasor transducer (proximity probe)
Thrust Position – SIL 3 Proximity Probes, TMR
Centrifugal Thrust Position Proximity Probes, dual
Compressor Shaft Radial Vibration Proximity Probes (x, y, configuration)
Bearing Temperature RTD ( 1 active, 1 spare)
Oil Pump Casing Vibration Piezo-electric accelerometer
Shaft speed & phase ref. Keyphasor transducer ( Proximity Probe)
Axial Position (wheel & pinions) Proximity Probes
Integrally Shaft Radial Vibration Proximity Probes ( x-y configuration)
Geared
Compressor Bearing Temperature RTD ( 1 active, 1 spare)
Bull Gear Casing Vibration Piezo-electric accelerometer
IGC Gearbox Oil Analysis Permanently installed oil sampling fitting
Crankshaft Phase Reference Keyphasor transducer (proximity probe)
Crankshaft Position Reference Keyphasor Probe & Multi-event wheel
Frame Vibration Low Frequency Piezo-Velocity Sensor
Bearing Temperature RTD ( 1 active, 1 spare)
Crosshead vibration Piezo – electric Accelerometer
Reciprocating
Rod Position Proximity Probes, two orthogonal probes
Compressor
Vent line temperature (*) RTD
Purge Gas Monitoring Flow transmitter, Pressure Transmitter
Valve Temperature RTD
Gas Discharge Temperature RTD
Cylinder Internal Pressure Dynamic Pressure Transducer
Shaft speed & phase ref. Keyphasor transducer ( proximity probe)
Large Motors
Casing Vibration Piezo – Electric Accelerometer
&Generators
Electrical protection Relay Standard CT’s, VT’s, Stator Winding RTD

DSN 11660
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SPECIFICATION

Machinery Monitoring System (MMS) and PDRP4200-8550-FS-

Condition Monitoring System (CMS) 1004
Functional Requirements PAGE 29 OF 32
REV F3

Machine Monitoring Point Transducer

Thrust Position (if applicable) Proximity Probes (dual probes)
Shaft radial vibration Proximity Probes ( x, y configuration)
Bearing Housing Vibration (*) Piezo-electric velocity sensor
Bearing Temperature RTD (1 active, 1spare)
Shaft Speed and Phase ref. Keyphasor transducer (proximity probe)
Shaft radial vibration Proximity Probes ( x, y configuration)
Gearbox & Bearing Temperature RTD (1 active, 1 spare)
Voith
Couplings Gearbox Casing Vibration Piezo – Electric Accelerometer
Gearbox Oil Analysis Permanently installed oil sampling fitting
Thrust Position (wheel & pinions) Proximity Probes
Shaft Speed and Phase ref. Keyphasor transducer (proximity probe)
Tachometer (reverse rotation) Keyphasor transducer (two probes)
Thrust Position Proximity Probes, dual
Critical Service
Pumps Shaft radial vibration Proximity Probes ( x, y configuration)
Bearing Housing Vibration (*) Piezo – velocity sensor
Bearing Temperature RTD (1 active, 1 spare)
Pump seal temperature RTD

Data from Class A equipment shall be continuously monitored by rack-mounted

vibration, displacement and/ or other monitors connected to equipment mounted field
transducers. The monitoring equipment should be provided by the MPV for
installation in the appropriate SRR. The transducers and drivers shall be supplied
installed, calibrated and wired to local junction boxes by the MPV.
Non-contacting phase reference (Keyphasor) probe shall be provided for each shaft
rotating at a different speed as per API 670. Where the machine train has a gear,
then the second probe shall be on the gear’s output shaft.
Class A machines shall be provided with full supervisory MMS driven transient data
capture, performance trending and decision support functions.

10.1.2 Class B
Applicable to major rotating equipment whose failure would result in lost throughput,
acute health risk, local fire risk, local environmental release or high maintenance cost.
Equipment in this class requires permanently installed continuous on-line condition
monitoring and safeguarding transducers connected to rack-mounted vibration
monitors with Dynamic Data Capture capability, but does not require performance
monitoring.
The transducers and drivers shall be supplied installed, calibrated and wired to local
junction boxes by the MPV.

DSN 11660
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SPECIFICATION

Machinery Monitoring System (MMS) and PDRP4200-8550-FS-

Condition Monitoring System (CMS) 1004
Functional Requirements PAGE 30 OF 32
REV F3

Class B equipment includes but is not limited to:

• Steam Turbines, general purpose to API 611
• Electric motors, all types less than 1000 kW
• Selected Forced and Induced draft Fans
The following is a list of typical instrumentation for Class B machinery.
Machine Monitoring Point Transducer
Shaft speed & phase ref. Keyphasor transducer ( proximity probe)
Tachometer (incl. zero speed) Keyphasor transducer (two probes)
Overspeed protection Proximity Probe
Steam Turbine
general purpose Thrust Position Proximity Probes
to API 611 Shaft radial vibration Proximity Probes
Piezo-electric Accelerometer or Velocity
Bearing Housing Vibration
sensor
Bearing Temperature RTD (1 active, 1spare)
Shaft Speed and Phase ref. Keyphasor transducer (proximity probe)
Shaft radial vibration Proximity Probes
Rotary
Thrust Position Proximity Probes
Compressors
and Blowers Tachometer Keyphasor transducer
>350kW Piezo-electric Accelerometer or Velocity
Bearing Housing Vibration
sensor
Bearing Temperature RTD (1 active, 1spare)
Shaft Speed and Phase ref. Keyphasor transducer (proximity probe)
Forced and
Shaft radial vibration Proximity Probes
Induced Draft
Fans Piezo-electric Accelerometer or Velocity
Bearing Housing Vibration
When specified sensor
Bearing Temperature RTD (1 active, 1spare)
Shaft Speed and Phase ref. Keyphasor transducer (proximity probe)
Motors
Shaft radial vibration Proximity Probes ( x, y configuration)
350KW to
3500KW Piezo-electric Accelerometer or Velocity
Bearing Housing Vibration
When specified sensor
Bearing Temperature RTD (1 active, 1 spare)

Non-contacting phase reference (Keyphasor) probe shall be provided for each shaft
rotating at a different speed as per API 670. Where the machine train has a gear,
then the second probe shall be on the gear’s output shaft.

10.1.3 Class C
Applicable to rotating equipment whose failure would significantly impact operations
and/ or safety.
Equipment in this class requires continuous safeguarding.

DSN 11660
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SPECIFICATION

Machinery Monitoring System (MMS) and PDRP4200-8550-FS-

Condition Monitoring System (CMS) 1004
Functional Requirements PAGE 31 OF 32
REV F3

Class C equipment shall have permanently installed condition monitoring transducers

and/ or alarm devices providing alarms to the operator through the DCS HMI. The
signals may be gathered using a sensor bus and transferred to the DCS over a series
of serial interfaces.
This shall be backed up by periodic data logging with portable data collection devices
and subsequent upload to the MMS.
Class C equipment includes but is not limited to:
• Centrifugal pumps to API 610 (hazardous service)
• Selected fin fans, cooling tower fans, boiler fans and furnace fans
• Boiler feed water pumps and primary cooling water pumps
Monitoring and protection equipment shall be reviewed and determined after the
mechanical design of the rotating equipment is defined but typically centrifugal pumps
to API 610 will require seal leakage detection instrumentation and fin fans will require
self actuated vibration switches.

10.1.4 Class D
Applicable to non-critical rotating equipment where intermittent condition monitoring
by off-line equipment is acceptable. Data from non-critical equipment shall be
obtained using portable data collection devices.
All Class D or non-critical machinery shall be supplied with machined flats and “quick
connect” studs, in two planes on each bearing housing and axially on the outboard
bearing, to enable the use of accelerometers or other hand held transducers with
portable data collectors.
Class D equipment includes but is not limited to:
• Balance of pumps, API 610 ANSI, rotary pumps
• Gearboxes, general purpose
• Electric motors less than 1000 kW
• Balance of fans, all types
Local panels are not required.

DSN 11660
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SPECIFICATION

Machinery Monitoring System (MMS) and PDRP4200-8550-FS-

Condition Monitoring System (CMS) 1004
Functional Requirements PAGE 32 OF 32
REV F3

11. APPENDIX B – LOCAL CONTROL PANEL GUIDELINES

Construction Welded, self standing

Degree of Protection WP to IP 65

Area Classification Zone 1 IIA, IIB

Material of Construction Stainless Steel 316

Structure Frame Angle frame (SS) – 50x50x6 mm

Base frame (SS) – 50x100x50 mm

6mm thick

Hardware SS

Sheet Thickness Front door - 3 mm

Rear door - 3 mm
Sides - 3 mm
Top - 3 mm
Bottom - 3 mm
Gland plates (removable) 3 mm
Sun shade (canopy) 2 mm

Cable Entry Bottom

Dimensions Width - 1000 mm

Depth - 800 mm
Height (including base) - 2200 mm
Canopy overhang - 500 mm

Access Rear door

Tag Plates (front and back) Black letters engraved on SS/traffolyte

plate, fixed with adhesive

DSN 11660
 PDRP‐8550‐SP‐0005  Annexure‐1

DOC NO: PDRP‐8550‐SP‐0005: CONTROL/MARSHALLING CABINET SPECIFICATION

SNO CLAUSE NO NEW CLAUSE

1 6.1.6 Separate marshalling cabinets shall be provided for IS & NIS types signal and if the signal quantity for
IS / NIS less than 32 (including spare) then it can be accommodated in same marshalling cabinet with
front & rear segregation.
2 6.1.10 Inter panel network cable like STP/OFC patch cord etc. shall be routed through PVC spiral. All STP
cable connector shall be industrial grade
3 6.1.11 Make & model of Fan , light & FFTDU used in side cabinets shall be provided to IOCL for review, also
standard make & model of Fan, light & FFTDU shall be included in the MSL after finalization. LED
lights from IOCL  approved vendor list  to be considered for better durability.

4 6.1.12 All charged electrical component like, busbar, MCB etc shall be covered with acrylic cover to avoid
accident and short circuit inside cabinets with easy access for measuring voltage and current, easy
dismantling of faulty item and better accessibility.
5 6.1.13 The acceptable make for the following items are:
Push buttons, Key Switches, Selector Switches: M/s Paramount, Siemens, Technic
Indicating lamps ( LED): M/s Paramount, Siemens, Technic.
CONTROL SYSTEM VENDOR TO PROVIDE PTR ALONG WITH OFFER
6 6.1.14 All the DOU rating shall be double of the PSU rating.The acceptable makes for DOU are Phoenix, TRC
Electronics ( Mean well)
CONTROL SYSTEM VENDOR TO PROVIDE PTR ALONG WITH OFFER
7 6.1.15 Separate cable duct shall be provided for field cable and internal / inter panel cables.

8 6.1.16 ATS( Auto transfer switch) & DOU( diode O ring ) alarm signal shall be considered during IO
assignment and shall be hooked up with system accordingly
9 6.1.17 a. Isolator Barrier Power Supply:Model will be selected with LED indication.

b. Third party DO & Third party interface DI terminal shall be provided with LED indication with fuse.

c. DO & DI terminals shall be without fused terminals: DO & DI from field and MCC shall be knife edge
type terminals without fuse. 

10 6.1.18 All isolators/ barrier shall be installed vertically for proper heat dissipation . Horizontal installation
of barrier shall be done if OEM recommends the same with prior intimation to IOCL

11 6.1.19 All the marshalling cabinet shall be provided with side covers by default or maximum suite of 03 nos
may be allowed 
12 6.1.20 All voltage and current meters for PDB cabinets shall be digital type only with provision of 4‐20mA
output for DCS indication
 PDRP‐8550‐SP‐0005  Annexure‐1

DOC NO: PDRP‐8550‐SP‐0005: CONTROL/MARSHALLING CABINET SPECIFICATION

SNO CLAUSE NO NEW CLAUSE

13 6.1.21 The accepted makes for the below mentioned items are:
Bulk Power Supplies 24VDC: Phoenix, Cosel, TRC Electronics ( Mean well)
Alarm Annunciators: Minilec
FF Junction boxes with barriers or segment protectors: MTL, P&F
Network Switches: Cisco, Siemens 
Printers, Copiers: HP, Canon
DIN rail Mounted relays with 2/3 changeover Contacts: Jyoti, Omron, Paramount
Relay boards with relays: UL. Approved makes of relays, Onron, Paramount, Honeywell
Contactors: Schneider
MCBs double pole fo dirrefent ratings: MDS, Siemens, Standard Kupp
MCCBs: Alsthom,L&T, Siemens
Voltmeters, Ammeters, CTs: AE
CONTROL SYSTEM VENDOR TO PROVIDE PTR WITH OFFER.

14 7.1.3 The insulation colour of cabinet internal wiring shall be as follows:
AC live:          Red
AC neutral:   Black
Safety ground:  Green with Yellow stripe
Instrument ground:  Green
DC positive:  White 
DC negative: Black 
IS signals:       Blue
All other signals:   Grey
15 7.1.5 Wire ends shall be terminated in twin grip, insulated Tubular type of lugs.. 
16 9.1.3 All front of console/local panel lamps shall be provided with lamp test facility. Lamp illumination shall
be achieved via light emitting diodes(LED's) type lamps.
17 9.1.4 Lamp colours shall be green for motor running or valve open; red for motor stopped or valve closed.
In case of motor trip the lamp colour shall be Orange. Other colours shall be agreed during detailed
engineering with IOCL.
18 10.1.4 All cabinet internals shall be suitably labelled .All cabinets internal labels shall be made from
laminated plastic.
19 12.1.7 Load calculation sheets for PSU sizing to be submitted by system provider. The rating of MCBs shall
be as finalised during detail engineering. The ratings of individual MCBs, and incomer shall be co‐
ordinated with the overall power distribution scheme to avoid spurious trips. Vendor shall submit a
consolidated document giving the characteristic curves of MCCBs, MCBs and fuses used by him;
calculation of co‐ordination with overall power distribution scheme, etc. for tkIS‐India/IOCL approval.

20 3.1.1 System Cabinets: Cabinet dimensions ( Height (H) x Width (W) x Depth (D) )shall be
maximum 2100 H X 600/ 800 /1200 W X 800 D. Construction shall be
modular, suitable to accommodate offered system.
Above flexibilty( 600/ 800 /1200 ) is provided to cater the requirement of different type of cabintes(
Marshalling & PDB) 
For Clauses within CLOUD mark refer Annexure
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SPECIFICATION PAGE 2 OF 11
REV F1

CONTENTS

SECTION SUBJECT

1.0 SCOPE ................................................................................................. 3

1.1 Introduction......................................................................................... 3
1.2 Definitions ........................................................................................... 3
2.0 APPLICABLE CODES, STANDARDS AND DRAWINGS................... 4
2.1 Project Standards ............................................................................... 4
2.2 International Standards...................................................................... 4
3.0 GENERAL REQUIREMENTS .............................................................. 4
4.0 CONSTRUCTION................................................................................. 6
5.0 ELECTRICAL ....................................................................................... 7
6.0 INTERNAL DESIGN............................................................................. 7
7.0 TERMINATION AND WIRING.............................................................. 8
8.0 EARTHING ........................................................................................... 9
9.0 SWITCHES AND LAMPS .................................................................. 10
10.0 NAMEPLATES AND LABELS........................................................... 10
11.0 TESTING ............................................................................................ 10
12.0 DOCUMENTATION............................................................................ 10

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SPECIFICATION PAGE 3 OF 11
REV F1

1.0 SCOPE

1.1 Introduction
This standard defines the requirements for customised instrument panels that
contain electronic instrumentation. This includes panels located both in field
areas and in buildings and is applicable to:
• Control Panels
• Control Consoles
• Control Cabinets
• Miscellaneous Instrument Cabinets
• Marshalling Cabinets

1.2 Definitions
The following definitions shall apply:

Local Control A panel located in a field area, employed as an

Panel: operator interface. This will typically contain simple
devices such as indicators, switches, lamps, etc.

Control Console: A desk assembly normally located in a control

room/SRR. This will typically contain video display
units (VDU’s) and keyboards, plus hard-wired switches
and lamps.

Control Cabinet: A cabinet located in an equipment room or Satellite

Rack Room (SRR). This will typically contain
electronic modules for an individual system.

Miscellaneous A cabinet normally located in an equipment room or

Instrument Cabinet SRR, typically containing electronic modules that do
not form part of a single system.

Marshalling A cabinet normally located in an equipment room or

Cabinet: SRR, and employed as the primary termination point
for incoming field cables, and the means to arrange
signals for input to other cabinets such as Control
Cabinets.

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SPECIFICATION PAGE 4 OF 11
REV F1

2.0 APPLICABLE CODES, STANDARDS AND DRAWINGS

2.1 Project Standards

This specification shall be applied to the following documents:
PDRP4200-8550-FS-1001 Distributed Control System Functional
Specification
Emergency Shutdown System Functional
PDRP4200-8550-FS-1002
Specification
PDRP4200-8550-FS-1005 Fire and Gas Detection System Functional
Specification
PDRP4200-8550-FS-1006 Tank Gauging Functional Specification
PDRP4200-8550-FS-1004 Custody Transfer Functional Specification
PDRP4200-8550-FS-1003 Machinery Monitoring System Functional
Specification
PDRP4200-8550-SP-1008 Analyser Houses and Local Panels Specification

2.2 International Standards

IEC 60364 Requirements for Electrical Installations (IEE
Wiring Regulations)
IEC-60529 Degrees of Protection provided by enclosures IP
Code)
IEC 60079 Electrical apparatus for explosive gas
Atmospheres

3.0 GENERAL REQUIREMENTS

3.1.1 Instrument Cabinets located in the Control Rooms, equipment rooms or

SRR’s shall be of standard modular design, typically of size 2100 mm. high
including a 100 mm. plinth, 800 mm. wide, and 800 mm deep with front and
rear vertically divided doors as follows:
• Manufacturer: Rittal or equal
• Model: PS 4808
• Locks: SZ 2450
• Colour: RAL 7035
3.1.2 Equipment on Control Panels normally used by the operator in the field shall
be readable and operable with the operator in a standing position. Equipment
on Control Consoles in the Control Rooms shall be readable and operable
when the operator is both in standing and sitting positions.
3.1.3 Spare capacity shall be provided on all Instrument Panels and cabinets. This
may be achieved by installed spares or by unused space as defined in the

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SPECIFICATION PAGE 5 OF 11
REV F1

applicable equipment or system specification. As a general guideline the

available spare capacity on completion of Factory Acceptance Testing (FAT)
shall be 20%.
3.1.4 All Panels and cabinets shall be designed so that the spare capacity can be
utilised without the removal of existing components, trunking, or wiring. DIN
rail shall be installed in readiness for use.
3.1.5 System cabinets shall be forced air ventilated by means of dual fans mounted
in the top of each cabinet. Openings for air/heat extraction shall be fitted with
finger guards.
3.1.6 Doors will be fitted with louvered openings and include dust filters.
3.1.7 ESD cabinets shall be fitted with doors with clear glass inserts to enable
monitoring of the status indicators with out opening the doors.
3.1.8 Cabinets shall be provided with internal bulkhead light fittings separately
fused and wired into the power supply from the main panel isolating switch.
The light fitting shall be suitably placed to provide adequate illumination for
maintenance work inside the cabinet and shall be controlled by switches
adjacent to the cabinet access door.
3.1.9 Each cabinet shall be provided with switched socket outlets suitable for
supplying soldering irons, hand lamps etc. separately fused and wired into the
240v ac non-essential power supply from the main panel isolating switch.
3.1.10 Fan failure shall be alarmed to the DCS by the use of a voltage free fan
failure contact.
3.1.11 The temperature inside each cabinet shall not exceed 10oC above ambient
conditions when all internal equipment and external loads are energised.
Vendor shall provide a calculation of heat generated under full load
conditions.
3.1.12 An additional RTD temperature transmitter shall be fitted in the cabinet. This
transmitter is to be connected to local IO in the panel and reported back to the
DCS for monitoring and alarming to the operator.
3.1.13 When simple panels are located in field areas all equipment shall be suitable
for the hazardous area classification. This shall be achieved by the use of
individual certified devices.
3.1.14 Panels located in buildings shall be protected to IP 53 standard as a
minimum.
3.1.15 All devices in field panels shall be suitable for the specified environmental
conditions. Unless otherwise specified, all electronic cards shall have
conformal coating to meet the environmental category class G3 as per ISA-
S71.04.
3.1.16 Instrument Panels located in field areas shall be equipped with a roof or
canopy for protection against sunlight and/or rain.

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SPECIFICATION PAGE 6 OF 11
REV F1

3.1.17 Instrument Panel components shall be selected from an IOCL approved

vendors list.

4.0 CONSTRUCTION

4.1.1 All cabinets located in buildings shall be fabricated from cold rolled carbon
steel. Instrument Panels in field areas shall be of stainless steel. Material
thickness shall be 3mm minimum, with internal bracing as necessary. All
external surfaces shall be smooth and flat on completion of fabrication. They
shall be provided with louvers and dust filters and removable, fully gasketed,
bottom entry gland plate. Any unused glands shall be plugged.
4.1.2 Instrument cabinets of carbon steel shall be painted internally and externally.
All external surfaces shall be finished to the agreed project standard. i.e. RAL
7035
4.1.3 Cabinets mounted on false floors shall be supported on fabricated steel
structures below the false floor. The design, manufacture, supply and erection
of this structure shall be in the scope of the Civil Works Contractor.
4.1.4 Suitable touch up paint of each colour shall be delivered with the equipment.
4.1.5 Instrument panels of stainless steel shall not be painted. All panel surfaces
shall be non-reflective.
4.1.6 Where a unit consists of a suite of modules they shall be mounted on a
fabricated plinth covering the full length and breadth of the suite. Single
module units shall be provided with removable eyebolts and blanking plugs
for lifting. Suites shall utilise removable lifting bars passing through the plinth.
All Instrument cabinets shall be provided with suitable lifting points complete
with removable eyebolts. In order to avoid damage during lifting, suites of
Instrument cabinets shall not exceed 2400mm in length.
4.1.7 Instrument cabinets’ doors shall be vertically divided full height, double
module width (400mm max.) and suitably reinforced to prevent distortion.
Doors shall be hinged on their outside edges, unless otherwise specified, and
provided with seals to prevent dust or moisture ingress. The hinge shall be
concealed type.
4.1.8 All doors shall be of the lift off type, and fitted with an espagnolette locking
system. Keys shall be identical for all cabinets. All doors shall be capable of
opening at least 90 degrees, and shall be equipped with mechanical stops
suitable for the location.
4.1.9 The inside of each door shall be equipped with pockets one suitable for A4
documents and one suitable for a hand held multimeter, with a minimum
depth of 40mm.

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REV F1

5.0 ELECTRICAL

5.1.1 Unless otherwise specified electrical supplies to Instrument Panels shall be

as follows:

Instrumentation 110Vac 50Hz UPS

Safety Systems 110Vac UPS

Lighting, Fans & consumer sockets 240Vac Non-UPS

5.1.2 Other required Instrument and Safety System voltages shall be derived within
the panel utilising redundant PSU’s

6.0 INTERNAL DESIGN

6.1.1 Unless otherwise specified Instrument Cabinets and Panels shall be designed
for the bottom entry of cables or cord sets, and shall be equipped with gland
plates. When the panel is installed in a field area the cable armouring will be
secured at the gland plate. When the cabinet is installed in a building then the
armouring will be secured below the cabinet and the gland plate will be
employed for sealing purposes only.
6.1.2 Electronic equipment shall be located in fixed racks, on rails. Equipment shall
be arranged to facilitate access for adjustment or maintenance, and shall not
be located within 300mm. of the gland plate. All equipment shall be arranged
to ensure the flow of cooling air, where necessary.
6.1.3 Separate power supply units (PSU’s) are normally included within the
cabinets, these shall be located to minimise heat flow over other electronic
components.
6.1.4 Field terminals shall be arranged in vertical columns.
6.1.5 All field cables shall be terminated using Weidmuller (or equal) knife edge
terminals.
6.1.6 For I.S. installations separate marshalling cabinets from the non-I.S.
installation shall be provided.
6.1.7 In marshalling cabinets, wiring from the safe area side of I.S. barriers shall be
terminated using Elco sockets.
6.1.8 Elco plugs and system cables shall be provided for cabling between each
marshalling cabinet and system cabinet or for interconnection between
system cabinets.
6.1.9 Each control, monitoring and safety system shall be provided with it’s own
suite of marshalling and system cabinets.
New clauses 6.1.10 to 6.1.21 added in Annexure

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7.0 TERMINATION AND WIRING

7.1.1 All Instrument Cabinet and Panel terminals shall be rail mounted, and of the
screw clamp type, unless otherwise specified.
7.1.2 Internal wiring shall be run using PVC insulated stranded conductors. Wire
size shall be selected to suit the load current, but for general services the wire
size shall be minimum 0.5 mm2. Insulation rating shall be not less than 600V
RMS.
7.1.3 The insulation colour of cabinet internal wiring shall be as follows:
- AC live Brown
- AC neutral Blue
- Safety ground Green/Yellow
- Instrument ground Green
- DC positive Red (bus feeds only)
- DC negative Black (bus returns only)
- IS signals Blue
- All other signals Grey
7.1.4 All terminals, and terminal groups, shall be individually identified. This shall be
achieved using markers supplied by the terminal manufacturer. Markers shall
have black lettering on a white background. IS and Non-IS terminals shall not
be mixed. Discrete terminal rails shall be utilised. Where this is not practical
sparking guards and minimum distance of 50mm shall divide IS and Non-IS
terminal groups.
7.1.5 Multi-stranded wire shall be employed. Wire ends shall be terminated in twin
grip, insulated crimp connectors. Crimps shall be selected to suit the wire
size, and shall be secured by means of an approved crimping tool. Not more
than one wire shall be terminated at any crimp. Only one crimp shall be
inserted into any one terminal. In cases where solid core wiring is required
crimps shall not be employed.
7.1.6 Where there is a need for parallel wire connections this shall be achieved by
the use of combs or shorting bars provided by the terminal manufacturer.
7.1.7 All wiring shall be permanently identified by sleeve type markers, correctly
sized for the wire, and attached prior to crimping. Lettering of inserts shall be
black on a white background.
7.1.8 Each wire end shall be identified with both source and destination. All lettering
or numbering shall read from left to right. Where the wiring is run vertically,
then identification shall read from below (left) to above (right).
7.1.9 All wiring within cabinets shall be routed via slotted plastic trunking complete
with covers. This shall be fully supported over its complete length, and
secured to the cabinet structure with stud bolts or screws. Trunking carrying
non-IS cables shall have Grey covers. Trunking carrying IS cables shall have

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Blue covers. To facilitate removal, when necessary, the length of trunking

covers shall not exceed 1m.
7.1.10 A minimum distance of 50mm shall be maintained between terminals and
trunking to ensure that wire markers are fully visible.
7.1.11 Wiring or cables inside trunking shall be supported or secured along the run
length. On cabinet completion the trunking shall not be more than 60% filled.
7.1.12 Where clusters of wires leave the trunking they shall be bundled together
using Spirolwrap, or similar, and suitably supported. Bundles shall not be
routed near sharp surfaces. Cables pass through access holes in gland plates
etc. shall be glanded.

8.0 EARTHING

8.1.1 All Instrument Panels shall be equipped with earthing busbars as follows:
• An Non-IS instrument earthing busbar
• An IS instrument earthing busbar
• A Safety Ground (SG) busbars.
• System earth (where required)

8.1.2 These should be located at the bottom of the cabinet. The Instrument earthing
busbars shall be isolated from the cabinet structure. They shall be employed
for the earthing of cable screens and have 0 Vdc reference points. When the
panel consists of a number of modules, the Non-IS instrument busbars shall
be star connected and one shall be selected as master. Each end of the
master Non-IS instrument busbar will be connected to the Site instrument
Non-IS earthing network. The IS instrument earthing busbars shall be
connected in a similar manner and connected to the Site IS earthing network.
8.1.3 In the case of instrument systems all spare cables shall be connected to
terminals and all spare cable screens shall be connected to the appropriate
earthing busbar.
8.1.4 The Safety Ground busbar shall be employed for the grounding of all cable
armouring and shall provide a reference point for safety grounding of the
cabinet.
8.1.5 All cabinet structure including doors shall be securely bonded, and shall be
linked to the SG busbar. When the cabinet contains a number of SG busbars
then one shall be selected as master and the other busbars shall be star
connected to it. Each end of the master SG busbar will be connected to the
site earth electrode via room earth bar.
8.1.6 All connections to grounding busbars shall be terminated with soldered or
crimped compression type ring lugs. Conductor minimum sizes shall be as
follows:

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- Stranded insulated leads 2.5 sq.mm

- Flexible bonding connectors 25 sq.mm
- Copper bonding strips 12mm x 1.5mm
- Earth bars 25mm x 5mm

9.0 SWITCHES AND LAMPS

9.1.1 Front of consoles switches and lamps shall be designed and/or located to
avoid inadvertent operation. Switches for initiation of any emergency
shutdown (ESD) shall be provided with guards.
9.1.2 Any MOS override switches shall be of the lockable type with key retained in
the override position.
9.1.3 All front of console lamps shall be provided with a lamp test facility. Lamp
illumination shall be achieved via light emitting diodes (LED’s) wherever
possible.
9.1.4 Lamp colours shall be green for motor running or valve open; red for motor
stopped or valve closed. Other colours shall be agreed during detailed
engineering with IOCL.

10.0 NAMEPLATES AND LABELS

10.1.1 All Instrument Cabinets and Panels shall be furnished with nameplates front
and rear. These shall show the Cabinet or Panel identification number and
service.
10.1.2 All nameplates shall be manufactured from laminated plastic and labels shall
be attached to the cabinets by stainless steel screws. General nameplates
shall be White-Black-White, Warnings & ESD labels shall be White-Red-
White and Intrinsically safe information labels White-Blue-White.
10.1.3 Size of lettering, Size and location of external labels shall be standardised
across the project. ECPm-1 will advise during detailed engineering.
10.1.4 All cabinet internals shall be suitably labelled.

11.0 TESTING

11.1.1 The requirements inspection, factory acceptance testing and integrated

testing shall be in accordance with the relevant functional specification for the
control, monitoring and safety systems. See PDRP-8550-SP-0011, Inspection
& Testing of Electronic Control Systems

12.0 DOCUMENTATION

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12.1.1 As a minimum, the following documents and/or drawings shall be supplied

and reviewed prior to manufacture to fully detail the design, construction and
installation requirements of Instrument panels:
12.1.2 Dimensional Drawings
Showing cabinet and panel types, sizes, weights, shipping breaks and lifting
points.
12.1.3 General Arrangement Drawings and Parts Lists
Showing the general arrangement of all cabinet and panel components with
dimensions, clearance provision etc. Where applicable the following shall be
provided:
• Fascia designs.
• Switch and Lamp arrangements.
• Graphic layouts.
12.1.4 Termination Drawings
Showing all required terminations of incoming and outgoing cables per
terminal rail:
• Cable number
• Tag number
• Terminal number
12.1.5 Wiring Drawings
Showing all required internal wiring requirements including power distribution
with the following information:
• Wire sizes.
• Fuse ratings and location.
• Allocation of signals to terminals and termination units.
12.1.6 Panel Construction Drawings
As required for construction purposes.

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SNO CLAUSE NO NEW CLAUSE

1 1.16 For the FAT/IFAT, all components of each susb‐system shall be connected including:
Operator consoles and printers
Engineering workstations and printers
System Cabinets
Marshalling Cabinets
Optical fiber/Cooper converters
Optical Fibre cables
All types of servers, like DCS /ESD system server, OPC server, PIMS, AV Patch PC, any third party
system
Demonstration of Bi‐directional communication with MIS & APC system with each network
component like, Switches, Routers, Firewall, Converters, terminal server etc shall be included as part
of FAT.
Any other system that forms part of the overall system (ESD,FDAS,GDS,BMS etc)
2 4.3.1 The inspection shall ensure that the different systems have been manufactured in accordance with
the specifications, datasheets and drawings as agreed with the vendor. 
All the bought out items shall be as per MSL, any specific item not mentioned in MSL shall be
accorded approval from IOCL. Copy of approval shall be produced during inspection / FAT.
3 4.3.21 Properly wiring according to specs, colours, looming, identification etc.
Wiring, dressing and workmanship shall be as per vendor’s global standard.

4 4.3.37 All mandatory spares shall also be offered for Visual inspection
5 5.1.7 All devices in field & control room panels shall be suitable for the specified environmental conditions.
All electronic cards shall have conformal coating to meet the environmental category class G3 as per
ISAS71.04. Certificate for the same to be produced during inspection / FAT.

All mandatory spares shall also be offered for testing during inspection / FAT.
6 7.3.5 Verification of OEM test certificate and warranty certificate.

7 5.1.8 Vendor shall submit their own testing, installation, commissioning and acceptance procedures for
hardware & software. Hard ware test procedures shall include
purpose of test, test definition of input, testing method, results expected and acceptance criteria. For
software, it shall include details of the method, list of tests, sequence of execution, results expected
and acceptance criteria.
8 7.3.4 New Para: Vendor shall perform tests at his works to ensure that each component functions as per its
respective specifications and the test. This in house testing report shall be submitted in detail to the
OWNER for review within two weeks of testing is done.
All sub‐systems shall undergo a minimum of 7 days burning period.
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SNO CLAUSE NO NEW CLAUSE

9 7.3.34 Quality Control test :
(a) Quality control tests shall be carried out to assure quality of all components and modules in
accordance with DCS & PLC System Vendor’s own quality control and assurance procedures. Vendor
shall forward the details of these procedures for OWNER review.
(b) The sampling procedures for all purchased components or components manufactured by the DCS
& PLC System Vendor for quality assurance tests shall be in accordance with relevant international
standards.
(c) All assemblies shall be aligned and adjusted and all test observations shall be recorded as
manufacturers published set ups and testing methods.

10 7.3.35 The Vendor shall notify the OWNER at least three weeks prior to final system testing is planned. In
the event of arrival of representatives, if the system is not ready state for testing, the Vendor will be
liable for back charges for any extra time and expenses incurred.

11 7.3.31 Testing of proper functioning of all printers and hard copy units.
Refer Annexure for clause which are highlighted by CLOUD marks
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CONTENTS

SECTION SUBJECT PAGE

1.0  INTRODUCTION .................................................................................. 3 

1.1  Purpose ............................................................................................... 3 
1.2  Facilities Overview ............................................................................. 4 
1.3  Scope ................................................................................................... 4 
2.0  DEFINITIONS ACRONYMS AND ABBREVIATIONS ......................... 5 
2.1  Definitions ........................................................................................... 5 
2.2  Acronyms and Abbreviations ............................................................ 7 
3.0  APPLICABLE CODES AND STANDARDS ......................................... 8 
3.1  International Standards...................................................................... 8 
3.2  Codes and Standards ......................................................................... 9 
4.0  INSPECTION GUIDELINES ............................................................... 10 
4.2  Progress Inspection ......................................................................... 10 
4.3  Visual Inspection: ............................................................................. 10 
5.0  TESTING OF ELECTRONIC CONTROL SYSTEMS ......................... 12 
5.1  General .............................................................................................. 12 
5.2  System Testing ................................................................................. 12 
6.0  PRE- FAT TESTS............................................................................... 13 
6.1  General Requirements ..................................................................... 13 
6.2  Manufacturing Test........................................................................... 14 
7.0  FACTORY ACCEPTANCE TEST (FAT) ............................................ 16 
7.1  FAT Requirements ............................................................................ 16 
7.2  Pre- requisites to Commencement of FAT ..................................... 17 
7.3  FAT Test ............................................................................................ 18 
8.0  INTEGRATED FACTORY ACCEPTANCE TESTS ........................... 23 
8.1  IFAT Requirements ........................................................................... 23 
8.2  Communication Link Tests .............................................................. 24 
9.0  THIRD PARTY VENDOR SERIAL LINK TESTING ........................... 26 
10.0  CLOSE OUT OF FAT ......................................................................... 26 
11.0  SITE ACCEPTANCE TESTING (SAT) ............................................... 27 
11.1  General .............................................................................................. 27 
11.2  Site Installation Testing (SIT) Requirements ................................. 27 
11.3  Loop/ Segment and Function Tests ................................................ 27 
11.4  Completion of SAT and System Handover ..................................... 29 

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1.0 INTRODUCTION

1.1 Purpose
1.1.1 This specification applies to electronic (analogue/ digital), electrical or
electromechanical process measurement and control systems which:
1.1.2 Measure and control directly or indirectly an oil/gas plant process through a
final control element (or elements)
1.1.3 Are intended to be connected to supply circuits which do not exceed 250 volts
rms, single phase, or dc.
1.1.4 Are rated for use in either indoor, outdoor or sheltered locations
1.1.5 This specification details the requirements for Inspection and Testing of the
following systems:
• Indicating, integrating or recording instruments with a control function
• Supervisory Control and Data Acquisition System(SCADA System)
• Distributed Control System (DCS)
• Fire Detection and Alarm System (FDAS)
• Gas Detection System (GDS)
• Burner Management System (BMS)
• Emergency Shutdown System (ESD)
• Machinery Monitoring System (MMS)
• Anti-surge Control System (ASCS)
• Turbine Speed Electronic Governors
• Analyser Systems
• Analyser Management and Data Acquisition System (AMADAS)
• PLC systems including any in Vendor Packages
• Telemetry Systems such as Remote Terminal Units
• Tank Gauging System (TGS)
• Custody Transfer Metering Systems (CTMS)
1.1.6 For the IFAT (Applies to MAC only) all components of each sub-system shall
be connected including:
• Operators Consoles and Printers
• Engineering workstations and printers

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• System cabinets
• Marshalling cabinets
• System cables
• Optical Fibre/Cooper converters
• Optical Fibre Cables
• Any other systems that form part of the overall system (ESD, FDAS,
GDS, BMS, etc.).

1.2 Facilities Overview

The project is a 15 MMTPA grassroots refinery complex located at a site 5
Km south of the Port of Paradip in the state of Orissa, on the northern part of
the east coast of India.

1.3 Scope
This specification forms the basis for the inspection and testing of the control,
monitoring and safety systems for the Paradip Refinery Project.
All instrumentation shall be engineered, designed, procured, installed and
tested in accordance with codes and standards defined in section 3.0.

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2.0 DEFINITIONS ACRONYMS AND ABBREVIATIONS

2.1 Definitions
2.1.1 General
The following defines the meaning of specific words used in this specification:

Contract Means the contract between the Contractor / Vendor

and IOCL for the supply of the Equipment / Services,
which comprises the General Terms and Conditions
of Contract / Purchase (together with any Special
terms and Conditions), the attachments, requisitions,
drawings, specifications and other documents
included and /or referred to in the Contract, together
with the Contractor’s / Vendor’s unconditional written
acceptance of the Contract, and any subsequent
written amendments to the original Contract
Contractor / Vendor Means the firm, company or other corporate entity
(including its successors and / or permitted assigns)
contracted to supply the Equipment / Services to
IOCL
Equipment/ Services Means the equipment and/or services, including but
not limited to, materials, equipment, fabricated
products, software, drawings, certification and other
documentation, to be supplied under the Contract
IOCL Means Indian Oil Corporation Ltd. And its legal
successors and assigns
Shall Refers to a requirement
Should Refers to a recommendation
May Refers to one acceptable course of action.

2.1.2 Technical Definitions

2.1.3 Basic Process Control System

The control equipment installed to perform the normal regulatory functions for
the process (e.g., PID control and sequential control)
2.1.4 Distributed Control System

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A Distributed Control System (DCS) refers to a control system usually of a

process or any kind of dynamic system, in which the controller elements are
not central located like in a host computer but are distributed throughout the
system, with each unit controlled by one or more controllers. The entire
system may be networked for communication and monitoring.
2.1.5 Fieldbus
Fieldbus is a Local Area Network for process control that uses shared wiring
for powering field instrumentation devices such as transmitters, control
valves, digital positioners, etc., and carrying signals between such measuring
and/or final control devices.
2.1.6 Foundation Fieldbus (FF)
Foundation Fieldbus (FF) is an all digital, serial, two-way communications
system. The Foundation Fieldbus (FF) protocol consists of a slow speed bus
(FF H1) designed for the connection of 2-wire field devices and a high speed
bus (FF HSE) allowing the connection of complex devices such as analysers,
PLC’s etc.
2.1.7 HMI
A HMI or Human Machine Interface is the apparatus such a terminal
computer, which presents process data to a human operator, and through
which the human operator controls the process.
2.1.8 LAN
A LAN or Local Area Network is a group of computers and associated devices
that shares a common communication link or wireless link.
2.1.9 LAS
Link Active Scheduler to schedule devices that need to be cyclically
transmitted. There must be at least one Link Master (LM) device on an H1
fieldbus link acting as LAS. Other devices on the H1 fieldbus link with a LM
capability are configured to function as backup LAS devices.
2.1.10 Link
A link is composed of one or more physical segments interconnected by bus,
repeaters or couplers. It is the data link layer name for a Network.
2.1.11 PLC
PLC or Programmable Logic Controller is an electronic device used for
automation of industrial processes. PLC’s are based in an input signals/output
signals arrangement. This arrangement connect the PLC to sensors and
signal transmitters either analogue or digital at the input side and in the output
side PLC operate electric motors, solenoid valves, visual and optical alarms
etc.

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PLC’s communicate to the DCS over a network using communications

protocol like RS-422/485,ControlNet, Modbus Plus, Profibus, Ethernet/IP
etc,.
2.1.12 RTU
An RTU or Remote Terminal Unit is a microprocessor controlled electronic
device which interfaces remote field measuring devices to a distributed
control system (DCS) or to a SCADA System by transmitting Telemetry Data
to the System and/or altering the state of final control elements based on
control instructions received from the system.
2.1.13 SCADA System
The term SCADA (Supervisory Control and Data Acquisition) refers to a
central system that monitors and controls a complete site or system spread
out over a long distance. A SCADA System includes input/output signal hard
ware, controllers, HMI, networks, communication, database and software.
2.1.14 Segment
A segment is the section of a Fieldbus that is terminated in its characteristic
impedance. Segments may be linked together by repeaters to form a longer
Fieldbus network. Each segment can include up to 12 field devices.
2.1.15 WAN
A WAN or Wide Area Network is a computer network, which covers a broad
area. WANs are used to connect LANs and other types of networks together,
so that users and computers in one location can communicate with users and
computers in other locations.

2.2 Acronyms and Abbreviations

AMADAS Analyser Management and Data Acquisition System

AMS Alarm Management System

ASCS Anti-Surge Control System

BMS Burner Management System

C&E Cause and Effect

EMC Electromagnetic Compatibility

ESD Emergency Shutdown System

FAT Factory Acceptance Test

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FDAS Fire Detection and Alarm System

GDS Gas Detection System

IFAT Integrated Factory Acceptance Test

IOCL Indian Oil Corporation Limited

I/O Input/Output

MMS Machinery Monitoring System

MOS Maintenance Override Switch

MTBF Mean Time Between Failure

MTTR Mean Time To Repair

OOS Operational Override Switch

SAT Site Acceptance Test

TGS Tank Gauging System

SER Sequence of Events Recorder

VDU Video Digital Unit

3.0 APPLICABLE CODES AND STANDARDS

3.1 International Standards

3.1.1 The following standards shall apply and are to be read in conjunction with this
specification:
3.1.2 ASTM D3359 Standard Test Methods for Measuring Adhesion by Tape Test
3.1.3 ASTM D4541 Standard Test Method for Pull-Off Strength using portable
adhesion tester
3.1.4 IEC 502 Power Cables
3.1.5 IEC 60079 Electrical apparatus for explosive gas atmosphere
3.1.6 IEC 60227 PVC Insulated Cables 450/750 volts
3.1.7 IEC 60529 Degrees of Protection Provided by Enclosures

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3.1.8 IEC 60654-1 Industrial Process Measurement and Control Equipment

3.1.9 IEC 61131 Programmable Controllers, Parts 1/2/5
3.1.10 IEC 61000 Electromagnetic Compatibility for Industrial Process
Measurement and Control Equipment
3.1.11 IEC 61158 Fieldbus for Use in Industrial Control Systems
3.1.12 IEC 60770 Transmitters for use in Industrial Control Systems, Parts 1/2/3
3.1.13 IEC 61298 Process Measurement and Control Devices-General methods
and procedures for evaluating performance, Parts 1/2/3/4
3.1.14 IEE 802.3 Information Processing Systems – Local Area Networks
3.1.15 ISA-RP55.1 Hardware Testing of Digital Process Computers
BS-588
3.1.16 ISBN 086341 IEEE Guidelines for the Documentation of Computer Software
Real Time and Interactive
3.1.17 ANSI/NEMA IC6, Enclosures for Industrial Control and Systems
3.1.18 NEMA 250 Enclosures for Electric Equipment (1000 Volts Maximum)
3.1.19 MIL-STD-217 Military Handbook – Reliability Prediction of Electronic
Equipment
3.1.20 All others International Codes and Standards applicable are listed in IOCL
Engineering Standard 3210-8820-IN-0002.
3.2 Codes and Standards
3.2.1 The applicable codes and standards are listed in IOCL Engineering Standard
3210-8820-IN-0001.
3.2.2 The Indian national codes and standards are listed in IOCL Engineering
Standard 3210-8820-IN-0003.

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4.0 INSPECTION GUIDELINES

4.1.1 Inspections of the Control Systems such as DCS and Sub-Systems (ASCS,
BMS, ESD, GDS, FDAS and MMS) should be conducted and planned in
mutual agreement between the EPCm/IOCL representative and the
corresponding Control System’s Vendor according to the Project Schedule.
4.1.2 Inspections for Package Control Systems shall be as per the schedule in the
mechanical package requisition.
4.1.3 The following types of inspection shall be conducted:
4.2 Progress Inspection
4.2.1 The EPCm/IOCL representative shall have access at the Vendor’s Workshop
to review the progress and status of the control system and control packages
that are part of this project.
4.2.2 All materials and system components shall be subject to inspection by the
EPCm/IOCL representative.
4.2.3 This Inspection shall ensure delivery on time and compliance with the
requirements of quality and project specifications and standards. Progress
required to reach each milestone shall be clearly defined and indicated in the
Vendor’s fabrication schedule.
4.2.4 Monthly meetings shall be scheduled between the Contractor and the Vendor
to review the Progress of the Work and the inspection activities.
4.2.5 A detailed description of the progress desired at each milestone will enable a
progress inspection report to be prepared and certified by the Contractor and
the corresponding Vendor.
4.2.6 The Vendor shall guarantee delivery on time and compliance with the
requirements of quality and project specifications and standards as indicated
in this specification.
4.2.7 The Inspection shall require from the Vendor a Quality Assurance/Quality
Control Program that should ensure Good Design, Manufacturing and
Workmanship. This Quality Assurance/Quality Control Program shall be
subjected to the approval of the Owner’s representative.

4.3 Visual Inspection:

4.3.1 This inspection shall ensure that the different Systems have been
manufactured in accordance with the specifications, datasheets, and
drawings as agreed with the Vendor,
4.3.2 The Inspection shall include, but not be limited to:

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4.3.3 Standard of workmanship

4.3.4 Agreement with the General Arrangement and any other layout drawings
4.3.5 Use of agreed components
4.3.6 Accessibility of components for adjustment and maintenance
4.3.7 Provisions for ventilation, cooling, etc.
4.3.8 Cabinet finish and sizes
4.3.9 Shipping breaks
4.3.10 Lifting arrangements
4.3.11 Verify that all components are properly tagged and labelled
4.3.12 Suitability according to the Environmental Conditions and Hazardous Area
Classification
4.3.13 Use of the previously accepted components
4.3.14 Rigidity of cabinet framework and equipment support for both static and
transit conditions
4.3.15 Accessibility of components for adjustment and maintenance
4.3.16 Provision for adequate cooling and ventilation
4.3.17 Compliance with wiring segregation requirements according to type of signals
4.3.18 Sizing and usage of Trunking
4.3.19 Terminations and Layout internal/external according to the corresponding
specs and drawings
4.3.20 Provision for spare capacity, the control system and safety systems shall
cover the project requirement and have minimum 15 percent spare slots in
the racks, 20 percent on installed I/O, 20 percent on area space in the
Equipment Room
4.3.21 Properly wiring according to specs, colours , looming, identification etc
4.3.22 Provision for earthing according to the specs and project drawings. The
grounding system for metallic enclosures and electronic circuits shall be
separate and designed for connection to the main grounding System of the
Plant
4.3.23 Each power user (consoles, controllers, I/O devices etc.) shall have a
separate circuit breaker with its own circuit protection in accordance with
specifications and drawings.
4.3.24 Provisions in System for Safety Interlocks to be tested without interruption of
the process that is being supervised, measured or protected.
4.3.25 Ease of installation on site.

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4.3.26 Maintainability should be checked, all equipment parts wherever possible

should be installed in such a manner that any hardware items can easily be
removed without the removal of any other hardware. Easy tool access to
screws, nuts, fittings, etc should be available.

New clause 4.3.27 added

5.0 TESTING OF ELECTRONIC CONTROL SYSTEMS

5.1 General
5.1.1 The Vendor shall be responsible to ensure that the test site and all equipment
meet all applicable electrical, safety and health requirements of the authority
having jurisdiction.
5.1.2 The tests to be conducted shall be agreed to early in the project between the
EPCm/IOCL representative and the Vendor.
5.1.3 All tests shall be witnessed by the EPCm/IOCL representative.
5.1.4 All outstanding action items should be resolved before the conclusion of the
acceptance test. In the event that an open item can not be resolved, an
expected date should be identified by which the item should be resolved
5.1.5 Every Control Strategy in the case of the control system and every safety
interlock and alarm in the case of Monitoring and Safety Systems should be
tested for its functionality and performance.
5.1.6 All tests shall be carried out in an environment suited to the conditions
defined in the specifications. New clause 5.1.7 added
5.2 System Testing New clause 5.1.8 added
In general, testing of electronic control systems should cover following
aspects:
5.2.1 Hardware testing:
a) Prove that the main control stations and peripheral I/O equipment operate
properly by running diagnostic software and by simulating the
corresponding process variables and conditions
b) Continuity check of termination panels and interconnecting cables
c) AC and DC power checks
d) Proper operation and switching and backup devices
e) Proper connection and operation of the communication network
f) Proper connection and operation of all serial interfaces
g) Diagnostic checks on all devices

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h) Hardware inventory including hardware part numbers and serial numbers

and firmware part numbers and version numbers.
5.2.2 Software testing
a) Run standard diagnostics tests for system hardware and software
functions, security performance, and software functions.
b) Load and verify all databases and displays for physical presence and
proper linkages
c) Check communications of networks and serial interfaces for proper
operation and monitor for excessive errors
5.2.3 Functional Testing
5.2.4 Prove that the System’s basic functions (alarming, control functions, logic
sequences,) are operating by exercising the features and capabilities
provided through the various system operator/engineering interfaces (HMI,
VDU)
5.2.5 Procedural Testing
5.2.6 Prove that the system helps the operations personnel in doing their job by
simulating process upset conditions and seeing how the system responds.
5.2.7 Control strategy testing
5.2.8 Prove that the controls/logic implemented in the control system will properly
control the process by providing a realistic, real-time simulation of process
measurement and dynamics.
5.2.9 For Fieldbus Segments, at least one complete control segment of each
instrument type shall be functionally tested.
5.2.10 The FF master scheduler (LAS) and backup scheduler (LAS) functions shall
be checked.
5.2.11 The communications interface for each type of FF instrument shall be
checked for configuration/ setup down loads and data reconciliation of
uploads.

6.0 PRE- FAT TESTS

6.1 General Requirements

6.1.1 A Pre Factory Acceptance Test (Pre-FAT) shall be carried out at each of the
Vendor’s works and may be witnessed by Contractor at their discretion.
6.1.2 The Pre-FAT is intended to verify that the system and its components function
properly. The Vendor shall demonstrate, to his and Contractor’s satisfaction,

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that the system conforms to the specification and that the configuration/
application software reflects the required functionality.
6.1.3 All sub-units shall be tested in a purpose built test set-up to detect and
diagnose hardware and software faults and errors.
6.1.4 A Pre-FAT procedure shall be prepared during the detailed engineering
phase by the Vendor and shall be submitted at least 30 days prior to the
commencement of the Pre-FAT for approval by IOCL/ Contractor.
6.1.5 The Vendor shall ensure full compliance with the approved procedure during
the Pre-FAT. Deviations from the approved procedure are not permitted.
6.1.6 The Vendor shall make a formal log of the results of all tests carried out and
faults found during the Pre-FAT. The log shall detail the remedial action taken
and changes made to the system configuration and / or I/O requirements.
The log shall be made available before the commencement of FAT for review
by EPCm/IOCL.
6.1.7 The following tests shall form part of the Pre-FAT for all systems to be carried
out by the Vendor at his works.
6.2 Manufacturing Test
6.2.1 The Vendor shall ensure that all standard tests on all manufactured, bought
out parts and components have been carried out in accordance with ISO
9000 standards.
6.2.2 Tests shall cover the following areas:
6.2.3 Correctness of component parts
6.2.4 Revision level
6.2.5 Hardware application
6.2.6 Wire-wrap workmanship (if applicable)
6.2.7 Soldering workmanship (if applicable)
6.2.8 Marking workmanship
6.2.9 Finish workmanship
6.2.10 Electromagnetic Compatibility (EMC)
6.2.11 The system equipment shall comply with IEC 61000-4 parts 1 to 6 as follows:
PART 1- General Introduction
PART 2- Electrostatic Discharge Requirements
PART 3-Immunity to Radiated Electromechanical Field
PART 4- Immunity against fast transients
PART 5-Surge Immunity Requirements

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PART 6- Immunity to Conductive Radio Frequency Disturbances

6.2.12 EMC tests for susceptibility to radiated energy shall be conducted in field
strength of 10 V/m.
6.2.13 Declaration of conformity with IEC 61000-4 shall be supplied with the system
documentation.
6.2.14 Burn-In Test
6.2.15 Components burn-in test documents shall be reviewed by EPCm.
6.2.16 Systems containing components without proven service history or which are
not “burnt-in” during manufacture shall be subjected to a burn-in test at the
Vendor’s workshop during or prior to Pre-FAT.
6.2.17 The Burn-In Test shall be conducted under controlled conditions at maximum
ambient design temperature of 40º C measured outside the cabinets. The test
shall be continued for a minimum of 48 hours following stabilisation of the
internal cabinet temperature.
6.2.18 During the test, the system shall be in an installed configuration fully powered
up and all I/O exercised. The performance of the System and temperatures of
all cabinets (external and at three points inside) will be monitored and the
temperature shall be recorded during the test. Any fault that occurs during the
test, shall be logged, investigated and repaired to the Contractor’s
satisfaction.
6.2.19 Equipment shall be powered on for at least 30 days before/during and after
FAT test. Any faults/failures will be recorded and reported to EPCm/IOCL.
6.2.20 Insulation Test
6.2.21 If the system is subjected to a burn-in test then insulation resistance test shall
be carried out after the burn-in test is completed.
6.2.22 Insulation resistance tests shall be carried out on all system’s cables using a
“Hi-Pot” or “Megger”, the DC Test Voltage shall be 500 VDC to 1000 VDC.
6.2.23 The measured insulation resistance for all cabling shall be in any case less
than 1 MΩ.
6.2.24 Coating Test
6.2.25 Test for Coating Conformity in regard to harsh environment shall be
conducted.
6.2.26 For coatings to perform satisfactorily, they must adhere to the substrates or
surfaces on which they are applied. Commonly used test methods are
described in ASTM D3359 (tape test) and ASTM D4541 (Pull-off test). The
test method should be submitted to Contractor for approval. After any test it is
important to record if the bond failure was adhesive (failure at the

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coating/substrate interface) or cohesive (failure within the coating film or the

substrate)
6.2.27 Internal Testing
6.2.28 All equipment shall be fully assembled and powered up 100 hours prior to the
start of FAT, with no hardware or software failure. The Vendor shall have
completed his own internal testing prior to the start of this 100 hours period.
6.2.29 The internal tests shall be conducted by the Vendor using a test procedure
covering all sub-unit/ module hardware and software testing. The test
procedure shall also cover as a minimum all the tests defined in section 7.3
with other tests as deemed appropriate by the Vendor added for
completeness. The test procedure shall include a field for each test for the
test engineers signature and date.
6.2.30 A signed and dated log of all faults found during the internal testing and
detailing the remedial action taken shall be made available for review by the
Contractor.
6.2.31 All test equipment such as power supplies, switch/lamp/timer panels,
simulators, hand tools, multimeters and any other equipment required to
exercise all I/O (including spare I/O) and test all the control, sequence and
logic functions of the system during the internal testing shall be listed.
6.2.32 Calibration certificates for test equipment shall be up to date and remain valid
for the duration of the tests and shall be made available for inspection by the
Contractor.
6.2.33 If any changes to the system configuration and/or I/O requirements are
identified during internal testing, these changes shall be made available for
review and approval by the EPCm/IOCL representative. All changes shall be
formally recorded.

7.0 FACTORY ACCEPTANCE TEST (FAT)

7.1 FAT Requirements

7.1.1 A FAT procedure shall be prepared during the detailed engineering phase by
each of the Vendors and shall be submitted at least 30 days prior to the
commencement of the FAT for approval by EPCm/IOCL representative.
7.1.2 The FAT is intended to verify that the electronic control systems and its
components functions properly as specified.
7.1.3 The Systems shall conform to the specifications, P&ID’s Drawings, Instrument
Loop/ Segment Diagrams, Sequential Logic Diagrams etc. of the Project, and
configuration/ application software shall reflect the required functionality.

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7.1.4 The FAT shall be carried out at the Vendor’s works and should be witnessed
and approved by the EPCm/IOCL representative.
7.1.5 Inspections and tests shall include demonstrations of all system functions
including service functions and diagnostic equipment.
7.1.6 In addition to the structured testing in accordance with the FAT procedure
time shall be made available for unstructured testing at the conclusion of the
formal testing.
7.2 Pre- requisites to Commencement of FAT
7.2.1 The Vendor shall provide all the necessary test equipment such as power
supplies, switch/ lamp/ timer panels, simulators, hand tools, multimeters and
any other equipment required to exercise all I/O (including spare I/O) and test
all the control, sequence and logic functions of the system.
7.2.2 A comprehensive set of approved project documents and drawings in addition
to the system standard documents and manuals shall be made available prior
to the commencement of the FAT for review and use by the EPCm/IOCL
representative during the FAT. These shall include but not limited to the
following: -
• Functional Design Specification
• Equipment Layouts
• Block Diagrams
• Communication Network diagrams
• Control Narratives And Associated diagrams
• Sequence and Interlocks Narratives And Charts
• Databases/Graphics/Configuration
• Application Software specification
• Alarms/Trips settings list
• Power Consumption list
• Hardwired Loop/ Segment drawings.
• Software Loop/ Segment drawings
• System Power Supply One Line Diagrams
• Material List With All Relevant Details
• EMC Test Results
• Logic Diagrams/C&Es

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7.2.3 A full set of signed internal test documents shall be available for review and
use by the EPCm/IOCL representative during the FAT.
7.2.4 All tests and instrument calibration shall be carried out using calibrated test
equipment. Calibration certificates for all the test equipment shall be up to
date, remain valid for the duration of the tests and shall be made available for
inspection by the EPCm/IOCL representative.
7.2.5 Sufficient FF devices shall be made available to configure all types of network
and a selection of representative segments shall be made available.
EPCm/IOCL representative shall review and confirm the suitability of the
selection.
7.2.6 The FF networks/ segments shall be available with the corresponding H1
cards and ports connected with power and grounding tests successfully
performed.
7.2.7 Adequacy of Hardware according to Project requirements has to be reviewed
and approved by Contractor. The Hardware will be checked by EPCm/IOCL
representative during the FAT.
7.3 FAT Test
The factory and site acceptance test specifications for the hardware and
software of the control system shall include as a minimum the following tests:
7.3.1 Manufacturing Test
7.3.2 Tests shall cover the following areas:
• Correctness of component parts
• Revision level
• Hardware application
• Wire-wrap workmanship (if applicable)
• Soldering workmanship (if applicable)
• Marking workmanship
• Finish workmanship
7.3.3 System Staging
7.3.4 All cabinets, components, and sub-assemblies shall be assembled in one
area at one time, simulation and loading equipment devices shall also be
corrected. New Para added for clause 7.3.4
7.3.5 A detailed logbook covering the following areas shall be maintained:
• Material deficiencies
• System activity

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• System problems and resolutions

• System testing New point added in annexure
7.3.6 System hardware inspection tests shall include:
• Hardware inventory
• Visual inspection of all components
• Continuity check of wiring and interconnecting system cables
• AC and DC power checks
• Proper operation of redundant devices
• Diagnostic checks of all devices
• Proper operation of communication networks
• Proper operation of serial links
• EMC requirements
7.3.7 Power Distribution and Supply Test
7.3.8 All power distribution and supplies shall be in accordance with the system
specification and agreed drawings.
7.3.9 The following tests shall be made for all power distribution and supplies:
• Power supply redundancy
• Power supply loading
• Blocking diode arrangement
• Fuse co-ordination
• Power disruption (>20m sec) test
• Voltage levels
• Fault alarms
• Wiring segregation
• Earthing
• Fan failure alarms
7.3.10 Display Tests
7.3.11 All custom graphics and standard displays shall be checked in accordance
with the approved design documents.
7.3.12 Custom graphics and standard displays shall be inspected to verify the
following:
• Background colours in accordance with the approved design
• Graphic layout and colours (vessels, storage tanks, valves, pumps, piping
etc.) are in accordance with the approved design

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• Live data points are configured in accordance with the approved design
• All live graphic page switching is configured (both mimic type graphics
pages and group/detail displays etc.)
• All system pages are configured
• Review graphics with respect to P&ID’s
• Logics Review
• Display update rate test (<1 sec) from a change of I/O value

7.3.13 Note: All dynamic points shall be exercised and checked during the I/O and
functional tests.
7.3.14 Input/Output Tests
7.3.15 All Inputs and Outputs shall be checked to ensure that tagged points within
the system correspond to the correct I/O at the terminals in the marshalling
cabinets.
7.3.16 Transmitters to be simulated and the accuracy of the system display to be
checked.
7.3.17 Redundancy of inputs or outputs shall be checked at this time and any
redundant I/O shall be checked simultaneously.
7.3.18 Dynamic graphic displays including alarm settings etc. shall be tested during
this section of the FAT and during the functional tests.
7.3.19 If the I/O is marshalled through cabinets being supplied by others, the Vendor
shall allow for these marshalling cabinets to be shipped to their works for an
integrated test.
7.3.20 A full 5 point range check of analogue inputs and outputs shall be carried out
corresponding to:
• 4mA 0%
• 8mA 25%
• 12mA 50%
• 16mA 75%
• 20mA 100%
7.3.21 I/O shall be checked both up and down the scale. Hysterisis shall be within
the manufacturer’s specified tolerances.
7.3.22 Alarms configured from analogue inputs shall be checked on the graphic
mimics, group, detail and alarm lists. Alarms displayed on screen graphics
shall be checked for colour changes and sequences are in accordance with
the specified requirements. SOE functionality including time stamping shall be
verified.
7.3.23 Structural Functional Tests
7.3.24 The following functional tests shall be carried out:

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• Any “driver” modules, e.g. Motor control interface, on/off valves with
position feedback
• Simple and complex controllers including control action, cascade loops,
etc.
• Redundancy fail over checks
• Communication checks
• Software and hardware configuration checks
• Compliance with the Conceptual control, monitoring and safety systems
diagram
• Functionality of equipment
• System loading test
• As far as possible testing shall simulate the process condition for each
loop/ segment using appropriate tools and inputs.
• Functional tests of all trip and interlock circuits
• Testing of all alarms messages and diagnostic facilities
• Linking out digital inputs at the marshalling cabinets and checking display
response on graphics and faceplates. A five point check of each analogue
input by injecting 4-20mA (0, 25, 50, 75 and 100%) in both directions
including hysteresis and check the graphics and faceplates.
• Changing the state of digital outputs from the display and measuring the
response at the field terminals in the marshalling cabinet.
• Changing the value of analogue outputs from the display (0, 25, 50, 75,
and 100%) and measuring the response at the field terminals in the
marshalling cabinet (4, 8, 12, 16, 20mA).
• Testing all sequences and any other purpose written software
• Checking the Database for integrity and correctness.
• Historian
• Network Loading test
• Reliability
• Redundancy/Auto switchover including failure of engineering functions
(engineering database changeover)
• Scantime Checking
7.3.25 The following systematic testing of all functions shall be carried out:
• Functional testing of all control loops and segments on a per loop/
segment basis (initialisation, set point tracking, outputs, values of
parameters, normal operating modes, algorithms, backup, configuration,
mode available, bad values, alarm settings etc.)
• Functional testing of all hardwired interlock circuits including MOS, OOS
etc.
• Functional testing of all interfaces with other systems (FDS, ESD, etc.)
• All sequence and control logic for simple and complex circuits shall be
tested.
7.3.26 For sequences, special attention shall be paid to:

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• Time out periods

• Activation/De-activation/Initialisation and shedding to safe modes of
complex loops.
• Sequence interruptions/recovery from bad inputs, reset and restart
sequences.
• Manual stepping through sequence
• MOS and OOS override sequences

7.3.27 ESD/FDAS/GDS/BMS testing requirements

In addition to the above
• All Logic related to ESD/FDAS/GDS/BMS shall be tested during FAT.
• All I/O shall be connected to lamp / switch boxes.

7.3.28 FF/HART Testing requirements

7.3.29 HART functionality will be tested as per FF where applicable.
7.3.30 Fieldbus migrates much of the system functionality down to the field level a
DCS FAT will typically only test the operator interface.
7.3.31 In addition to the normal host system tests the following additional tests need
to be carried out for Foundation Fieldbus.
• Plug and play interconnectivity to host system
• Verify access to all function blocks
• Actual device operation, including IAMS
• Verify ease of access to calibration and setup procedures (setup wizards)
for each type of FF device with multiple live devices on a segment
• Redundancy switch over for H1 interface cards and Fieldbus power
conditioners. All power supply and power conditioner failure alarms shall
be witnessed and signed off
• Network/ Segment checks including:
o Firmware/ software revisions
o Communication parameters
o Short circuit tests
o Current consumption
o Host system interface module operation and failure modes
o Check spare capacity by adding two extra FF devices and
measuring the volts drop and bandwidth
o Check that the LAS is executing the correct schedule from the Link
Master device and that the backup LAS also functions correctly
• Device checks including:

New point, refer annexure

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o Database upload checks

o FF configurator download checks
• Data reconciliation checks including:
o Verify scale/ engineering units in both function block and transducer
block
o Verify scale/ engineering units are correct for the FF device,
associated faceplate, graphics and rends
o Simulate process variable change and verify accuracy within PV
parameter field of function block, process graphic and trend display.
o Simulate process variable change and verify that pre-configured
alarms appear at the operator workstation
7.3.32 Intelligent positioners shall be tested for all agreed functionality including
partial stroke testing initiated from DCS and storage of valve travel fingerprint.
7.3.33 All higher level systems functionality shall be demonstrated including
IAMS/PIMS/SOE/AMS.
New clause 7.3.34, refer annexure
New clause 7.3.35, refer annexure
8.0 INTEGRATED FACTORY ACCEPTANCE TESTS

8.1 IFAT Requirements

8.1.1 An IFAT procedure shall be prepared during the detailed engineering phase
by the MAC and shall be submitted at least 60 days prior to the
commencement of the IFAT for approval by EPCm/IOCL representative.
8.1.2 All MAC supplied equipment which forms part of the overall control,
measuring, monitoring and safety systems shall be brought together at one
time at the MAC Vendor’s works. Systems shall be shipped with all
interconnection cables, configurations and test equipment required to
complete the integration tests.
8.1.3 MAC shall manage, co-ordinate and be responsible for system integration
testing and shall ensure that Vendors are fully aware of the requirements of
the testing. MAC shall co-ordinate and be responsible for ensuring all OEM
representatives required for testing are present for tests.
8.1.4 System integration shall be carried out at the MAC vendor’s works during the
DCS FAT in order to ensure full integration between the DCS and the other
systems can be carried out.
8.1.5 System Integration testing shall include without exceptions all and every part
of the overall control, monitoring and safety system including DCS, ESD,
GDS, BMS, FDAS, video wall and any other sub systems.
8.1.6 All HMI of all systems shall be checked on a random basis as part of the IFAT

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8.1.7 HWC shall be fully tested including all remote I/O systems
8.1.8 MAC shall ensure that any sub-suppliers provide technical support and test
equipment in order to carry out tests on their part of the system with the DCS.
8.1.9 All systems will be connected using the actual system cables to be installed at
site. This shall include the interconnection of all pre-formed cables between
the DCS and other systems, any hardwired I/O between systems, serial links,
fibre optic cables etc.
8.1.10 All system integrated testing shall be performed with project application
configuration, database and software. Test software shall not be substituted
for project software.
8.1.11 System communication loading shall be representative of plant operation.
8.1.12 Wind direction and speed sensor shall be connected and demonstrated.
8.1.13 All tests shall be witnessed by the EPCm/IOCL representative and the
respective System Vendor.
8.1.14 Upon completion of each test, a test report shall be signed and dated by the
appropriate parties. The EPCm/IOCL representative reserves the right to call
for additional testing of any part of the control system if it considers that the
test has not been carried out satisfactorily.
8.1.15 Fault logs shall be produced for any aspect of the test that does not meet the
project specification. All faults shall be rectified and the test shall be repeated
and witnessed by all parties.
8.1.16 In addition to the structured testing in accordance with the FAT procedure
time shall be made available for unstructured testing at the conclusion of the
formal testing.
8.1.17 The integration test shall include the handing over of all records made during
the testing period, such as test results, list changes, as-built drawings,
calibration certificates and any other relevant documentation.
8.1.18 Tests shall be fully documented and recorded including equipment failures,
repairs and replacements.
8.1.19 During IFAT changes as required in Software Engineering and Graphics have
to be done without any further implication.
8.2 Communication Link Tests
8.2.1 Serial communication links shall be checked in the same configuration that is
to be used when installed at site.
8.2.2 As a minimum, addressing, data formatting, error detection and recovery and
all configured points shall be checked.
8.2.3 Where the system is to be linked to another system not in the MAC’s supply
(e.g. DCS-MMS.) using MODBUS RTU /OPC protocol for example, the

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testing of the serial links shall be performed during FAT using an emulation
PC.
8.2.4 The interfaces between ESD/DCS and FDS/DCS shall be tested as follows:
• The functional test of the logic shall be tested as a block.
• By injecting hardwired input signals from the simulation panels at the
marshalling cabinet(s) and simultaneously observing hardwired signals on
the simulation panels such as lamps (outputs) the block logic function
and all associated interfaces to the DCS shall be tested and proved
accordingly.
• A fault simulation may be introduced for each input and the subsequent
action observed on all relevant DCS displays, the SER printer etc.
• The MOS function and all associated DCS displays shall be tested for
each input of the logic block.
8.2.5 Similarly, all other systems serial links connected to the DCS shall be tested
where possible as above for the ESD/FDAS interfaces to the DCS depending
on the applicable functional requirements. Full graphic check shall be carried
out.
8.2.6 Where serial links are configured with redundancy, a full check of channel
failure, changeover and recovery shall be carried out.

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9.0 THIRD PARTY VENDOR SERIAL LINK TESTING

9.1.1 For third party systems, full functional control and logic interface tests shall be
carried out by 3rd party Vendor using hardwired simulation panels with
pushbuttons, lamps, indicators etc. to ensure that the full functional interfaces
have been implemented correctly.
9.1.2 MAC shall work with 3rd party vendor to agree and document serial link
protocols and wiring details.
9.1.3 For unproven serial links (those that the MAC has no track record of working
with), MAC shall visit 3rd party vendors works with a test DCS system to prove
the operation of those serial links. This is expected to include;
Machine monitoring.
Custody transfer metering
Loading Arms
Gas Chromatographs
Analyser Management System
Final list to be detailed by EPCm/IOCL during detailed engineering
9.1.4 Depending on schedule and completeness of configuration the serial link test
may range from a type test of each type of IO data to a full bitmap test of all
registers used. This will be mutually agreed by all parties during detailed
design.
9.1.5 The remaining untested serial links will be fully tested during SAT. MAC shall
support 3rd party vendor and EPCm/IOCL in this activity.
9.1.6 Where serial links are configured with redundancy, a full check of channel
failure, changeover and recovery shall be carried out.
9.1.7 The test procedure shall be submitted to EPCm/IOCL for review and
approval.

10.0 CLOSE OUT OF FAT

10.1.1 Signed and dated formal logs of Faults, remedial actions and changes shall
be maintained.
10.1.2 All recorded faults and changes will be signed off and dated by EPCm/IOCL
representative prior to shipment.
10.1.3 All tests carried out will be recorded and signed off by all parties at an
loop/component level based on approved FAT & IFAT procedure.

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10.1.4 The FAT may be stopped or re-planned/ rescheduled to a later date by

EPCm/IOCL representative if the equipment is found to be non-compliant with
the functional specification or if Vendor’s FAT test sheets are found to be
unreliable or missing.
10.1.5 Vendor’s shall note that no system shall be released for shipment to site prior
to rectifying and retesting all punch listed items found during the IFAT without
prior agreement.

11.0 SITE ACCEPTANCE TESTING (SAT)

11.1 General
11.1.1 SAT represents the collective set of tests required to be conducted on the
electronic control, monitoring and safety systems at site, including site
installation test, loop tests and full functional tests. Successful completion of
SAT is a pre-requisite for completion of pre-commissioning and in achieving
the Vendors System Handover.
11.1.2 System handover shall be defined as completion of all activities as per
purchase order, including completion of SAT, all loop test sheets signed off,
any changes raised at site completed and signed off as complete, all punch
list items complete and signed off. System Handover shall be completed as
part of the pre-commissioning phase and before the start of commissioning.
11.2 Site Installation Testing (SIT) Requirements
11.2.1 A SIT shall be conducted once the system equipment has been shipped to
site and fully installed in the appropriate building.
11.2.2 A SIT test procedure shall be prepared by the Vendor and submitted for
approval to EPCm/IOCL representative.
11.2.3 SIT of the Control, Monitoring and Safety Systems shall include power up
tests and be identical to the FAT and IFAT procedure but at reduced amount.
i.e. 10% of all tests that have been carried out at the FAT/ IFAT shall be
repeated at the SIT.
11.2.4 SIT shall include 10% of hardware and software of all the DCS and all other
systems ensuring as a minimum that each component or a part of a
component has been tested after installation at site.
11.2.5 Control, Monitoring and Safety Systems SAT shall be carried out prior to any
loop/ segment functional testing and commissioning work.

11.3 Loop/ Segment and Function Tests

11.3.1 After completing the SIT, each control loop/ segment, logic circuit, sequence
control etc. for all control, monitoring and safety systems shall be fully function

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tested prior to acceptance and system handover. The testing of inputs and
outputs only shall not constitute a loop/ segment check. Full functional tests in
conjunction with inputs and outputs shall be deemed as a complete loop/
segment test.
11.3.2 As far as possible testing shall simulate the process conditions using
appropriate tools such as hand pumps, baths, wobble meters etc.
11.3.3 Any calibration/simulation testing equipment shall have testing certificate,
shall be up to date and remain valid for the duration of the tests
11.3.4 The functionality of the loop/ segment shall be tested but not limited to:
• 5 point accuracy test (0%, 25%, 50%, 75%, 100%)
• alarm point settings
• Control functionality
• ESD and F&G logic circuits
• Output actions
• Inhibits
• Resets
• Ranges
• Scaling
• Graphics
11.3.5 In addition to the above checks FF installations need to include the following
additional checks:
• Verify all spur lines and terminators are connected to the trunk cable
• Perform cable impedance and grounding tests
• Verify power supplies, power conditioner, grounds and H1 interface is
connected to the trunk
• Using a Fieldbus monitor, perform network/ segment tests including:
o DC voltage measurements
o Signal levels
o Noise levels
• Connect field devices one at a time and check DC voltage, signal and
noise levels remain within tolerance
• Check that the LAS is executing the correct schedule from the Link
Master device and that the backup LAS also functions correctly

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11.3.6 EPCm/IOCL shall witness each loop/ segment and function test.
11.3.7 Upon completion of each loop/ segment and function test a test report shall
be signed and dated by the appropriate parties.
11.3.8 During above testing any malfunction of the system components shall be
replaced / repaired free of cost. Once the system failure is detected, the
acceptance test (subject to IOCL approval) shall start all over again from the
beginning.

11.4 Completion of SAT and System Handover

11.4.1 Any FAT faults not fixed or tested before the end of the FAT shall be tested
and signed off during SAT.
11.4.2 A review of all documentation, including documents revised after the FAT, to
assess its correctness and its suitability to be part of the AS-BUILT
documentation for the system. Any documents failing this review will be
added to the SAT punchlist.
11.4.3 All punch list items shall be cleared or waived before the system is handed
over.
11.4.4 During SAT, changes as required in Software Engineering and Graphics have
to be done without any further implication.

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CONTENTS

SECTION SUBJECT

1.0 PURPOSE ...........................................................................................3

2.0 DEFINITIONS AND ABBREVIATIONS ...............................................3
3.0 REFERENCE DOCUMENTS...............................................................5
4.0 QUALITY CONTROL ..........................................................................5
5.0 DOCUMENTATION.............................................................................5
6.0 GUARANTEE FOR SPARE PARTS ...................................................5
7.0 PAINTING ...........................................................................................5
8.0 PROCUREMENT AND HANDLING ....................................................6
8.1 Procurement ......................................................................................6
8.2 Packaging and Shipping ...................................................................6
8.3 Preservation and Storage .................................................................6
9.0 SPARE PARTS LIST AND INTERCHANGEABILITY RECORD .........7
10.0 MANDATORY SPARE PARTS ...........................................................7
10.1 IOCL SPECIFIED MANDATORY SPARES.........................................7
10.2 CONSULTANT RESPONSIBILITY......................................................7
11.0 TWO YEAR OPERATION AND MAINTENANCE SPARES ................7
11.1 Selection of Two Year Operation and Maintenance Spares............8
11.2 Quantity of Operation and Maintenance Spare Parts......................9
12.0 SELECTION OF COMMISSIONING SPARE PARTS..........................9
13.0 SELECTION OF SPECIAL TOOLS.....................................................9

ATTACHMENTS

ATTACHMENT 1 MANDATORY TYPE OF SPARES TO BE SPECIFIED

ATTACHMENT 2 SPIR SYSTEM WORK FLOW DIAGRAM
ATTACHMENT 3 TYPICAL SPIR FORM

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1.0 PURPOSE

The purpose of this document is to define the CONSULTANT’s

responsibilities to provide spare parts and related documentation on the
Paradip Refinery Project (PDRP). It provides IOCL’s minimum requirements
for the Plant.
This Specification covers the selection and quantities of the following:
 MANDATORY SPARES
 TWO YEARS OPERATION AND MAINTENANCE SPARES
 COMMISSIONING SPARES
 SPECIAL TOOLS
Spare parts will be required for all mechanical equipment, piping items, non-
bulk electrical equipment, and instruments supplied for the Plant.
Throughout this Specification, the term “spare parts” is used in a broad sense,
i.e. the component parts of any piece of equipment.
Any references to ‘Vendor’ define the requirements to be imposed on the
Vendor by the CONSULTANT.

2.0 DEFINITIONS AND ABBREVIATIONS

For the purposes of this Specification, the following definitions shall apply:
IOCL – Means Indian Oil Corporation Ltd. and its legal successors and
assigns.
CONSULTANT – Means the firm, or other corporate entity (including its
successors and/or permitted assigns) contracted to supply the Services to
IOCL.
Equipment / Services –Means the equipment and/or services, (including
spare parts) including but not limited to, materials, equipment, fabricated
products, software, drawings, certification and other documentation, to be
supplied under the Contract.
Project – Means the IOCL’s Paradip Refinery Project, Paradip, Orissa, India.
Plant - Means the IOCL’s Paradip Refinery Project, Paradip, Orissa, India in
connection with the construction and/or operation of which the Equipment /
Services are to be supplied.
Vendor – Means the firm, IOCL or other corporate entity (including its
successors and/or permitted assigns) contracted to supply the Equipment to
IOCL.
Shall and Must– Indicate a mandatory requirement.

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Mandatory Spare Parts - Parts of equipment, equipment assemblies, or

complete items of equipment that will be required for replacement of items not
subject to deterioration by normal use but where failure of which will be critical
for continuous safe operation of the plant.
These spares shall be available on site prior to equipment start-up. Where
required it is necessary for Mandatory Spare Parts to be manufactured at the
same time as the equipment, i.e., where fitting of the part into the equipment
is necessary during manufacture.
The original equipment Material Requisitions shall include all Mandatory
Spare Parts and clearly indicate the quantity required. All such spares quoted
extra by vendors against the specified Material Requisition requirement will
be evaluated and recommended for ordering with the main equipment. In
case a vendor does not quote for all spares or their prices do not include all
spares, their bid shall be loaded with the maximum price quoted by other
vendors for price evaluation.
These parts will be subjected to the same stringent inspection requirements
as the main equipment.
Commissioning Spares - Spare parts needed to adequately cover the
requirements of day to day maintenance and any premature failures for the
period of start-up, commissioning and trial run operations. Commissioning
Spare Parts shall be ordered at such a date that they should arrive on site at
the same time as the parent equipment, but in any case prior to the
equipment commissioning and start-up activities. Commissioning Spare Parts
also include parts and assemblies normally used or consumed during
installation of equipment, cleaning, flushing, and inspection.
Commissioning spares that are recommended by Vendors, or requested in
Material Requisitions, will be considered for price evaluation and ordering as
quoted by Vendors.
Two Years Operation and Maintenance Spares - Parts or assemblies
normally used or consumed on the basis of scheduled maintenance,
overhauls, inspections, wear, corrosion, erosion or deterioration in normal
service for a period of TWO years after start-up.
Vendors will be requested to quote for their recommended two years
operation and maintenance spares but these spares will not be considered for
price evaluation. These will be selected and ordered by IOCL.
Special Tools - These are the tools, jigs and fixtures, including hand held and
portable spot measurement instruments which are necessary to carry out
maintenance activities on all parts of the Plant.
Special Tools that are recommended by Vendors, or requested in Material
Requisitions, will be considered for price evaluation and ordering as quoted
by Vendors.

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Spare Parts List and Interchangeability Record (SPIR) - The SPIR system is
the means by which the Vendor submits the details of the recommended
Operation and Maintenance Spares, Mandatory Spares and Special Tools.
CONSULTANT shall ensure that the SPIR Forms are completed by each
Vendor with the details required by IOCL.
SAP Material Number - This is the IOCL material designated number for each
Spare part and must be written clearly on every spare part delivered to IOCL.
It shall be on every SPIR Form and Purchase Order for each Spare item.

3.0 REFERENCE DOCUMENTS

The following Reference Documents form a part of this Specification.

PDRP-8820-SP-0001 Basic Engineering Design Data

PDRP-8440-SP-0006 Protective Painting Systems

PDRP4280-8610-PR-0014 Project Logistics Instruction to
EPCMs Contractors

4.0 QUALITY CONTROL

The CONSULTANT shall ensure that the QC/QA program used by the
Vendor for spare parts manufacture is the same program previously approved
by the CONSULTANT for use on the original equipment purchase.

5.0 DOCUMENTATION

CONSULTANT shall ensure documentation is provided as required for the

original equipment purchase.

6.0 GUARANTEE FOR SPARE PARTS

The CONSULTANT/Vendor shall guarantee the availability of spare parts for

their equipment for a minimum period of 10 years from the equipment delivery
date or as required by IOCL.
If any parts become obsolete the CONSULTANT/Vendor shall guarantee
equivalent and suitable parts consistent with the original equipment
purchased.

7.0 PAINTING

The CONSULTANT shall ensure surfaces are prepared and painted in

accordance with Specification PDRP-8440-SP-0006 Protective Painting
Systems.

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8.0 PROCUREMENT AND HANDLING

8.1 Procurement
Two Year Operation and Maintenance Spares shall be recommended by the
respective equipment Vendors and entered into the SPIR system.
CONSULTANT shall review and correct the SPIR information in line with this
Specification.
IOCL shall review the SPIR information and, if required, authorise the SPIR
for purchase by IOCL or the CONSULTANT on behalf of IOCL.
Mandatory Spares, Commissioning Spares and Special Tools shall be
purchased with the Equipment and shall be included on Equipment Purchase
Orders placed by the CONSULTANT. CONSULTANT shall ensure Mandatory
Spares and Special Tools are entered into the SPIR system.
8.2 Packaging and Shipping
Packaging and shipping of spare parts shall be consistent with that of the
original equipment purchased.
Preparation for shipment and packing may be subject to inspection by
IOCL’s/CONSULTANT’s Inspectors.
The CONSULTANT shall ensure that all Mandatory Spares, Commissioning
Spares and Special Tools are delivered in accordance with the Purchase
Order.
Packaging of spare parts shall be labelled as stated in Specification
PDRP4280-8610-PR-0014 ‘Project Logistics Instruction to EPCMs
Contractors
.
8.3 Preservation and Storage
All spares are to be packed and stored in a manner to ensure a minimum
shelf life of four years in a non air conditioned warehouse sighted in a tropical
climate with marine exposure location where the maximum temperature and
relative humidity conditions are as stated in the BEDD Specification PDRP-
8820-SP-0001.
CONSULTANT shall advise IOCL of any spare parts which cannot be stored
under the above stated conditions, and their recommended method of storage
to achieve the required minimum shelf life.

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9.0 SPARE PARTS LIST AND INTERCHANGEABILITY RECORD

It is not proposed to develop a specific SPIR Software Package in order to

achieve a Plant wide interchangeability check.
The CONSULTANT shall present the SPIR information to IOCL as per the
typical form shown in ATTACHMENT 3. The CONSULTANT shall also be
capable of exporting all information in an electronic file format (to be agreed),
into IOCL’s system prior to the commissioning stage.
In addition the CONSULTANT shall identify and utilise the IOCL SAP
Catalogue references for any identical spares listed within the IOCL SPIR
software, if this information is made available to the CONSULTANT.

10.0 MANDATORY SPARE PARTS

10.1 IOCL SPECIFIED MANDATORY SPARES

Mandatory Spares shall be supplied for the equipment listed in
ATTACHMENT 1

10.2 CONSULTANT RESPONSIBILITY

The Mandatory Spares defined in the Equipment Specifications and Material
Requisitions shall be considered as a minimum requirement. The
CONSULTANT shall be responsible for confirming, recommending and
supplying these and any additional Mandatory Spares for any equipment that
in his experience should be supplied.

11.0 TWO YEAR OPERATION AND MAINTENANCE SPARES

Model guidelines to identify the Operation and Maintenance spare parts

requirements based on interchangeability are included in this Specification,
but these are only for reference and do not relieve the CONSULTANT of his
responsibility for the quantity, accuracy and completeness of the Spare Parts
recommendations.
The basis for the selection of the Two Year Operation and Maintenance
Spares is the CONSULTANT’s recommendation by means of the SPIR. For
that purpose, the available SPIRs shall be used for recording and identifying
of interchangeable parts and calculating the quantity of two year Operation
and Maintenance Spares to be ordered.

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It is the CONSULTANT’s responsibility to ensure that the Spare Parts

recommended by each Vendor is complete and the quantities sufficient for
the two year operation requirement.

11.1 Selection of Two Year Operation and Maintenance Spares

The following guidelines apply:
 Key operation and safety functions of the equipment.
 Current delivery time and transportation time to site of items not stocked.
 Possibility of damage during installation and commissioning.
 Expected normal wear and tear during first TWO years of operation.
 Service interval stated by Manufacturers maintenance policy.
 Possible repair/exchange items.
 When spare parts need to be tested / inspected together with the
equipment, it shall be assured that they are available at the workshop
during the equipment testing/inspection.
 To assist in reducing excessive stock, repair kits typically used for
overhauls and repairs shall be considered. Each repair kit shall be
provided with a part number and sub-assembly and all repair kit
components shall be given part numbers. Low-value items, such as small
O-rings, small diaphragms, electronic components, gaskets, fuses, signal
lamps, etc. not included in the repair kits shall be ordered in standard
commercial package quantities, e.g., 10, 25, 144.
 CONSULTANT/Vendor shall identify and utilize the SAP Material Number
references for any identical equipment / spare listed if the IOCL supplied
SAP Catalogue is made available.
Consideration shall also be given to ordering complete assemblies and
instrument assemblies such as controllers, recorders, amplifiers, transmitters,
printed circuit boards, regulators, chart drive units, pressure gauges,
temperature gauges, pressure switches, and common valves up to and
including 2 inch (50mm).
Furthermore, various installation materials shall be ordered such as
instrument cables, fittings, copper, plastic and stainless steel tubing,
equalizing assemblies for flow meters, (blank) orifice plates, thermocouple
assemblies, terminal blocks, and compression fittings. Recommended
quantities for ordering are approximately 5% of quantities installed, unless
specified otherwise.

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11.2 Quantity of Operation and Maintenance Spare Parts

The Vendor shall initially recommend the quantity of spares for two years
Operation and Maintenance. The following general guidelines can be used by
the CONSULTANT when making quantity recommendations:
 CONSULTANT/Vendor experience should be exercised when giving
quantity recommendations.
 In general, spare parts should not be recommended where a warehouse
spare of the equipment has been supplied.
 Instrumentation - maximize the use of whole unit replacement items.

12.0 SELECTION OF COMMISSIONING SPARE PARTS

Commissioning spares are not included in the 2 years operational spares

inventory. They shall be separately identified, listed and provided by the
CONSULTANT based on the requirements stated in the Material Requisition
and the recommendations of the Vendor. Commissioning Spare Parts,
including Construction and Pre-Commissioning Spare Parts, are replacement
parts that would be required during the start-up of the various systems of the
Plant.
CONSULTANT shall procure Commissioning Spare Parts at the same time as
the main Equipment items.
Upon completion of the Commissioning, the CONSULTANT shall inventory all
unused Commissioning Spare Parts. IOCL and CONSULTANT shall agree on
spare parts to be transferred to IOCL from any remaining Commissioning
Spare Parts and consumables purchased by CONSULTANT and not used or
consumed during Commissioning.

13.0 SELECTION OF SPECIAL TOOLS

Special tools shall be identified by the equipment Vendor and the

CONSULTANT shall purchase them when procuring the equipment items to
which they relate. Special tools are those tools which are not readily
available. CONSULTANT shall procure at least 2 sets for each relevant
equipment tag item and upon completion of the Plant transfer all special tools
to IOCL.

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ATTACHMENT 1 MANDATORY TYPE OF SPARES TO BE SPECIFIED

The following lists are guidelines illustrating the “type” of parts and quantities of
spares to be specified and quoted by the Vendor.
Fired Heaters 1
Heat Exchangers 2
Columns/Reactors/Vessels/Trays & Tower Internals 3
Mixers/Agitators 4
Centrifugal Pump (Horizontal / Inline- General Purpose Process) 5
Centrifugal Pump (Vertical) 6
Centrifugal Pumps with Submerged Motor (Cryogenic Service) 7
Sundyne Pump 8
Centrifugal Horizontal Pumps (Multistage) 9
Rotary Pump 10
Reciprocating Pump 11
Reciprocating Pump (Diaphragm Type) 12
Positive Displacement Pump (Controlled Volume) 13
Reciprocating Compressor 14
Reciprocating Compressor (Diaphragm Type) 15
Reciprocating Compressor (Labyrinth Type) 16
Centrifugal Compressor 17
Packaged, Integrally Geared, Centrifugal Compressor 18
Rotary Compressor (Lobe Type) 19
Rotary Compressor (Liquid Ring Type) 20
Rotary Compressor (Screw Type) 21
Expander Compressor 22
Centrifugal Fan 23
General Purpose Steam Turbine 24
Special Purpose Steam Turbine 25
Gear Box (Special/General Purpose) 26
Diesel/gas Engines 27
Electric asynchronous motors 28
Electric generators and synchronous motors 29
Electric variable speed drives 30
High and low-voltage switchgear 31
Power and telecommunication cables and accessories 32
Lighting fittings 33
Instruments 34
Safety relief valves 35
Piping/Valves 36
Miscellaneous Equipment 37

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ATTACHMENT 1 (CONT’D)

LIST 1 - Fired Heaters

ITEM SPARE PART QUANTITY REQUIRED NOTES
1.1 Radiant and shock row tubes 1. Length: Maximum found in any heater. 1
(Per size and wall thickness of 2. Quantity: Greater of 20% of number of tubes per 2
each material) heater or 5% of total number of tubes in all heaters. 3
3. Minimum quantity 4 lengths.
1.2 Radiant return bends (Internal) Quantity: 10% of number of bends per heater to a
(Per size and wall thickness of cumulative maximum of 20 pieces for all heaters.
each material)
1.3 Convection tubes 1. Length: Maximum found in any heater. 4
(Per size and wall thickness of 2. Quantity: Greater of 10% of number of tubes per 5
each material) heater or 5% of total number of tubes in all heaters. 6
(Finned tubes supplied without fins) 3. Minimum quantity 4 lengths. 7
1.4 Convection return bends None required.
(External)
1.5 Plug headers/clean-out fittings Quantity: 10% of number of bends per heater to a 8
(Per size and rating of each cumulative maximum of 10 pieces for all heaters.
material)
1.6 Radiant coil support castings Quantity: 10% of number of supports per heater. 9
1.7 Peep door assemblies Quantity: 10% (minimum 2 nos) If applicable, 10
view glass (part of peep door assembly) - 20%
1.8 Burners Quantity: One of each model and size. 11
1.9 Oil tip assembly(including Oil 1 no. per 3 nos. (Min.1 no.)-Also see 1.17 below
tip, atomizer, spud, inert &
sleeve)
1.10 Gas tip assembly(including 1 set. per 3nos. (min.1 no.)
primary & stages gas tip/risers
1.11 Air swirler If applicable, 1 no. per 3 nos. (min.1 no.)

1.12 Muffle block & Regen tile 1 set. per 3 nos. (min.1 no.)

1.13 Gaskets 1 complete set per burner

1.14 Pilot Jet / mixer, nozzle/tip, spud 1 set. per 3 nos. (min.1 no.)

1.15 Ignition Transformer / Power 1 no

pack
1.16 Igniter Electrode 1 no. per igniter

1.17 Oil gun assembly 1 no.

1.18 Gas burner assembly 1 no. Also see 1.8 above

1.19 Burner Management System One PCB of each type

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NOTES (Applicable to List 1)

1. Tubes can be cut to fit where shorter ones are required.
2. For heaters with same tube material, size and wall spares do not need to be duplicated.
3. Minimum covers losses and damage in storage
4. Tubes can be cut to fit where shorter are required.
5. For heaters with same tube material, size and wall spares do not need to be duplicated.
6. Minimum covers losses and damage in storage.
7. Assumes that fin application is available locally.
8. Quantities will cover occasional failure (usually leakage)
9. As in Fired Heater specification.
10. Castings may crack.
11. Allows replacement of a faulty burner. The faulty burner can then be overhauled in the workshop
and then it becomes the spare.

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ATTACHMENT 1 (CONT’D)
LIST 2 - HEAT EXCHANGERS
ITEM SPARE PART QUANTITY REQUIRED
SHELL AND TUBE EXCHANGERS
1
Heat Exchanger/Cooler/Condenser No Spare Tubes are required
to be purchased – IOCL shall
follow its insurance Spares
Procurement Philosophy.
2 Gaskets (each type) 400%
3 Bolts/studs and nuts for nozzles with companion flanges. 10%
4 Tube sheet girth joints of each size/type 10%
5 Test Ring/ Test Flange - 1 Set For Each Exchanger/Cooler/
Condenser
(Irrespective of interchangeability)
AIR COOLERS
1 Gaskets for Header Cover and nozzles 400%
2 Gaskets for Plugs 200%
3 Plugs 20%
4 Bolts/studs and nuts 10%
5 Belts and Bearings 100%
6 Fan blades for each size/type of Fan 10%
7 Diaphragm Actuator /Positioner for each type of Auto- 20%
Variable Pitch Fan

LIST 3 - Columns/Reactors/Vessels/Trays & Tower Internals

ITEM SPARE PART QUANTITY REQUIRED
1 Bolting for each nozzle with blind companion flange of 10%
each size/type
2 Gaskets for each nozzle with blind companion flange of 2
each size/type
3 Bolting for internal flanges of each size/type 10%
4 Gaskets for internal flanges flange of each size/type 2
5 Demister Pads 100%
6 Sight/light glass assembly complete with bolting/gaskets

TRAYS AND TOWER INTERNALS

1 Bolts/nuts of each size/type 10%
2 Clamp Assemblies 10%
3 Valves for Trays 5%
4 Gasketing or tapes 100%
5 Sealing Foil for Cartridge Trays 200%
6 U-Clamps 10%
7 Tower Packings 10%-Metallic/Plastic
15%-Carbon/Ceramic

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ATTACHMENT 1 (CONT’D)

LIST 4 – AGITATORS / MIXERS

ITEM SPARE PART QUANTITY REQUIRED
1 Complete set of bearings for each agitator/mixer 1
2 Mechanical seal cartridge for each agitator/mixer 1
3 Shaft Sleeve for each agitator/mixer 1
4 Oil seal for each a agitator/mixer agitator 1
5 Mechanical seal components ( seal rings O-rings, springs) 1
for each agitator/mixer
6 V-Belts Specified by CONSULTANT
7 Hydraulic drive Specified by CONSULTANT
8 Coupling Membrane Specified by CONSULTANT

EJECTORS / EDUCTORS
1 Ejector, Single Stage, Nozzle (or Nozzle Components) 1, (1 Set) Notes 1,3
2 Ejector, Multi Stage, Nozzle (or Nozzle Components) 1 Per Stage (1 Set) Notes 1,3
3 Eductor, Single Stage, Nozzle (or Nozzle Components) 1, (1 Set) Notes 2,3
Notes

1 Ejectors, Venturi or Venturi liner, not usually spared unless

advised by Vendor as wear prevalent. Remedial rework of
Venturi or Venturi liner is possible but preferably carried out
by specialist contractor
2 Eductors, Chamber, Venturi or Venturi liner, each
application to be spared. High wear is usually combated by
using wear resistant materials e.g. for abrasive solids
transfer, ceramic chamber liners are used
3 Ejectors, Eductors, Where multiple common units, same
size, duty etc are used remain with single spare for nozzles
venturi or chambers unless Vendor advises wear prevalent,
review wear advice.

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ATTACHMENT 1 (CONT’D)

LIST 5 - Centrifugal Pump (Horizontal / Inline- General Purpose Process)

ITEM SPARE PART Quantity Required
( BASED ON THE NUMBER OF INSTALLED ITEMS)

1 2 3 4 5 6 7 Notes
MECHANICAL 1,2,3
Pump
1 Set of Impellers (Full Dia) 1 1 1 1 1 2 2
2 Set of Shaft with keys 1 1 1 1 1 2 2
3 Set of Interstage Shaft sleeves 1 1 1 1 1 2 2
4 Set of Case wearing rings 1 1 2 3 3 3 3
5 Set of Impeller wearing rings 1 1 2 3 3 3 3
6 Set of Gaskets, O-rings 2 4 6 8 8 8 8
7 Set of Interstage Bushings 1 1 1 1 1 2 2
8 Set of Mechanical Seals along
with Shaft Sleeves under seals 1 1 2 2 3 3 3
with gland plates for Cartridge
seals / without gland plate for
other seals
9 Set of gland packings 2 4 6 8 8 8 8
10 Set of Labyrinths for bearing 1 1 2 3 3 3 3
housing
11 Set of Oil Seals for bearing 1 2 3 4 4 4 4
housing
12 Set of bearings (Non drive end 1 1 2 3 3 3 3
side)
13 Set of bearings (Drive end 1 1 2 3 3 3 3
side)
14 Set of flexible element of 1 1 1 1 1 2 2
coupling
15 Set of Bearing Lock Washer 1 1 2 2 2 2 2
16 Throat Bush 1 1 1 2 2 2 2
17 Bearing Nut 1 1 1 1 1 1 1
18 Impeller Nut with washer 1 1 1 1 1 1 1
19 Deflector 1 1 1 1 1 1 1
20 Bearing Bracket 1 1 1 1 1 1 1
21 Bearing Cover 1 1 1 1 1 1 1
22 Coupling Complete Set 1 1 1 1 1 1 1
(including Fasteners)

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23 Set of Mech. Seal Spares 1 1 2 2 2 2 2

ELECTRICAL
Motor
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (Only for 1 1 1 1 1 2 2
M.V. Motor)

General Notes (Applicable to Lists 5 to 36):

1. The word `Set' means the quantity required for full replacement of that
part in one machine.
2. The Vendor shall quote for all the mandatory spares as defined above
& as applicable to the proposed design of the equipment. In case, any spare
which is listed above but not applicable due to specific construction/design of
the equipment, the same shall be highlighted as `Not Applicable' against that
spare supported with proper technical explanation.
3. Spare parts shall be identical in all respects to the parts fitted on the
main equipment, including dimensions, material of construction & heat
treatment.

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ATTACHMENT 1 (CONT’D)

LIST 6 - Centrifugal Pump (Vertical)

ITEM SPARE PART Quantity Required
( BASED ON THE NUMBER OF INSTALLED ITEMS)
MECHANICAL Notes
Pump 1,2,3
1 Set of Impellers (Full Dia) 1 1 1 1 1 2 2
2 Set of Pump Shaft with keys 1 1 1 1 1 2 2
(excluding driver & column
shaft)
3 Set of Interstage Shaft 1 1 1 1 1 2 2
sleeves
4 Set of Interstage Bushings 1 1 1 1 1 2 2
5 Set of Case wearing rings 1 1 2 3 3 3 3
6 Set of Impeller wearing rings 1 1 2 3 3 3 3
7 Set of Gaskets, O-rings 2 4 6 8 8 8 8
8 Set of Line Bearings (Spider 1 1 2 3 3 3 3
Bearings)
9 Set of Mechanical Seals 1 1 2 2 3 3 3
along with Shaft Sleeves
under seals with gland
plates for Cartridge seals/
without gland plate for other
seals
10 Set of gland packings 2 4 6 8 8 8 8
11 Set of Vapour Seals 1 2 3 4 4 4 4
12 Set of bearings 1 1 2 3 3 3 3
13 Set of flexible element for 1 1 1 1 1 2 2
coupling
14 Stuffing Box Spacer 1 1 1 1 1 1 1
15 Set of Mechanical Seal 1 1 2 2 2 2 2
Spares
16 Impeller Nut with Washer 1 1 1 1 1 1 1
17 Bearing Nut 1 1 1 1 1 1 1
18 Bearing Bracket 1 1 1 1 1 1 1
19 Bearing Cover 1 1 1 1 1 1 1
20 Set of joint rings 1 1 1 1 1 1 1

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21 Coupling Complete Set 1 1 1 1 1 1 1

(including Fasteners)
ELECTRICAL
Motor
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (Only 1 1 1 1 1 2 2
for M.V. Motor)

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ATTACHMENT 1 (CONT’D)

LIST 7 - Centrifugal Pumps with Submerged Motor (Cryogenic Service)

ITEM SPARE PART Quantity Required
( BASED ON THE NUMBER OF INSTALLED ITEMS)

1 2 3 4 5 6 7 Notes
MECHANICAL 1,2,3
Pump
1 Complete Pump assembly 1 1 1 1 1 1 1
2 Set of Impellers (Full Dia) 1 1 1 1 1 2 2
3 Set of Inducers, if any 1 1 1 1 1 2 2
4 Set of Case wearing rings 1 1 2 3 3 3 3
5 Set of Impeller wearing rings 1 1 2 3 3 3 3
6 Set of shaft bush bearings, if 1 1 2 3 3 3 3
any
7 Set of Gaskets, O-rings 2 4 6 8 8 8 8
8 Set of Thrust Balancing 1 1 2 3 3 3 3
Mechanism
9 Coupling Complete Set 1 1 1 1 1 1 1
(including Fasteners)
ELECTRICAL
Motor
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3

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ATTACHMENT 1 (CONT’D)

LIST 8 - Sundyne Pump

ITEM SPARE PART Quantity Required
( BASED ON THE NUMBER OF INSTALLED ITEMS)

1 2 3 4 5 6 7 Notes
MECHANICAL 1,2,3
Pump
1 Impeller (Rated Dia.) 1 1 1 1 1 2 2
2 Set of High Speed Shaft 1 1 1 1 1 2 2
Assy. with Impeller keys
3 Ball bearing for Low Speed 1 1 2 2 3 3 3
Shaft (lower)
4 Ball bearing for Low Speed 1 1 2 2 3 3 3
Shaft (upper)
5 Journal bearing for High 1 1 2 2 3 3 3
Speed Shaft (lower)
6 Journal bearing for High 1 1 2 2 3 3 3
Speed Shaft (upper)
7 Sets of O-ring repair kit 2 4 6 8 8 8 8
8 Mechanical Seal for Gear 1 1 2 2 3 3 3
Box Side
9 Seal Rotating Face for 1 1 2 2 3 3 3
Gear Box Side
10 Coupling Complete Set 1 1 1 1 1 2 2
(including Fasteners)when
applicable
11 Seal rotating Face for 1 1 2 2 3 3 3
process Side
12 Oil Filter 2 4 6 8 8 8 8
13 Shaft Seal 2 4 6 8 8 8 8
14 Impeller Tab Washer 1 2 3 4 5 7 7
15 Low Speed Shaft Assembly 1 1 1 1 2 2 2
(Intermediate/Idler)
16 Shaft Spacer 1 1 1 1 2 2 2
17 Set of Gaskets 2 2 2 2 3 3 3

Addnl. spares with

SINGLE Seal

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1 Set of throttle bushing 1 1 1 1 1 2 2

2 Shaft sleeve 1 1 2 2 3 3 3
3 Set of Mech. Seal 1 1 2 2 3 3 3
(Complete Assy., Process
Side only)
4 Set of Mech. Seal Parts (as 1 1 2 2 3 3 3
Mech. Seal Repair Kit for
Process Side Only)

Addnl. spares with

DOUBLE/TANDEM Seal
1 Shaft sleeve (lower) 1 1 2 2 3 3 3
2 Shaft sleeve (upper) 1 1 2 2 3 3 3
3 Set of Mech. Seal 1 1 2 2 3 3 3
(Complete Assy., Process
Lower Side)
4 Set of Mech. Seal 1 1 2 2 3 3 3
(Complete Assy., Process
Upper Side)
5 Seal Rotating Face for 1 1 2 2 3 3 3
Process Lower side
6 Seal Rotating Face for 1 1 2 2 3 3 3
Process Upper side
7 Set of Mechanical Seal 1 1 2 2 3 3 3
Parts (as Mech. Seal
Repair Kit for Process
Lower Side Only)
8 Set of Mechanical Seal 1 1 2 2 3 3 3
Parts (as Mech. Seal
Repair Kit for Process
Upper Side Only)

ELECTRICAL
Motor
1 Set of Bearings (NDE + 1 1 2 2 3 3 3
DE)
2 Set of Cooling Fans 1 1 1 1 1 2 2
3 Terminal Box Cover with 1 1 1 1 1 2 2
Screws
4 Terminal Block 1 1 1 1 2 2 2

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ATTACHMENT 1 (CONT’D)
LIST 9 - Centrifugal Horizontal Pumps (Multistage)
ITEM SPARE PART Quantity Required
( BASED ON THE NUMBER OF INSTALLED ITEMS)

MECHANICAL Notes
Pump 1,2,3
1 Set of case wearing rings 1 1 2 3 3 3 3
2 Set of Impeller wearing rings 1 1 2 3 3 3 3
3 Set of Intermediate bushings 1 1 2 3 3 3 3
4 Set of Balance Drum Sleave 1 1 2 3 3 3 3
(Bushing)
5 Set of Mechanical Seals along 1 1 2 2 3 3 3
with Shaft Sleeves
under seals with gland plates for
Cartridge
seals without gland plate for
other seals
6 Set of Labyrinths for bearing 1 1 2 3 3 3 3
housing
7 Set of Gaskets, O-rings 2 4 6 8 8 8 8
8 Set of Bearings, NDE 1 1 2 3 3 3 3
9 Set of Bearings, DE 1 1 2 3 3 3 3
10 Set of Flexible elements of 1 1 1 1 1 2 2
Coupling
11 Complete Set of Mechanical 1 1 2 2 2 2 2
Seal Spares
12 Throat Bush 1 1 1 2 2 2 2
13 Lock Nut 1 1 1 2 2 2 2
14 Deflector 1 1 1 1 1 1 1
15 Set of impellers 1 1 2 2 2 2 2
16 Coupling Elements- Complete 1 2 2 2 2 2 2
Set (including Fasteners)

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Additional Spares for Axially

Split Pumps
1 Complete Rotor assembly 1 1 1 1 1 2 2
dynamically
balanced including balance drum
2 Set of Interstage bushings 1 1 1 1 1 2 2
3 Set of Balance Drum 1 1 1 1 1 2 2
Sleeve(Bushing)
Additional Spares for Radially
Split Double Case Pumps
1 Complete replaceable inner- 1 1 1 1 1 2 2
case element consisting of all
rotating & stationary hydraulic
elements
Lube Oil Pump Rotary (Main +
Stand By)
1 Complete bare pump assembly 1 1 1 1 1 2 2
excluding driver couplings &
base plate
2 Set of bearings 1 1 2 3 3 3 3
3 Set of Mechanical Seals 1 1 2 2 3 3 3
4 Set of Gaskets, O - rings 2 4 6 8 8 8 8

Lube Oil Filters

1 Filter cartridge / element along 10 20 30 30 30 30 30
with set of gaskets, O - rings

Lube Oil Coolers

1 Set of Gaskets, O Rings 2 4 6 8 8 8 8

ELECTRICAL
Motor for Main Pump
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (For M.V. 1 1 1 1 1 2 2
motor only)

Electric Motor for L.O. Pump

1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
motor only)

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ATTACHMENT 1 (CONT’D)

LIST 10 - Rotary Pump

ITEM SPARE PART Quantity Required
( BASED ON THE NUMBER OF INSTALLED ITEMS)

1 2 3 4 5 6 7 Notes
MECHANICAL 1,2,3
Pumps
1 Set of Rotors 1 1 1 1 1 2 2
2 Casing Insert (Stator) [only for 1 1 1 1 1 2 2
screw pump]
3 Set of Bearings (Drive End) - 1 1 2 3 3 3 3
Each Screw
4 Set of Bearings (Non Drive End) 1 1 2 3 3 3 3
- Each Screw
5 Set of Gaskets, O - rings 2 4 6 8 8 8 8
6 Set of Labyrinths 1 1 2 3 3 3 3
7 Set of Oil Seals 1 2 3 4 4 4 4
8 Set of Mechanical Seals along 1 1 2 2 3 3 3
with Shaft Sleeves under seals
with gland plates for Cartridge
seals / without gland plate for
other seals
9 Set of Gland Packings (Where 2 4 6 8 8 8 8
Applicable)
10 Coupling Complete Set 1 1 1 1 1 2 2
(including Fasteners)
ELECTRICAL
Motor
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
motor only)

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ATTACHMENT 1 (CONT’D)
LIST 11 – Reciprocating Pump
ITEM SPARE PART Quantity Required
( BASED ON THE NUMBER OF INSTALLED ITEMS)

MECHANICAL Notes
Pumps 1,2,3
1 Set of Suction Valve Assembly 1 1 2 2 3 3 3
2 Set of Discharge Valve 1 1 2 2 3 3 3
Assembly
3 Set of bearings 1 1 2 3 3 3 3
4 Set of Gaskets, O - rings 2 4 6 8 8 8 8
5 Set of Plungers 1 1 1 1 1 2 2
6 Set of Plunger Packings 2 4 6 8 8 8 8
7 Valve Seat 1 1 2 2 2 2 2
8 Oil seal 1 2 2 2 3 3 3
9 Valve Disc 1 1 2 2 2 2 2
10 Ball 1 1 2 2 2 2 2

ELECTRICAL
Motor
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
Motor)

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ATTACHMENT 1 (CONT’D)

LIST 12 - Reciprocating Pump (Diaphragm Type

ITEM SPARE PART Quantity Required

( BASED ON THE NUMBER OF INSTALLED ITEMS)

1 2 3 4 5 6 7 Notes
MECHANICAL 1,2,3
Pumps
1 Set of Suction Valve 1 1 2 2 3 3 3
Assembly
2 Set of Discharge Valve 1 1 2 2 3 3 3
Assembly
3 Set of bearings 1 1 2 3 3 3 3
4 Set of Gaskets, O - rings 2 4 6 8 8 8 8
5 Set of Diaphragms 2 2 4 6 6 6 6
6 Set of Hydraulic piston 2 2 4 6 6 6 6
packings / rings
7 Valve Seat 1 1 2 2 2 2 2
8 Oil Seal 1 2 2 2 3 3 3
9 Valve Disc 1 1 2 2 2 2 2
10 Ball 1 1 2 2 2 2 2

ELECTRICAL
Motor
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
Motor)

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ATTACHMENT 1 (CONT’D)

LIST 13 - Positive Displacement Pump (Controlled Volume)

ITEM SPARE PART Quantity Required

( BASED ON THE NUMBER OF INSTALLED ITEMS)

1 2 3 4 5 6 7 Notes
MECHANICAL 1,2,3
Pumps
1 Set of Suction Valve 1 1 2 2 3 3 3
Assembly
2 Set of Discharge Valve 1 1 2 2 3 3 3
Assembly
3 Set of bearings 1 1 2 3 3 3 3
4 Set of Gaskets, O - rings 2 4 6 8 8 8 8
5 Set of oil seals 1 1 2 2 2 3 3

Additional Spares for

Plunger Pumps
1 Set of Plungers 1 1 1 1 1 2 2
2 Set of Plunger Packings 2 4 6 8 8 8 8
3 Worm Wheel Assembly 1 1 2 2 2 2 2

Additional Spares for

Diaphragm Pumps
1 Set of Diaphragms 2 2 4 6 6 6 6
2 Set of Hydraulic piston 2 2 4 6 6 6 6
packings / rings
3 Worm Wheel Assembly 1 1 2 2 2 2 2

ELECTRICAL
Motor
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
Motor)

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ATTACHMENT 1 (CONT’D)

LIST 14 - Reciprocating Compressor

ITEM SPARE PART Quantity Required

( BASED ON THE NUMBER OF INSTALLED ITEMS)

1 2 3 4 5 6 7 Notes
MECHANICAL 1,2,3
Compressor
1 Set of all Compressor 1 1 2 3 3 3 3
Bearings/bushes (main crank
shaft bearings, connecting rod
big-end & small end bearings,
cross head bearings etc.
2 Connecting rod assembly 1 1 1 1 1 2 2
(without bearings)
3 Set of piston rings for all 1 1 2 3 3 3 3
lubricated cylinders
4 Set of piston rings (sealing 3 3 6 9 9 9 9
rings & rider rings) for all mini-
lubricated/non-lubricated
cylinders
5 Valve assembly (suction) - 2 2 4 6 6 6 6
each type
6 Valve assembly (discharge) - 2 2 4 6 6 6 6
each type
7 Set of Valve springs, Valve 1 2 3 4 4 4 4
plates etc
8 Piston rod packing assembly - 1 1 1 1 1 2 2
each type
9 Set of replaceable part of 1 1 2 3 3 3 3
piston rod packing- lubricated
cylinder
10 Set of replaceable part of 3 3 6 9 9 9 9
piston rod packing-non
lubricated cylinder
11 Set of all wiper rings 1 1 2 3 3 3 3
12 Packing cooling oil pump 1 1 1 1 1 2 2
assembly (where applicable)
13 Set of all Gaskets & `O' - rings 2 4 6 8 8 8 8
for the compressor

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14 Valve unloader assembly - 1 1 2 2 3 3 3

each type
15 Lubricator assembly (full 1 1 1 1 1 2 2
assembly)
16 Set of air filters elements (for 2 4 6 8 8 8 8
air service only)
17 Crankshaft - for Each Type 1 1 1 1 1 1 1
Lube Oil Pump Centrifugal
(Main + Stand By)
1 Complete bare pump 1 1 1 1 1 2 2
assembly excluding driver
couplings & base plate
2 Set of bearings 1 1 2 3 3 3 3
3 Set of Mechanical Seals 1 1 2 2 3 3 3
4 Set of Impeller Wear Rings 1 1 2 3 3 3 3
5 Set of Casing Wear Rings 1 1 2 3 3 3 3
6 Set of Gaskets ,’O’- rings 2 4 6 8 8 8 8
7 Complete set of coupling of 1 1 1 1 1 1 1
each type
Lube Oil Pump Rotary (Main
+ Stand By)
1 Complete base pump 1 1 1 1 1 2 2
assembly excluding driver
couplings & base plate
2 Set of bearings 1 1 2 3 3 3 3
3 Set of Mechanical Seals 1 1 2 2 3 3 3
4 Set of Gaskets, ’O’- rings 2 4 6 8 8 8 8
5 Complete set of coupling of 1 1 1 1 1 1 1
each type
Cylinder Cooling Pump
Centrifugal (Main + Stand
By)
1 Complete bare pump 1 1 1 1 1 2 2
assembly excluding driver
couplings & base plate
2 Set of bearings 1 1 2 3 3 3 3
3 Set of Mechanical Seals 1 1 2 2 3 3 3
4 Set of Impeller Wear Rings 1 1 2 3 3 3 3
5 Set of Casing Wear Rings 1 1 2 3 3 3 3
6 Set of Gaskets, ‘O’ - rings 2 4 6 8 8 8 8
7 Complete set of coupling of 1 1 1 1 1 1 1
each type

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Lube Oil Filters

1 Filter cartridge / element along 10 20 30 30 30 30 30
with set of gaskets, ‘O’ - rings
Lube Oil Coolers
1 Set of Gaskets, ‘O’ - Rings 2 4 6 6 8 8 8
Interstage Coolers
1 Set of Gaskets, ‘O’ - Rings 2 4 6 6 8 8 8
After Coolers
1 Set of Gaskets, ‘O’ - Rings 2 4 6 6 8 8 8

ELECTRICAL
Main Motor (Compressor
Driver)
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
motor only)
Electric Motor for L.O.
Pump
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
motor only)
Electric Motor for Cooling
Pump
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
motor only)

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ATTACHMENT 1 (CONT’D)

LIST 15 - Reciprocating Compressor (Diaphragm Type)

ITEM SPARE PART Quantity Required

( BASED ON THE NUMBER OF INSTALLED ITEMS)

1 2 3 4 5 6 7 Notes
MECHANICAL 1,2,3
Compressor
1 Set of all Compressor 1 1 2 3 3 3 3
Bearings/bushes (main crank
shaft bearings, connecting rod
big-end & small end bearings,
cross head bearings etc.
2 Connecting rod assembly 1 1 1 1 1 2 2
(without bearings)
3 Set of Piston Rings for 1 1 2 3 3 3 3
hydraulic piston/plunger
4 Set of Diaphragms 2 4 6 8 8 8 8
5 Valve assembly (suction) - 2 2 4 6 6 6 6
each type
6 Valve assembly (discharge) - 2 2 4 6 6 6 6
each type
7 Set of Valve springs, Valve 1 2 3 4 4 4 4
plates etc
8 Set of all Gaskets & `O' - rings 2 4 6 8 8 8 8
for the compressor (including
plate O-rings, holddown O-
rings etc.)
9 Set of Hydraulic Pressure 1 1 1 1 1 1 1
Limiter Device
10 Set of Compensating Pump 1 1 1 1 1 1 1
repair kit
11 Crankshaft - for Each Type 1 1 1 1 1 1 1
Lube Oil Pump Rotary (Main
+ Stand By)
1 Complete base pump 1 1 1 1 1 2 2
assembly excluding driver
couplings & base plate
2 Set of bearings 1 1 2 3 3 3 3
3 Set of Mechanical Seals 1 1 2 2 3 3 3

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4 Set of Gaskets,’O’- rings 2 4 6 8 8 8 8

5 Complete set of coupling of 1 1 1 1 1 1 1
each type
Lube Oil Filters
1 Filter cartridge / element along 10 20 30 30 30 30 30
with set of gaskets, ‘O’ - rings

Lube Oil Coolers

1 Set of Gaskets, ‘O’ - Rings 2 4 6 6 8 8 8

Interstage Coolers
1 Set of Gaskets, ‘O’ - Rings 2 4 6 6 8 8 8

After Coolers
1 Set of Gaskets, ‘O’ - Rings 2 4 6 6 8 8 8

ELECTRICAL
Main Motor (Compressor
Driver)
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
motor only)

Electric Motor for L.O.

Pump
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
motor only)

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ATTACHMENT 1 (CONT’D)

LIST 16 - Reciprocating Compressor (Labyrinth Type)

ITEM SPARE PART Quantity Required

( BASED ON THE NUMBER OF INSTALLED ITEMS)

1 2 3 4 5 6 7 Notes
MECHANICAL 1,2,3
Compressor
1 Set of all Compressor 1 1 2 3 3 3 3
Bearings/bushes (main crank
shaft bearings, connecting rod
big-end & small end bearings,
cross head bearings etc.
2 Connecting rod assembly 1 1 1 1 1 2 2
(without bearings)
3 Valve assembly (suction) - 2 2 4 6 6 6 6
each type
4 Valve assembly (discharge) - 2 2 4 6 6 6 6
each type
5 Set of Valve springs, Valve 1 2 3 4 4 4 4
plates etc
6 Piston rod packing assembly - 1 1 1 1 1 2 2
each type
7 Set of replaceable part of 1 1 2 3 3 3 3
piston rod packing
8 Set of Piston Rod guide 1 1 2 3 3 3 3
bearings
9 Set of Crankshaft seals 1 1 2 2 3 3 3
10 Set of all Gaskets & `O' - rings 2 4 6 8 8 8 8
for the compressor
11 Valve unloader assembly - 1 1 2 2 3 3 3
each type
12 Crankshaft - for Each Type 1 1 1 1 1 1 1
Lube Oil Pump Rotary (Main
+ Stand By)
1 Complete base pump 1 1 1 1 1 2 2
assembly excluding driver
couplings & base plate
2 Set of bearings 1 1 2 3 3 3 3

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3 Set of Mechanical Seals 1 1 2 2 3 3 3

4 Set of Gaskets, ’O’- rings 2 4 6 8 8 8 8
5 Complete set of coupling of 1 1 1 1 1 1 1
each type
Lube Oil Filters
1 Filter cartridge / element along 10 20 30 30 30 30 30
with set of gaskets, ‘O’ - rings

Lube Oil Coolers

1 Set of Gaskets, ‘O’ - Rings 2 4 6 6 8 8 8

Interstage Coolers
1 Set of Gaskets, ‘O’ - Rings 2 4 6 6 8 8 8

After Coolers
1 Set of Gaskets, ‘O’ - Rings 2 4 6 6 8 8 8

ELECTRICAL
Main Motor (Compressor
Driver)
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
motor only)

Electric Motor for L.O.

Pump
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
motor only)

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ATTACHMENT 1 (CONT’D)

LIST 17 - Centrifugal Compressor

ITEM SPARE PART Quantity Required

( BASED ON THE NUMBER OF INSTALLED ITEMS)

1 2 3 4 5 6 7 Notes
MECHANICAL 1,2,3
1 Complete Rotor dynamically 1 1 1 1 1 1 1
balanced including balance
drum (with permanent storage
container for vertical storage)
2 Set of Interstage Shaft 1 2 3 3 3 3 3
Sleeves
3 Set of Labyrinths including 1 2 3 3 3 3 3
interstage balance drum &
bearing housing
4 Set of Radial Bearings (DE + 1 2 3 4 4 4 4
NDE)
5 Set of Thrust Bearings 1 2 3 4 4 4 4
6 Set of Shaft Seal Assembly 1 2 3 3 3 3 3
(DE + NDE) including sleeve
under seals
7 Set of Gaskets, O - rings 2 4 6 8 8 8 8
8 Sealing compounds for casing 4* 8* 8* 8* 8* 8* 8*
joints (if reqd.)
* Suitable for as many
applications
9 Complete Set Of Coupling Of 1 1 1 1 1 1 1
Each Type
Lube Oil Pump Centrifugal
(Main + Stand By)
1 Complete bare pump 1 1 1 1 1 2 2
assembly excluding driver
couplings & base plate
2 Set of bearings 1 1 2 3 3 3 3
3 Set of Mechanical Seals 1 1 2 2 3 3 3
4 Set of Impeller Wear Rings 1 1 2 3 3 3 3
5 Set of Casing Wear Rings 1 1 2 3 3 3 3
6 Set of Gaskets, O - rings 2 4 6 8 8 8 8

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7 Complete set of coupling of 1 1 1 1 1 1 1

each type
Lube Oil Pump Rotary (Main
+ Stand By)
1 Complete bare pump 1 1 1 1 1 2 2
assembly excluding driver
couplings & base plate
2 Set of bearings 1 1 2 3 3 3 3
3 Set of Mechanical Seals 1 1 2 2 3 3 3
4 Set of Impeller Wear Rings 1 1 2 3 3 3 3
5 Set of Casing Wear Rings 1 1 2 3 3 3 3
6 Set of Gaskets, O - rings 2 4 6 8 8 8 8
7 Complete set of coupling of 1 1 1 1 1 1 1
each type

Seal Oil Pump Rotary (Main

+ Stand By)
1 Complete bare pump 1 1 1 1 1 2 2
assembly including driver
couplings & base plate
2 Set of bearings 1 1 2 3 3 3 3
3 Set of Mechanical Seals 1 1 2 2 3 3 3
4 Set of Gaskets, O - rings 2 4 6 8 8 8 8
5 Complete set of coupling of 1 1 1 1 1 1 1
each type
Emergency Oil Centrifugal
Pump
1 Complete bare pump 1 1 1 1 1 2 2
assembly excluding driver
couplings & base plate
2 Set of bearings 1 1 2 3 3 3 3
3 Set of Mechanical Seals 1 1 2 2 3 3 3
4 Set of Impeller Wear Rings 1 1 2 3 3 3 3
5 Set of Casing Wear Rings 1 1 2 3 3 3 3
6 Set of Gaskets, O - rings 2 4 6 8 8 8 8
7 Complete set of coupling of 1 1 1 1 1 1 1
each type
Steam Turbine for Lube Oil
Pump
1 Dynamically balanced turbine 1 1 1 1 1 2 2
Rotor

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2 Set of Bearings 1 1 2 3 3 3 3
3 Set of Complete Shaft Seal 1 1 2 3 3 3 3
Assembly
4 Set of Gaskets, O-rings 2 4 6 8 8 8 8

Steam Turbine for Seal Oil

Pump
1 Dynamically balanced turbine 1 1 1 1 1 2 2
Rotor
2 Set of Bearings 1 1 2 3 3 3 3
3 Set of Complete Shaft Seal 1 1 2 3 3 3 3
Assembly
4 Set of Gaskets, O-rings 2 4 6 8 8 8 8

Lube Oil Filters

1 Filter cartridge / element along 10 20 30 30 30 30 30
with set of gaskets, O - rings

Seal Filters (Oil / Gas)

1 Filter cartridge / element along 10 20 30 30 30 30 30
with set of gaskets, O - rings
for Oil Seals
2 Set of Seal Gas filter elements 5 10 15 15 15 15 15
for Gas Seals

Oil Coolers
1 Set of Gaskets, O-Rings 2 4 6 8 8 8 8

Interstage Coolers
1 Set of Gaskets, O-Rings 2 4 6 8 8 8 8

After Coolers
1 Set of Gaskets, O-Rings 2 4 6 8 8 8 8

ELECTRICAL
Main Motor (Compressor
Driver)
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
motor only)

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Electric Motor for Lube Oil

Pump
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
motor only)

Electric Motor for Seal Oil

Pump
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
motor only)

Electrical Motor for

Emergency Oil Pump
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
motor only)

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ATTACHMENT 1 (CONT’D)

LIST 18 - Packaged, Integrally Geared, Centrifugal Compressor

ITEM SPARE PART Quantity Required

( BASED ON THE NUMBER OF INSTALLED ITEMS)

1 2 3 4 5 6 7 Notes
MECHANICAL 1,2,3
Compressor
1 Set of High Speed rotors 1 1 1 1 1 1 1
(including pinion, shaft &
impeller)
2 Set of Compressor Bearings 1 1 2 3 3 3 3
3 Set of Shaft Seals & carbon 1 2 3 3 3 3 3
rings
4 Set of all Labyrinths 1 1 2 3 3 3 3
5 Set of Gaskets, Packings, O - 2 4 6 8 8 8 8
rings
6 Set of air filters elements 2 4 6 8 8 8 8
7 Damper/ IGV 1 1 1 1 1 1 1
Seals 100%
Actuator-1 set of each type

8 Complete Set of Coupling of 1 1 1 1 1 1 1

Each Type
Lube Oil Pump Centrifugal
(Main + Stand By)
1 Complete bare pump 1 1 1 1 1 2 2
assembly excluding driver
couplings & base plate
2 Set of bearings 1 1 2 3 3 3 3
3 Set of Mechanical Seals 1 1 2 2 3 3 3
4 Set of Impeller Wear Rings 1 1 2 3 3 3 3
5 Set of Casing Wear Rings 1 1 2 3 3 3 3
6 Set of Gaskets, O - rings 2 4 6 8 8 8 8
7 Complete set of coupling of 1 1 1 1 1 1 1
each type
Lube Oil Pump Rotary (Main
+ Stand By)
1 Complete bare pump 1 1 1 1 1 2 2

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assembly excluding driver

couplings & base plate
2 Set of bearings 1 1 2 3 3 3 3
3 Set of Mechanical Seals 1 1 2 2 3 3 3
4 Set of Gaskets, O - rings 2 4 6 8 8 8 8
Lube Oil Filters
1 Filter cartridge / element along 10 20 30 30 30 30 30
with set of gaskets, O - rings

Lube Oil Coolers

1 Set of Gaskets, O-Rings 2 4 6 6 8 8 8

Interstage Coolers
1 Set of Gaskets, O-Rings 2 4 6 6 8 8 8

After Coolers
1 Set of Gaskets, O-Rings 2 4 6 6 8 8 8

ELECTRICAL
Motor (Compressor Driver)
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans 1 1 1 1 1 2 2
Seal Filters (Oil / Gas)
1 Filter cartridge / element along 10 20 30 30 30 30 30
with set of gaskets, O - rings
for Oil Seals
2 Set of Seal Gas filter elements 5 10 15 15 15 15 15
for Gas Seals

Oil Coolers
1 Set of Gaskets, O-Rings 2 4 6 8 8 8 8

Interstage Coolers
1 Set of Gaskets, O-Rings 2 4 6 8 8 8 8

After Coolers
1 Set of Gaskets, O-Rings 2 4 6 8 8 8 8

ELECTRICAL

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Main Motor (Compressor

Driver)
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
motor only)

ATTACHMENT 1 (CONT’D)

LIST 19 - Rotary Compressor (Lobe Type)

ITEM SPARE PART Quantity Required

( BASED ON THE NUMBER OF INSTALLED ITEMS)

1 2 3 4 5 6 7 Notes
MECHANICAL 1,2,3
Compressor
1 Set of Rotors 1 1 1 1 1 1 1
2 Set of Radial Bearings (DE + 1 2 3 4 4 4 4
NDE)
3 Set of Thrust Bearings 1 2 3 4 4 4 4
4 Set of Shaft Seal Assembly 1 2 3 3 3 3 3
(DE + NDE) including sleeves
under seals
5 Set of Timing Gears 1 1 1 1 1 2 2
6 Set of Gaskets, O - rings 2 4 6 8 8 8 8
7 Set of air filters elements 2 4 6 8 8 8 8
8 Complete Set of Coupling of 1 1 1 1 1 1 1
Each Type
Lube Oil Pump Rotary (Main
+ Stand By)
1 Complete bare pump 1 1 1 1 1 2 2
assembly excluding driver
couplings & base plate
2 Set of bearings 1 1 2 3 3 3 3
3 Set of Mechanical Seals 1 1 2 2 3 3 3
4 Set of Gaskets, ’O’- rings 2 4 6 8 8 8 8
5 Complete set of coupling of 1 1 1 1 1 1 1
each type
Lube Oil Filters

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1 Filter cartridge / element along 10 20 30 30 30 30 30

with set of gaskets, ‘O’ - rings
Oil Coolers
1 Set of Gaskets, ‘O’-rings 2 4 6 8 8 8 8
ELECTRICAL
Main Motor (Compressor
Driver)
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
motor only)

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ATTACHMENT 1 (CONT’D)

LIST 20 - Rotary Compressor (Liquid Ring Type)

ITEM SPARE PART Quantity Required

( BASED ON THE NUMBER OF INSTALLED ITEMS)

1 2 3 4 5 6 7 Notes
MECHANICAL 1,2,3
Compressor
1 Set of Rotors 1 1 1 1 1 1 1
2 Set of Radial Bearings (DE + 1 2 3 4 4 4 4
NDE)
3 Set of Thrust Bearings 1 2 3 4 4 4 4
4 Set of Shaft Seal Assembly 1 2 3 3 3 3 3
(DE + NDE) including sleeves
under seals
5 Set of Gaskets, O - rings 2 4 6 8 8 8 8
6 Set of air filters elements (for 2 4 6 8 8 8 8
air service only)
7 Complete Set of Coupling of 1 1 1 1 1 1 1
Each Type
Coolers
1 Set of Gaskets, ‘O’-rings 2 4 6 8 8 8 8

ELECTRICAL
Main Motor (Compressor
Driver)
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
motor only)

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ATTACHMENT 1 (CONT’D)

LIST 21 - Rotary Compressor (Screw Type)

ITEM SPARE PART Quantity Required
( BASED ON THE NUMBER OF INSTALLED ITEMS)

1 2 3 4 5 6 7 Notes
MECHANICAL 1,2,3
Compressor
1 Set of Screws 1 1 1 1 1 1 1
2 Set of Radial Bearings (DE + 1 2 3 4 4 4 4
NDE)
3 Set of Thrust Bearings 1 2 3 4 4 4 4
4 Set of Shaft Seal Assembly 1 2 3 3 3 3 3
(DE + NDE) including sleeves
under seals
5 Set of Timing Gears (for oil 1 1 1 1 1 2 2
free screw compressor)
6 Set of Gaskets, O - rings 2 4 6 8 8 8 8
7 Set of air filters elements 2 4 6 8 8 8 8
8 Sealing Compounds for 4* 8* 8* 8* 8* 8* 8*
casing joints
* Suitable for as many
applications
9 Complete Set of Coupling of 1 1 1 1 1 1 1
Each Type
Lube Oil Pump Centrifugal
(Main + Stand By)
1 Complete bare pump 1 1 1 1 1 2 2
assembly excluding driver
couplings & base plate
2 Set of bearings 1 1 2 3 3 3 3
3 Set of Mechanical Seals 1 1 2 2 3 3 3
4 Set of Impeller Wear Rings 1 1 2 3 3 3 3
5 Set of Casing Wear Rings 1 1 2 3 3 3 3
6 Set of Gaskets, ‘O’- rings 2 4 6 8 8 8 8
7 Complete set of coupling of 1 1 1 1 1 1 1
each type

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Seal Oil Pump Rotary (Main

+ Stand By)
1 Complete bare pump 1 1 1 1 1 2 2
assembly including driver
couplings & base plate
2 Set of bearings 1 1 2 3 3 3 3
3 Set of Mechanical Seals 1 1 2 2 3 3 3
4 Set of Gaskets, ‘O’- rings 2 4 6 8 8 8 8
5 Complete set of coupling of 1 1 1 1 1 1 1
each type
Lube Oil Filters
1 Filter cartridge / element along 10 20 30 30 30 30 30
with set of gaskets, ‘O’ - rings
Seal Oil Filters
1 Filter cartridge / element along 10 20 30 30 30 30 30
with set of gaskets, ‘O’ - rings
2 Set of Seal Gas filter elements 10 20 30 30 30 30 30
for Gas Seals
Oil Coolers
1 Set of Gaskets, ‘O’-rings 2 4 6 8 8 8 8
Interstage Coolers
1 Set of Gaskets, ‘O’-rings 2 4 6 8 8 8 8
After Coolers
1 Set of Gaskets, ’O’-rings 2 4 6 8 8 8 8
ELECTRICAL
Main Motor (Compressor
Driver)
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
motor only)
Electric Motor for Lube Oil
Pump
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
motor only)
Electric Motor for Seal Oil
Pump
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
motor only)

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ATTACHMENT 1 (CONT’D)

LIST 22 - Expander Compressor

ITEM SPARE PART Quantity Required

( BASED ON THE NUMBER OF INSTALLED ITEMS)

1 2 3 4 5 6 7 Notes
MECHANICAL 1,2,3
1 Set of Mechanical Centre 1 1 1 1 1 1 1
Section (MCS) including
expander-compressor rotor
dynamically balanced
including bearings, seals and
bearing housings complete
2 Set of combined radial & 1 2 3 4 4 4 4
thrust bearings (Expander +
Compressor)
3 Set of Labyrinth shaft seals 1 2 3 3 3 3 3
(Expander + Compressor)
4 Set of Expander Wheel Seal 1 2 3 3 3 3 3
Assembly
5 Set of Compressor Wheel 1 2 3 3 3 3 3
Seal Assembly
6 Set of Gaskets, O – rings 2 4 6 8 8 8 8
7 Set of Heat Barrier, if 1 1 1 1 1 1 1
applicable
9 Complete Set of Coupling of 1 1 1 1 1 1 1
Each Type
Lube Oil Pump Rotary (Main
+ Stand By)
1 Complete bare pump 1 1 1 1 1 2 2
assembly excluding driver
couplings & base plate
2 Set of bearings 1 1 2 3 3 3 3
3 Set of Mechanical Seals 1 1 2 2 3 3 3
4 Set of Gaskets, O – rings 2 4 6 8 8 8 8
5 Complete set of coupling of 1 1 1 1 1 1 1
each type
Lube Oil Filters
1 Filter cartridge / element along 10 20 30 30 30 30 30

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with set of gaskets, O – rings

Seal Gas Filters
1 Set of Seal Gas filter elements 5 10 15 15 15 15 15
for Gas Seals
Oil Coolers
1 Set of Gaskets, O-Rings 2 4 6 8 8 8 8
ELECTRICAL
Electric Motor for Lube Oil
Pump
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
motor only)

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PAGE : 48 of 75
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ATTACHMENT 1 (CONT’D)

LIST 23 - Centrifugal Fan

ITEM SPARE PART Quantity Required

( BASED ON THE NUMBER OF INSTALLED ITEMS)

1 2 3 4 5 6 7 Notes
MECHANICAL 1,2,3
Fan
1 Complete Rotor dynamically 1 1 1 1 1 1 1
balanced
2 Set of Shaft Sleeves 1 2 3 3 3 3 3
3 Set of Labyrinths 1 2 3 3 3 3 3
4 Set of Radial Bearings (DE + 1 2 3 4 4 4 4
NDE)
5 Set of Thrust Bearings 1 2 3 4 4 4 4
6 Set of Shaft Seal Assembly 1 2 3 3 3 3 3
(DE + NDE) including sleeves
under seals
7 Set of Gaskets, O - rings 2 4 6 8 8 8 8
8 Set of flexible element of 1 1 1 1 1 2 2
coupling (Complete flexible
coupling)
9 Set of Air filter elements (for 2 4 6 8 8 8 8
air service only)
10 Damper/ IGV 1 1 1 1 1 1 1
Seals 100%
Actuator-1 set of each type
11 Complete Set of Coupling of 1 1 1 1 1 1 1
Each Type
Fluid Coupling
1 Set of Rotors, dynamically 1 1 1 1 1 1 1
balanced
2 Set of Bearings 1 2 3 4 4 4 4
3 Set of Labyrinths, Oil Seals 1 2 3 3 3 3 3
4 Set of Gaskets, O-Rings 2 4 6 8 8 8 8

Changeover Clutch
1 Set of Rotors 1 1 1 1 1 1 1

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2 Set of Bearings 1 2 3 4 4 4 4
3 Set of Labyrinths, Oil Seals 1 2 3 3 3 3 3
4 Set of Gaskets, O-Rings 2 4 6 8 8 8 8
Lube Oil Pump Centrifugal
(Main + Stand By)
1 Complete bare pump 1 1 1 1 1 2 2
assembly excluding driver
couplings & base plate
2 Set of bearings 1 1 2 3 3 3 3
3 Set of Mechanical Seals 1 1 2 2 3 3 3
4 Set of Impeller Wear Rings 1 1 2 3 3 3 3
5 Set of Casing Wear Rings 1 1 2 3 3 3 3
6 Set of Gaskets, O - rings 2 4 6 8 8 8 8
Lube Oil Pump Rotary (Main
+ Stand By)
1 Complete bare pump 1 1 1 1 1 2 2
assembly excluding driver
couplings & base plate
2 Set of bearings 1 1 2 3 3 3 3
3 Set of Mechanical Seals 1 1 2 2 3 3 3
4 Set of Gaskets, O - rings 2 4 6 8 8 8 8
Lube Oil Filters
1 Filter cartridge/element along 10 20 30 30 30 30 30
with set of gaskets, O-rings

Oil Coolers
1 Set of Gaskets, O-Rings 2 4 6 8 8 8 8

ELECTRICAL
Main Motor (Fan Driver)
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
motor only)

Electric Motor for Lube Oil

Pump
1 Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2 Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
motor only)

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ATTACHMENT 1 (CONT’D)

LIST 24 - General Purpose Steam Turbine

ITEM SPARE PART Quantity Required

( BASED ON THE NUMBER OF INSTALLED ITEMS)

1 2 3 4 5 6 7 Notes
MECHANICAL 1,2,3
1 Dynamically balanced turbine 1 1 1 1 1 2 2
Rotor
2 Set of Bearings 1 1 2 3 3 3 3
3 Set of Complete Shaft Seal 1 2 3 4 4 4 4
Assembly
4 Set of all Gaskets, O-rings 2 4 6 8 8 8 8

Lube Oil Pump, Pump-

Driver, Filters & Coolers
1 Combined with driven
equipment
(Mandatory Spare Parts as
applicable for
The driven equipment shall be
followed).

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ATTACHMENT 1 (CONT’D)

LIST 25 - Special Purpose Steam Turbine

ITEM SPARE PART Quantity Required

( BASED ON THE NUMBER OF INSTALLED ITEMS)

1 2 3 4 5 6 7 Notes
MECHANICAL 1,2,3
Steam turbine
1 Complete turbine spare rotor 1 1 1 1 1 1 1
dynamically balanced (with
permanent storage container)
plates, spacers, shrouding
etc.
2 Complete set of radial 1 2 3 4 4 4 4
bearings
3 Complete set of thrust 1 2 3 4 4 4 4
bearings
4 Thrust disc (if detachable 1 1 1 1 1 1 1
type) with nut
5 Complete set of Shaft Seals 1 2 3 3 3 3 3
6 Set of all labyrinths seals for 1 2 3 3 3 3 3
complete turbine including
inter-stage
7 Set of Caulking tools & tackles 1 1 1 1 1 1 1
for labyrinth insertions
8 Complete set of Gaskets, ‘O' 2 4 6 8 8 8 8
rings

Condensate Extraction
Pump - Centrifugal (Main +
Stand By)
1. Set of bearings 1 1 2 3 3 3 3
2. Set of Mechanical Seals 1 1 2 2 3 3 3
3. Set of Impeller Wear Rings 1 1 2 3 3 3 3
4. Set of Casing Wear Rings 1 1 2 3 3 3 3
5. Set of Gaskets, O – rings 2 4 6 8 8 8 8

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Turbine Cooling Oil Pump -

Centrifugal
(Main + Stand By)
1. Set of bearings 1 1 2 3 3 3 3
2. Set of Mechanical Seals 1 1 2 2 3 3 3
3. Set of Impeller Wear Rings 1 1 2 3 3 3 3
4. Set of Casing Wear Rings 1 1 2 3 3 3 3
5. Set of Gaskets, O – rings 2 4 6 8 8 8 8

Turbine Cooling Oil Pump-

Rotary
1. Complete bare pump 1 1 1 1 1 2 2
assembly excluding driver
couplings & base plate
2. Set of bearings 1 1 2 3 3 3 3
3. Set of Mechanical Seals 1 1 2 2 3 3 3
4. Set of Gaskets, O – rings 2 4 6 8 8 8 8

Steam Turbine for

Condensate Extr. Pump
1 Dynamically balanced turbine 1 1 1 1 1 2 2
Rotor
2 Set of Bearings 1 1 2 3 3 3 3
3 Set of Complete Shaft Seal 1 2 3 4 4 4 4
Assembly
4 Set of all Gaskets, O-rings 2 4 6 8 8 8 8
Surface Condensor
1. Set of gaskets, O – rings 2 4 6 8 8 8 8
Gland Steam Condensor
1. Set of gaskets, O – rings 2 4 6 8 8 8 8
Inter-Condensor
1 Set of Gaskets, ‘O’ Rings 2 4 6 8 8 8 8
After-Condensor
1 Set of Gaskets, ‘O’ Rings 2 4 6 8 8 8 8

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Lube Oil Pump, Pump-

Driver, Filters & Coolers
1 Combined with driven
equipment (Mandatory Spare
Parts as applicable for the
driven equipment shall be
followed).

ELECTRICAL
Electric Motor for
Condensate Extr. Pump
1. Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2. Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
motor only)
Electrical Motor for Turbine
Cooling Oil Pump
1. Set of Bearings (NDE + DE) 1 1 2 3 3 3 3
2. Set of Cooling Fans (for M.V. 1 1 1 1 1 2 2
motor only)

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ATTACHMENT 1 (CONT’D)

LIST 26 - Gear Box (Special/General Purpose)

ITEM SPARE PART Quantity Required

( BASED ON THE NUMBER OF INSTALLED ITEMS)

1 2 3 4 5 6 7 Notes
MECHANICAL 1,2,3
1 Set of High Speed/Low Speed 1 1 1 1 1 1 1
Gears & Shaft Assembly
2 Set of Radial Bearings 1 2 3 4 4 4 4
3 Set of Thrust Bearings 1 2 3 4 4 4 4
4 Set of Labyrints, Oil Seals 1 2 3 4 4 4 4
5 Set of all Gaskets, O-rings 2 4 6 8 8 8 8
6 Complete bare lube oil pump 1 1 1 1 1 1 1
(if integral with gear box)

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ATTACHMENT 1 (CONT’D)

LIST 27 - DIESEL/GAS ENGINES

ITEM SPARE PART QUANTITY REQUIRED
1 Gaskets Specified by CONSULTANT
2 Inlet and exhaust valves Specified by CONSULTANT
3 Valve spring Specified by CONSULTANT
4 Valve guide Specified by CONSULTANT
5 Valve seat Specified by CONSULTANT
6 Injector nozzle Specified by CONSULTANT
7 Joint or washer for injector Specified by CONSULTANT
8 Piston rings Specified by CONSULTANT
9 Main bearing Specified by CONSULTANT
10 Connecting rod bearing (big end) Specified by CONSULTANT
11 Connecting rod bearing (small end) Specified by CONSULTANT
12 Cam shaft bearing Specified by CONSULTANT
13 Filter elements (disposable type) Specified by CONSULTANT
14 Water pump seal Specified by CONSULTANT
15 Fan belt Specified by CONSULTANT
16 Sparking plugs Specified by CONSULTANT
17 Governor Specified by CONSULTANT
18 Fan belt Specified by CONSULTANT
19 Ignition Switch Specified by CONSULTANT
20 Starter Specified by CONSULTANT

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ATTACHMENT 1 (CONT’D)

LIST 28 - ELECTRIC ASYNCHRONOUS MOTORS

ITEM SPARE PART QUANTITY REQUIRED
1 Oil seal ring (simmer ring) Specified by CONSULTANT
2 Sleeve bearings Specified by CONSULTANT
3 Sleeve bearing pads Specified by CONSULTANT
4 Humidity detection systems for CACW cooled motors Specified by CONSULTANT
6 Auxiliary heaters Specified by CONSULTANT

LIST 29 - ELECTRIC GENERATORS AND SYNCHRONOUS MOTORS

ITEM SPARE PART QUANTITY REQUIRED
1 Ball/roller bearings Specified by CONSULTANT
2 Oil seal ring (simmer ring) Specified by CONSULTANT
3 Sleeve bearings Specified by CONSULTANT
4 Sleeve bearing pads Specified by CONSULTANT
5 Generator and exciter brushes Specified by CONSULTANT
6 Brush holders Specified by CONSULTANT
7 Exciter brush holders Specified by CONSULTANT
8 Humidity detection systems for water cooled CACW machines Specified by CONSULTANT
9 Fan system/housing for aux. fan cooled machines Specified by CONSULTANT
10 Auxiliary heaters Specified by CONSULTANT
11 Field coils Specified by CONSULTANT
12 Pole insulation material for salient part of M/CS Specified by CONSULTANT
13 Rotating diodes, mounting brackets and fixing materials One Complete Set
14 AVR control PCB cards One no. each type
15 AVR (complete) for small M/CS Specified by CONSULTANT
16 Control fuses, control board Specified by CONSULTANT

LIST 30- CONVERTERS FOR ELECTRICAL VARIABLE SPEED DRIVES

ITEM SPARE PART QUANTITY REQUIRED
1 Converters One Complete Set
2 Controllers One Complete Set
3 Fuses Specified by CONSULTANT
4 Lamps Specified by CONSULTANT
5 Thyristors (power) One Complete Set

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LIST 31- HIGH AND LOW-VOLTAGE SWITCH GEAR

ITEM SPARE PART QUANTITY REQUIRED
1 Terminal blocks Specified by CONSULTANT
2 Fuse bases Specified by CONSULTANT
3 Fuses Specified by CONSULTANT
4 Auxiliary relays/contactors Specified by CONSULTANT
5 Trip coils Specified by CONSULTANT
6 Complete set of fixed and moving arcing contacts Specified by CONSULTANT
7 HV fuses for motors/transformers Specified by CONSULTANT
8 HV fuses for service transformer Specified by CONSULTANT
9 Closing coil for circuit breaker Specified by CONSULTANT
10 Contactors, to 60A incl. Specified by CONSULTANT
11 Contactors, more than 60A Specified by CONSULTANT
12 Contactor coil Specified by CONSULTANT
13 LV thermal overload relays Specified by CONSULTANT
14 Signal lamps Specified by CONSULTANT
220 KV & 66 KV GIS SWITCHGEAR
1 GIS breaker accessories, including Interrupters, Trip Specified by CONSULTANT
free mechanism, spring changing mechanism along
with its Limit switch, Breaker Contacts (as applicable).
2 GIS Busbar accessories, supports & insulators, Specified by CONSULTANT
connectors, below,
3 Breaker T-N-C Control Switches, Discrepancy Specified by CONSULTANT
Switches, etc
4 SF6 DILO type GAS cart complete with its trolleys, Specified by CONSULTANT
Compressors for filling up & refining SF6 gases,
metering panels & SF6cylinders, etc
5 Anti pumping contactors, Auxiliary relays, Guard Specified by CONSULTANT
relays, Indication lamps, etc
6 CT & PT -all types & ratings Specified by CONSULTANT
7 Meters -all types & ratings Specified by CONSULTANT
8 Transformer Differential Projection Relays Specified by CONSULTANT
9 IDMT Over current relays & Earth Fault Relays. Specified by CONSULTANT
10 IDMT Over current relays with high set of Specified by CONSULTANT
instantaneous units.
11 Pilot Wire cable differential Relays Specified by CONSULTANT
12 Distance Relays, if applicable Specified by CONSULTANT
13 Transformer Restricted Earth Fault Relays Specified by CONSULTANT
14 Standby Earth Fault Protection relays Specified by CONSULTANT
15 Control panel & protection panel accessories, Specified by CONSULTANT
including terminal blocks, isolators, Fuses, switches,
Control Transformers & its shorting terminal, Power &
control Fuse links (all types & ratings), Spare
electronic cards for Numerical relays & meters,
Illuminated mimic tiles, and annunciation / indication
lamps, etc

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ATTACHMENT 1 (CONT’D)

LIST 32 - POWER AND TELECOMMUNICATION CABLES AND ACCESSORIES

ITEM SPARE PART QUANTITY REQUIRED
1 High-voltage feeder cables Specified by CONSULTANT
2 High-voltage motor supply cables Specified by CONSULTANT
3 Low-voltage power cables Specified by CONSULTANT
4 Low-voltage and auxiliary cables Specified by CONSULTANT
5 Low-voltage lighting cables Specified by CONSULTANT
6 Main telecommunication cables Specified by CONSULTANT
7 Branch telecommunication cables Specified by CONSULTANT
8 * Components for making straight-through joints in HV cable Specified by CONSULTANT
9 * Components for making straight-through joints in LV cable Specified by CONSULTANT
10 * Components for making straight-through joints in Specified by CONSULTANT
telecommunication cables
11 * Components for making branch-off joints in Specified by CONSULTANT
telecommunication cables

Notes: 1. Comprising connectors, tapes, sleeves, joint boxes,

bitumen/resin compounds, etc.
2. For repair of damaged and faulty cables. Surplus stock of
construction materials shall be taken into account before
ordering.

LIST 33- LIGHTING FITTINGS

ITEM SPARE PART QUANTITY REQUIRED
1 Lamp fittings (complete) Specified by CONSULTANT
2 Lamps and tubes Specified by CONSULTANT
3 Starters Specified by CONSULTANT

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ATTACHMENT 1 (CONT’D)

LIST 34- INSTRUMENTS

ITEM SPARE PART QUANTITY REQUIRED
1 FIELD INSTRUMENTS
1.1 20% (Subject to min. of 2) of each type, range,
Pressure
material of construction and rating.
Gauges/Differential
pressure Gauge
(Normal/Diaphragm
type/Capillary type/Seal
type)
1.2 Draft Gauges 10% (subject to minimum of 2) of each range of
Draft gauge.
1.3 Temperature Gauges 20% (Subject to min. of 2) of each type / range of
(Normal as well as Capillary) Temperature Gauges.
1.4 Level Gauges A) For transparent gauges, 20% of illuminators with
holder and reflector and 50% of bulbs
B) In case of magnetic type level gauges, 10% of
bi-color rollers for each gauge to be provided in
addition to above.
C) 30% subject to minimum one number of glass of
each type, size along with pair of Gaskets (
Cushion & Wet Gaskets ),
D) 20% subject to minimum one number of Gaskets
for Gauge Cocks/Valves Bonnet / Packing
1.5 SMART Transmitters for Pressure, Flow 10% (subject to minimum of 1) of each type, range,
(DP), Level(DP) and Temperature make and material of construction.
1.6 3 Way manifold 10% (subject to minimum of 1) of each size and
material of construction.
1.7 Displacer Type Level Transmitters a) Displacer and chain for each transmitters-10%
(subject to minimum of 1)
b) 10% (subject to minimum of 1) of Head assembly
for each type, range and make ,
c) 20% (subject to minimum of 1) of torque tube,
pull rod, gasket spindle for mechanical zero
adjustment.
1.8 Servo Type Level Gauges A) 10% or minimum one number of each type of
electronic card.
B) 10% or minimum one number of each type of
displacer.
C) 10% or minimum one number of local indicators.
1.9 Ultrasonic / Radar instrument A) 10% or minimum one number for each type of
flow instrument & 10% or minimum one number
probe / antenna for each level instrument
B) 10 % or minimum one number of electronic card
of each type
C) 2 number fuses against each instrument

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Capacitance/RF type instruments 10% or minimum one number of each type of

1.10 electronic cards of each type.
1.11 Temperature Element: Thermocouple 20% (subject to minimum of 1) of each type, range,
length of Thermocouple with Thermo well.
1.12 RTDs 20% (subject to minimum of 1) of each length of
RTD with Thermowell.
1.13 Skin & flexible and multipoint bed 10% (subject to minimum of 1) of each length &
thermocouples type of skin Thermocouple.
1.14 Ceramic Thermowell 1 no. for each type range, length.
1.15 Temperature transmitters 10% (subject to minimum of 1) of each type, range,
make.
1.16 Variable Area Flowmeter (Rotameters) 20% or minimum one no. (Complete set) for each
type, size, rating and material.

1.17 Averaging Pitot Tube Set of Gasket, O-ring, Packing for Retract
Mechanism and one no. Needle Valve with each
Pitot Tube.
1.18 Mass Flow Meter (Coriolis and Thermal A) Power fuses 6 no. per set
) B) 10 % of Sensor Assembly or minimum 1
one.
C) 10% or minimum one number of each type
of electronic cards
D) 10 % or minimum 1 No. of Display module.
1.19 Vortex Flow Meter A)One set of gasket and Packing for each type and
Size
B) 10% or minimum one number of each type of
electronic cards
1.20 PH & conductivity Transmitter A) 10% or minimum two number of each type of
sensor
B) 10% or minimum one number of full set of
transmitter
1.20 Nucleonic Level Instrument 10% or minimum one number of each type of
cards for detector and converter.
1.21 Neutron Back scattering Level 10% or minimum one number of each type cards
Instrument for sensor and converter.
1.22 Copper tube 10% of installed quantity of each size.
1.23 SS tube 10% of installed quantity of each size
1.24 Instrument Signal Cable (single pair & 10% of installed quantity of each size
multi pair)
1.25 Thermocouple extension cable 10% of installed quantity of each type and size
1.26 Control cable 10% of installed quantity of each size
1.27 Terminal blocks 10% of installed quantity of each size
1.28 Steam Trap 10% of installed quantity of each size
1.29 I/P Converter 10% of installed quantity

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1.30 Fittings/Lugs/Nipples/ 10% of installed quantity of each type and size

Sockets/blinds/Unions
1.31 ½” Valves 10% of installed quantity of each type
(Ball, Needle, Gate,Globe)

2 IN-LINE INSTRUMENTS
2.1 Control Valves A) 10 % or minimum 1 nos of each type, size, rating
of Trim set consisting of seat, seat ring / seal ring,
plug with stem, cage (wherever applicable), packing
material.
B) 20% (subject to minimum of 2) of Positioners
(Smart) with links of each type and make.
C) 20% (subject to minimum of 2) of Diaphragm,
D) 20% (subject to minimum of 2) of Air filter
regulators of each make,
E) 10% (subject to minimum of 1) of Bonnet
Gaskets/gland packings, piston O-rings, bearing &
liner(of butter-fly valves) ( for all types of valves )
F) 10% (subject to minimum of 1) of any special
accessories provided along with the control valve
like boosters, position transmitters (wherever
applicable), proximity switches, I/P converters etc.

2.2 Shutdown Valves A) 20% (subject to minimum of 1) of Air filter

regulators,
b) Seal kit consisting of O rings, gaskets, etc.
against each valve.
c) 20% (subject to minimum of 1) of proximity
switches,
d) 20% (subject to minimum of 2) of solenoid valves
of each type,
e) 10% (subject to minimum of 1) of accessories
like quick exhaust valves and temperature
dependent fuses,

2.3 Pressure control Valve (Self actuating A) Repair kit consisting of (orifice, plug, spring,
valve) gasket, diaphragm, O-ring for each valve.
B) 20 % or minimum 2 nos of each type/size,rating
etc. of Trim set consisting of seat, seat ring / seal
ring, plug with stem, cage (wherever applicable),
packing material for each valve to be provided as
spare.

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2.4 PRDS & De-superheater unit A) 20% (subject to minimum of 2) of Positioners

(Smart) with links of each type and make.
B) 20% (subject to minimum of 2) of Diaphragm,
C) 20% (subject to minimum of 2) of Air filter
regulators of each make,
D) 10% (subject to minimum of 1) of Bonnet
Gaskets/gland packings, piston O-rings.
E) 10% (subject to minimum of 1) of any special
accessories provided along with the control valve
like boosters, position transmitters (wherever
applicable), proximity switches, I/P converters
etc.
2.5 Butterfly valves a)20% or minimum two set of actuator seal kits
b) Same as that of Control valve

2.6 Saunder’s Valves 20% or minimum two numbers of bottom body

diaphragm
20% (subject to minimum of 2) of Actuator
diaphragms of Saunder valve of each type/size
used.
3 ANALYSER (Spares for each analyser)
3.1 O2 Analyser a) Furnace Assembly – 1
b) Thermocouple –1
c) Sensor board –1
d) Each type/rating of Fuses – 1 set
e) Thermistor assembly –1
f) Ceramic filter –1
g)Processor card – 1
h)Power Supply card-1
i)Display Board-1
j)Cell Replacement kit-1
k) Any Other card – 1
L) Calibration kit (Regulator for Calibration gas
cylinder and calibration rotameter) - One set for
each of the units where O2 Analyser is installed.
3.2 Methane Analyser (Infrared ) a)Rings and gasket – 2 set of each type
b) Sensor and Detector – 1 no.
c) Rotameter – 1no.
D) Pressure Control Valve – 1no.
e)Fuses – 5 sets
f) Electronic card – 1no.
g)Other Aux. Cards – 1 each
B) Processor card and other electronic – 1no.
Each

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3.3 Moisture Analyser a) Sensor and detector –1 no.

b) Electronic card – 1 no. each type
c) Fuses – 5 sets
d) Flow indicator & switch – 1 no.

3.4 Hydrogen Analyser a)Rings and gasket – 2 set of each type

b)Sensor and Detector – 1 no. with each
analyser
c) Rotameter – 1no.
d) Pressure Control Valve – 1no.
e)Each type/rating of Fuses – 5 sets
f) Electronic card – 1no. with each analyser
g)Other Aux. Cards – 1 each

3.5 H2S Analyser a) Cadmium lamp – 2 nos.

b)Cell window – 2 nos.
c)Window gasket – 10 nos.
d) Air regulator – 1no.
e)Seal kit fro ball valve – 4nos.
f)Kit-o-ring – 2 sets
g) Seal kit, Air act. – 2no.
h)Fuse – 5 Set each
I)Relay – 1 set each
j)Display Board – 1no.with each analyser
K) Processor Board –2no.
l) Other Cards – 2each

3.6 CO + CO2 Analyser a) Fuses – 1 set of each type

b) Ring – 2 sets of each type
c) Mother board –2 nos.
d) Filter assembly band pass with guard – 2 no.
e) Filter – 1 set of each type
f) IR/UV Lamp – 2 nos.
g) Other cards – 1 each
h) Detector heaters – 1 each
3.7 Sox/Nox Analyser a) Filter of each type – 2 sets
b) Critical orifice – 1 no.
c) Vacuum pump / Ejector – 1 no.
d) Ring set – 1 no. each
e) Processor / Mother board – 2 nos.
f) Display board – 2 nos.
g) Optical bench – 1 no.
h) Filter detector – 2 nos.
i) Fuses – 1 set of each type
j) Other cards –1 each
k) Ozonaotor –1

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l) Cuvette –2 nos
m)chopper motor – 1 no.
n) Dessican & flow sensor – 1 no. each
3.8 Chromatograph a) Filter. – 2 sets
b) Display Board –1 no.
c) Processor Board –1 no.
d) Chromatograph Column
e) Solenoid valve (10% subject to minimum of 1
of each type
f) Vaporization system if required, which includes
vaporizer, thermostat, electrical tracing cable and
heater etc. – 1 set
g) Cooling system if required, which includes one
cooler, flow conditioning system etc., - 1 set.
h) Probe Filter – 2 Nos.
i)Probe Tube – 2 Nos.
J) Probe heater & Temp. sensors – 2 nos.
3.9 Sampling systems Manufacturer’s / Vendor’s recommendation need
to be followed.

3.10 SILICA ANALYSER Control module- one

Display board-10% or minimum one
Stream selector-10% or minimum one
Mixing chamber-10% or minimum one
Bulb-10% or minimum one
Pressure transmitter-10% or minimum one
SOVs-10% or minimum 1
Mirror-10% or minimum one
Stirrer motor-10% or minimum one
Cell kit and maintenance kit etc.10% or minimum
two sets.
3.11 Dissolved Oxygen Analyser a)Maintenance Kit-20% or minimum of two sets

4 DCS , PLC and SCADA These spares are in addition to 20% installed
spares
A) Modules 10% or minimum two module of each type which
are being used in DCS,PLCSER,DBM,DON,UHN
and other system oriented items like I/O cards,
all type of processor cards, all type of power
supply cards, controlle cards, communication
cards, interface cards etc. as required for the
system including in consoles ,i.e. Operator
/Engineering/PLC. This shall include spare
modules/complete item for personal computer,
PLC, Power supplies, LCD monitors/CRT, Disc
Drives etc...
10 % for items like hardwired instruments,

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barriers, signal converters, Trip amplifiers,

auxiliary modules, relays, converters,
annunciator cards, fuses, fused terminals,
lamps/LEDs, Push buttons, selector switches.
Prefabricated cables 10 Set with connecting
plugs for each type of peripherals
10 % or minimum 2 nos. of IS mV/I Converters,
IS RTD/I Converters, Alarm
cards (receiver switches)
10 % or minimum 2 nos. of RS232/485
converters ,cables
10 % or minimum 2 nos. of
Keyboard/Mouse/Track Balls
System Cabinet Air Filter 100%

10 % or minimum 2 nos. of Cabinet Cooling Fans

of each type.
20% or minimum one no. of each type of Fuses,
MCBs, Auxiliary relays.
10 % or minimum 2 Nos. of bulk power supply
unit of each rating
10 % or minimum 2 nos. of communication
system components such as hubs, switches,
routers, etc.
B) Operator/Engineering console 20% or minimum 2 numbers of latest version to
PC/Subsystem PC be supplied as spare for each control room
C) Consumables Consumable spares including
Laser printer cartridges,
Blank CD (RW),
Printer head
Inking arrangement for hard copy unit
Magnetic cartridge tape
Floppy disc
Printer Ribbon
Paper or any other consumable items supplied
along with the system required for a minimum of
6 months duration after system acceptance.
D) 10% or minimum two nos. of printers of each
type
5 OTHER ITEMS
5.1 Snubber, Syphon, Gauge Saver, etc. 10% (subject to minimum of 1) of each item
used,
5.2 Loop powered indicators 20% (subject to minimum of 2) of Loop powered
indicators used,
5.3 Solenoid Valves 20% or minimum 2 nos. of solenoid valves of
each type used.
5.4 MCT Block 10% of each type of MCT Block used.
5.5 Panel mounted instruments 10% or minimum one number of each instrument

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5.7 Flame Detector 10% subject to minimum one no. for each type
5.8 Annunciators Power Supply Module 5% subject to minimum 1
No.of each type
Tone Generator Card 5% subject minimum 1
No.of each type
Flasher Module 5% subject to minimum 1 No.of
each type
I/O Module 5% subject to minimum 1 No.of each
type
- Lamps 10%
- Fuses 1 dozen per Annunciator
Hooter –5% or minimum one
5.9 CCTV Camera - 20% (subject to minimum of 2) of each
type
Lens with zoom - 20% (subject to minimum of 2
)of each type
Receiver and drive - 20% (subject to minimum of
2 )of each type
Keypad including joystick - 20% (subject to
minimum of 2) of each type
All type of cards/modules - 20% (subject to
minimum of 2 ) of each type
6 Machine Monitoring System/Condition A) 10 % or minimum 2 nos of each type of
monitoring system probes (vibration, speed, displacement etc.) and
transducers/proximate/extension
cables/connector protective sleeves etc.
B) Electronic modules / cards : 10% or minimum
1 no. of each type,
C) portable, offline measurement kits : 1 set of
each type used
D) monitor units & LCD display unit for local
control panel : 10% or minimum 1 no. of each
type,
E) TDxNet cards : 1 set of each type used
F) One Calibration kit for vibration probes for
each unit wherever vibration probes are installed.
8 Gas detection system Sensors : 20% or minimum 2 sets of each type,
monitor units : 10% or minimum 1 no. of each
type,
Electronic cards / modules : 10% or minimum of
1 set of each type used,
9. Fire Detection and Alarm system Sensors : 20% or minimum 2 sets of each type,
monitor units : 10% or minimum 1 no. of each
type,
Electronic cards / modules: 10% or minimum of 1
set of each type used,
10 Custody Transfer metering As per vendor’s recommendation
11 Weigh Bridges/In motion weigh bridges As per vendor’s recommendation for two years of

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maintenance.
12 LPG bottling plant a)LPG Filling gonge:-10% or minimum two
number
b) Other field /control room instruments as per
the spare philosophy listed above.
c) Any special instrument as per vendor’s
recommendation.
13. Package equipment-Gas Turbine a)Control room spares in line with that of
DCS/PLC
b)Field Instruments(Transmitters/Switches,
vibration probes, SOVs, Control valves,
analysers, thermocouples etc . in line with field
instrument philosophy
c)special instruments ,As Per Vendor’s
Recommendation
14. Package equipment-Compressors a)Control room spares in line with that of
(Hydrogen/nitrogen/PSA/ Air/other ) DCS/PLC
b)Field Instruments(Transmitters/Switches,
condition monitoring, SOVs, Control valves
,analysers ,thermocouples etc . in line with field
instrument philosophy
c)special instruments ,As Per Vendor’s
Recommendation
15. All other package equipments-Air driers or a)Control room spares in line with that of
others DCS/PLC
b)Field
Instruments(Transmitters/Switches,vibration
probes,SOVs,Control
valves,analysers,thermocouples etc . in line with
field instrument philosophy
c)special instruments ,As Per Vendor’s
Recommendation

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NOTES: - Applicable to List 34.

1. Above-mentioned mandatory spares list defines the minimum requirement. CONSULTANT to
provide any additional items as recommended by manufacturer.
2. Similar philosophy shall be followed for packaged units and other items not covered in this list.
3. CONSULTANT to submit spares list for 2-year operation and maintenance. The prices shall be
valid for at least 2 years from date of order.
4. Commissioning spares are part of CONSULTANT scope of supply. Mandatory spares as indicated
above does not cover commissioning spares
5. Next rounded figure to be considered wherever % is specified. Example: For total 11 Nos.
Instruments with 10%> spares basis, 2 Nos. spares shall be provided.
6. The word 'TYPE' means the Make, Model no., Type, Range, Size/ Length, Rating, Material as
applicable.
7. The terminology used under 'Part Description' is the commonly used name of the part and may vary
from manufacturer to manufacturer.
8. For all type of analysers and gas chromatographs, calibration cylinders, carrier gas cylinders to be
supplied for one year operation after SAT.

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ATTACHMENT 1 (CONT’D)

LIST 35- SAFETY RELIEF VALVES

ITEM SPARE PART QUANTITY REQUIRED
1 Complete safety/relief valves for systems provided with Specified by CONSULTANT
locking device (without spring)
2 Nozzle, disc Specified by CONSULTANT
3 Spring Specified by CONSULTANT
4 Bellows Specified by CONSULTANT
5 Gaskets (except CA F type) Specified by CONSULTANT
6 Pilot valve assembly Specified by CONSULTANT
7 Rupture discs holder Specified by CONSULTANT
8 Rupture discs Specified by CONSULTANT

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ATTACHMENT 1 (CONT’D)

LIST 36- PIPING/VALVES

ITEM SPARE PART QUANTITY REQUIRED
(% of As Built)
1 Pipe and Fittings( ½” to 11/2”) 2
2 Pipe and Fittings( 2” to 8”) 2
3 Pipe and Fittings( 10” to 36”) 2
4 Valve and Flanges( ½” to 11/2”) 2
5 Valve and Flanges( 2” to 8”) 2
6 Valve and Flanges( 10” to 36”) 2
7 Gaskets (except compressed asbestos type) 100
8 O-rings and seals Specified by CONSULTANT
9 Seats - resilient Specified by CONSULTANT
10 Seats - metal Specified by CONSULTANT
11 Trim Specified by CONSULTANT
12 Actuator Specified by CONSULTANT
13 Steam Traps(ALL SIZES) 2
14 Expansion Bellows (ALL SIZES) 100%
Note 1. No Spare requirement for Pipe and Fittings or for valves
over 36 inch

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LIST 37- MISCELLANEOUS EQUIPMENT

ITEM SPARE PART QUANTITY REQUIRED
1 Erosion-resistant parts of various equipment Specified by CONSULTANT
2 Knife edges of weighbridges Specified by CONSULTANT
3 Oil hoses for handling products on jetties, filling stations and Specified by CONSULTANT
rail/road tankcar loading and unloading:
A. For crude oil and all finished products up to 25% Specified by CONSULTANT
aromatics content
B. For high aromatics, LPG, ethylene and chemical products Specified by CONSULTANT
4 Oil hoses for handling products offshore: Specified by CONSULTANT
A. Conventional buoy mooring Specified by CONSULTANT
B. Single buoy mooring Specified by CONSULTANT
5 Parts for loading arms Specified by CONSULTANT
6 Wire mesh for strainers Specified by CONSULTANT
7 Filter cloth Specified by CONSULTANT
8 Glasses for level indicators tubular type Specified by CONSULTANT
9 Glasses for level indicators Klinger patent type Specified by CONSULTANT
10 Fire fighting equipment Specified by CONSULTANT
11
Slide Valve (FCCU only) 1 set of seat, guide, stem, disc
& fasteners
12 Controlled volume pump for slide valve hydraulic system-
1 pump for each slide valve
hydraulic circuit

13 Filter for slide valve hydraulic system-

100%
14 Filter separator internals (replaceable)- One set for each filter separator
15 Cartridge Filter/Coalescer –
1 set of coalescing /cartridge
element

DSN 2671
 PARADIP REFINERY PROJECT
PROJECT SPECIFICATION

REQUIREMENTS FOR SPARE PARTS PDRP-8820-SP-0008

PAGE : 72 of 75
REV : F2

ATTACHMENT 2 SPIR SYSTEM WORK FLOW DIAGRAM

To provide an understanding of the proposed steps involved with spare parts
recommendation and approval (SPIR), a Workflow diagram has been
provided below. This shows the main stages involved and identifies who is
responsible (Vendor/CONSULTANT/IOCL).
The CONSULTANTs will manage the interface with the Vendors of the
equipment items within their scope of work.
Diagram Notes
1 IOCL selects an electronic format for SPIR system. A Project Management
Consultant (PMC) input will be required to ensure that an optimum system for
the size and complexity of the Paradip Project is specified and developed.
2 Electronic format SPIR system and procedures are made available to the
CONSULTANTs.
3 Vendor shall enter all spare parts descriptions with original manufacturer’s
information.
4 The CONSULTANT shall issue Purchase Orders (PO) for main equipment
including Commissioning Spares, Mandatory Spares and Special Tools. The
Purchase Order shall include a recommended Operation and Maintenance
Spares list with a validity period ex works 2 years after start up (with
escalation formula) to ensure better spare parts management. The
Equipment Purchase Order is not part of the SPIR system.
5 Details to be reviewed by CONSULTANT shall be as described in this
Specification. The CONSULTANT shall undertake interchangeability and
duplication check across all equipment items entered into the SPIR system
by all Vendors within the CONSULTANTs scope of supply.
6 Based on CONSULTANT SPIR information IOCL shall undertake an overall
interchangeability check against existing stock and between all EPC
CONSULTANTs.
Technical Approval of Mandatory Spares and Special Tools are limited to the
correct completion of the SPIR and exclude quantity approval. It should be
noted that Mandatory Spares and Special Tools will be evaluated (including
quantities) at the equipment order stage, which is prior to the population of
the SPIR.
7 Operation and Maintenance Spares require IOCL technical and purchase
approval of SPIR’s.
8 Interface requirements with the IOCL SAP system to be established.

DSN 2671
 PARADIP REFINERY PROJECT
PROJECT SPECIFICATION

REQUIREMENTS FOR SPARE PARTS PDRP-8820-SP-0008

PAGE : 73 of 75
REV : F2

TECHNICAL - SPARE PART RECOMMENDATION & APPROVAL PROCESS (SPIR) DIAGRAM

Vendor CONSULTANT IOCL - PMC

Customise the SPIR

(2)
Create SPIR electronic format for the Start
Electronically CONSULTANTS
Scope of Work (1)

Select an electronic format

Issue Equip. Purchase Orders
for the SPIR System
incl. Mandatory, Commissioning
Spares & Special Tools (4)
Enter Equipment , but excluding
Details Operation & Maintenance
Spares

Review Vendor
Submitted SPIR for all (5)
Enter Spare Part
(3) Details including
Detailed
Description & Qty Interchangeability

No Yes Review
Submit SPIR for Sufficient SPIR Submitted SPIR for
Review & Reject Acceptance & Approval
Approval ‘Approved’
(6)

No
Technically
Acceptable
Modify SPIR as Reject SPIR
Instructed
Yes
‘Approved’ (8)

Add SAP Numbers

(7)
Mandatory, Commissioning No Operation &
Spares & Special Tools Maintenance
purchased Spare Parts
With Main Equipment

Yes

Next Page

DSN 2671
 PARADIP REFINERY PROJECT
PROJECT SPECIFICATION

REQUIREMENTS FOR SPARE PARTS PDRP-8820-SP-0008

PAGE : 74 of 75
REV : F2

COMMERCIAL - SPARE PART RECOMMENDATION & APPROVAL PROCESS (SPIR) DIAGRAM

Vendor CONSULTANT IOCL/PMC

Previous Page
Yes
Procurement Authorisation
Receipt, Review and
of SPIR Form
Acknowledgement of
(Operation & Maintenance
Authorised SPIR Form
Spares)

Acknowledgement

Issue Sub-Order for Issue PO for

Spare Parts Authorised Spare Parts

Inspection of
Spare Parts by Accepted
Vendor/
CONSULTANT

Rejected

Vendor Spare Parts Spare Parts Delivery to

Rectification Site by CONSULTANT
(IOCL Warehouse)

Yes

Rejected IOCL/
No CONSULTANT
Spare Parts CONSULTANT
Rectification Spare Parts
Inspection

Accepted

CONSULTANT to Submit Invoice Approval and

Invoice for Spare Parts Payment
Payment

DSN 2671
 PARADIP REFINERY PROJECT
PROJECT SPECIFICATION ATTACHMENT 3 - TYPICAL SPIR FORM

REQUIREMENTS FOR SPARE PARTS PDRP-8820-SP-0008

PAGE : 75 of 75
REV : F2

Paradip Project - Spare Parts & Intercheangability Record Sheet

Project Document Number & Revision: Currency:
SPIR Number: Main Equipment PO: IOCL Authorisation for Operating Spares Purchase
SPIR Description: Price Validity Date: Signed: Date:
Supplier Reference Number: SPIR Discount %: Purchase Order/Reference Number:
Equipments Tag No.: Date of Submission:
Equipment Description: Supplier Contact Details (& URL): Contractor Acknowledgement of Spares Purchase Order
No. of Units: Bulk Item: Signed: Date:
Equipment Manufacturer: Comments (e.g. INCO terms etc.):
Manufacture Serial no. of Equipment:
Additional Equipment Info: Operating Spare Parts Total Price:
Model number of Equipment:

Applies to Operating Spares Only

Equipment Original Position Part per Unit Kits Required Vendor C'tractor Unit Original Part
Seq SAP Equipment Original Drawing Part Repairable Special Mandatory IOCL Final Unit Price Total Spare Part Detail Shelf Life Delivery
Spare Part Description Manufacturer Manufacturer Part no. in the (Qty. UOM to Repair Recommen Recommend Discount % Dimensions Material Hazardous Manufacturer Web Remarks
No. Number Manufacturer Manufacturer Number YES / NO Tools Qty. Spares Qty. Order Qty. Price Specification Months Time
Part No. No. drawing Installed) YES /NO dation Qty. ation Qty. Address (URL)

10

11

12

13

14

15

16

17

DSN 2671
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8820-PI-000-0002 66-6699

Vendor Documentation Procedure

Rev 01 Page 1 of 16

01 IFE Issued for Implementation 07.06.201 PVG VBJ PRD / KKS -

00 IFR Issued for Implementation 05.01.2018 PVG VBJ PRD / KKS -
Rev. Status Description Date Prepared Date Checked Date Approved AC
Category Code: - I

Barcode
© thyssenkrupp Industrial Solutions (India) Private Limited 2016
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8820-PI-000-0002 66-6699

Vendor Documentation Procedure

Rev 01 Page 2 of 16

Contents:
1. Scope ................................................................................................................................................... 3
2. Aim / purpose ....................................................................................................................................... 3
3. Abbreviations and Definitions ................................................................................................................. 3
4. Responsibilities: .................................................................................................................................... 4
5. Procedure: Preparation of Documents ..................................................................................................... 4
5.1 General ................................................................................................................................................. 4
5.2 Document identification and attributes..................................................................................................... 4
5.3 Document layout ................................................................................................................................... 4
5.4 Doc-ID code (IOCL / tkIS document identification number) ........................................................................ 5
5.5 Revision index ....................................................................................................................................... 5
5.6 Contractual language ............................................................................................................................. 6
5.7 Document formats ................................................................................................................................. 6
5.8 Document quality .................................................................................................................................. 6
6. Procedure: Handling of documents and documentation binders ................................................................ 6
6.1 Submission of documents and documentation binders ............................................................................. 6
6.2 Guidelines for documentation binders ..................................................................................................... 7
6.3 Guidelines for expediting documents ....................................................................................................... 7
6.4 Guidelines for generation of electronic files .............................................................................................. 7
6.5 Electronic submission ............................................................................................................................ 8
7. Approvals by tkIS .................................................................................................................................. 8
7.1 Category Codes ..................................................................................................................................... 8
7.2 Acceptance Codes ................................................................................................................................. 8
7.3 General ................................................................................................................................................. 9
7.4 Documentation binders as part of final inspection..................................................................................... 9
8. Structure of documentation binders ........................................................................................................ 9
8.1 Documentation structure for package units and heavy machinery ............................................................ 10
8.2 Test Certificates and inspection reports submitted as part of section C ..................................................... 10
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8820-PI-000-0002 66-6699

Vendor Documentation Procedure

Rev 01 Page 3 of 16

1. Scope
This procedure shall apply to the thyssenkrupp Industrial Solutions (India) Private Limited (tkIS-India) and
vendor, contractor (including project partners) contractually obliged to supply project material and
associated drawings, documents including complete set of final documentation for their scope of supply /
work for the following contract.
IOCL Contract Identifier : 25284124
tkIS Contract No.: 66-6699
These requirements shall be practiced for components with equipment Tag No. (thyssenkrupp Technical
Organisation Number “TON”), material with item number, components with TAG number (electrical /
instrumentation material) and completely engineered systems and equipment packages (package units).
These requirements shall not apply to piping components with an item number requiring quality certificates
below 3.1 acc. to. EN 10204 and to individually ordered bolts and nuts.

2. Aim / purpose
This procedure shall provide instructions for preparation, handling of Vendor’s document, drawings and
compiled sets of documentation to facilitate handover of documentation to customer.
This procedure shall guide vendor to follow uniform concepts in addition to the purchase order documents,
the Discipline-Specific requirements and technical information requirement indicated in the Technical
Specifications / Datasheets.
Purchase order execution shall not be deemed to be complete until after all requirements for the
documentation are satisfied.

3. Abbreviations and Definitions

Client Means recipient of a product, e.g. plant or services (Indian
Oil Corporation Limited)
tkIS / tkIS-India/ tkIS-Site thyssenkrupp Industrial Solutions (India) Private Limited and
other offices of tkIS responsible for execution of the project
wherever applicable
Vendor / Contractor Vendor/Contractor shall mean the bidder during the bidding
phase and the supplier / contractor after purchase order
award. The Vendor supplies the equipment and/or services
as specified by tkIS.
Construction Documentation (CD) The Construction Documentation shall mean latest revisions
of vendor’s documents required for construction, erection
and on-site preservation of equipment / machinery.
Final Vendor Documentation (FD) The Final Vendor Documentation shall mean latest revisions
of vendor’s all technical documents (including As-Built - i.e.
as fabricated at vendor’s works), spare parts lists, list of
special tools and other manufacturer instructions /
procedures (QA / testing plans / procedures and storage,
installation, maintenance, operation instructions etc.).
Manufacturer's Data Report (MDR) The MDR comprises the quality assurance documentation
consisting material test certificates, inspection records /
reports, as well as all other reports and certificates as
indicated in Order Specification in accordance with sections
8.2 of this document.
Doc-ID Code / Doc-ID Number IOCL / tkIS document identification number as per IOCL
requirements
Document Individual document (or Drawing) as described in purchase
order, order specifications / data sheets or any other
contractual document etc.
Documentation Documents compiled in files as per the sequence /
guidelines given and issued for specific purpose (i.e. “for
Construction”)
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8820-PI-000-0002 66-6699

Vendor Documentation Procedure

Rev 01 Page 4 of 16

Tag No. Specifically identified unique number of an Equipment or

Electrical, Instrumentation or Piping Item.

4. Responsibilities:
x Project Document Manager / Document Controller:
o Preparation of Project Documentation Structure in line with the Contract Requirement.
o Documentation (documents and files) prepared and submitted by TKIS-India / vendors /
subcontractors are identified, registered and controlled in the manner defined herein to enable
the easy identification and retrieval of documents.
o To compile documentations according to this procedure.
x Lead Engineers:
o Checking of documentation structure.
o Identification of tkIS deliverables against each file / documentation structure defined in
documentation structure
o Approval of final documentation submitted by the vendors / construction sub-contractors.

5. Procedure: Preparation of Documents

5.1 General
Documents shall follow the industry practice for preparation of technical drawings and documents based on
relevant standards.
As a rule, a separate document shall be prepared for each itemised equipment (Tag No.). The presentation
of several equipment items with different item numbers in a single document shall not be allowed.
Exceptions from this rule are flow diagrams, common arrangement drawings etc. as well as standby
machines if these are identical with the main machine (same type, construction, material, dimensions,
weight, accessories, connections etc.). For this, conformation is to be obtained from the person In-Charge
(i.e. Lead Engineer) before preparation of the drawing / document.
If one Tag and/or Item number includes more than one drawing, these additional drawing numbers /
document identification numbers shall be listed on the general arrangement drawing. Each of these
additional drawings shall contain cross-references to the general arrangement drawing.
All information submitted through Drawings / Documents shall be explicit, rule out misinterpretations and
relate to the specific application or operating conditions of the equipment supplied. The number of
documents shall be kept to a minimum, i.e. as much information as possible should be incorporated in one
document. Exceptionally long documents shall be split into logical parts / sections.

5.2 Document identification and attributes

For the unique identification of a document all documents shall be unambiguously marked by the following
information at least.
x IOCL Contract Identifier 25284124 and tkIS Contract number 66-6699,
x IOCL / tkIS Doc-ID code,
x Revision No.
In addition to the above mentioned information for the document identification all documents shall bear
x the document title,
x the vendor Name,
x the purchase order number,
x the applicable Tag / Item / Part Number and its description,
x the revision date,

5.3 Document layout

The drawings / documents shall be prepared using tkIS supplied templates. Vendors shall adopt the native
files of the drawing / document templates to the Engineering tool being used for execution. Vendors can
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8820-PI-000-0002 66-6699

Vendor Documentation Procedure

Rev 01 Page 5 of 16

use their own title block in addition to the tkIS title block. However to avoid any inconsistency, revision index
must be single (Common).
The information for the documents identification and the corresponding attributes as listed in chapter 5.2
shall be mentioned at the specified location in the drawing title-block or on the cover page of the document.
Alternatively the information listed in chapter 5.2 shall be incorporated with contract-specific mark-up on
the first page of the standard document / manual / brochures or typical drawings clearly indicating the exact
applicable type / model and/or relevant dimensions.

5.4 Doc-ID code (IOCL / tkIS document identification number)

All documents to be submitted shall be marked by a defined Doc-ID code pre-determined and given by
tkIS. The structure of the Doc-ID shall be as given below;

Vendor Doucment Numbering

25284124 - BBBB - VE - DDD - FFFF - XXX

Contract Identifier Subsequence No. for individual documents

Discipline Identifier For equipment tagged items or for PO
Document / Drawing Type
Plant / Unit Number
Sequential Number (For particular equipment tagged Item)
In case of Electrical, Instrumentation and Bulk items for a PO.

Note : Discipline Identifier and Plant / Unit Number shall be identified to the Technical Specification number.
Document / Drawing Type must be VE.

The vendor shall submit the “Master Document Index” (list of deliverables) for each of the ordered Tag /
Item No. to tkIS, immediately after the equipment / item is ordered with the letter-of-intent / purchase order.
tkIS shall review this list and inform vendor the vendor document series for each Tag / Item No. indicating
the IOCL / tkIS Doc-IDs for the documents listed in Master Document Index. For any new / additional
documents vendor shall allocate subsequent incremental sub-serial numbers and update the Master
Document Index. Vendor shall indicate the tkIS Doc-ID on all drawings / documents submitted to tkIS. tkIS
may reject the drawings / documents submission if the formal aspects are not fulfilled according to this
instruction. This Master Document Index shall be submitted by vendor to tkIS along with the monthly status
reports.

5.5 Revision index

The revision index shall also be indicated on each document. The level of progress shall be indicated
unambiguously by the revision index on the title block. The first issue of a document shall also indicate the
revision index appropriately.
The content of the modification/purpose shall be briefly stated in the revision column. For example the
following descriptions shall be used:
Rev. 00 - First issue
Rev. 01 - tkIS’s comments / remarks incorporated
Rev. 02 - Renewed submission for comment / approval)
The terms “last revision” or “total revision” shall not be used.
Each document modification and distribution, whether internal for vendor or for external distribution to tkIS,
shall increase the revision index by one counter.
All revisions of the Vendor documents shall have passed the Vendor's internal review and approval
procedure. The date of review and approval shall be indicated on the document. With this vendor confirms
that the documents have been checked for conformance with the requirements of the purchase order
documents.
Each revised drawing / document shall be prepared, checked, approved and distributed like the first issue
of the document. Each document revision shall be submitted to tkIS only once. While re-submission of the
revised documents all triangles and clouds relating to the previous revision shall be removed. In the case of
revision, the complete document affected by the revision shall be resubmitted as one pdf document. The
submission of part document with specific revised content individually shall not be allowed.
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8820-PI-000-0002 66-6699

Vendor Documentation Procedure

Rev 01 Page 6 of 16

All modifications, contained in the latest revision as compared to the previous one, shall be clearly marked
in the document. (The revision index shall be indicated in a triangle following the modification.) Modified
parts of a drawing shall be marked by enclosing them in “clouds” with revision index triangle. Any
intermediate revisions not submitted to tkIS shall also be submitted for information along with the latest
revision. This is to enable tkIS to track changes happened during intermediate revisions. However review of
the revised documents shall be limited to the marked revisions and tkIS shall provide
approval/comments/receipt-confirmation only on the last revision submitted.
As-Built documents shall not show any revision triangles and clouds and shall be indicated as “As-Built” in
the revision index. As-Built Drawings / documents shall be submitted as part of Final Documentation.

5.6 Contractual language

All documents to be submitted shall be prepared in English language. Contract specific requirements if any
for translated / bi-lingual documents (i.e. operating and service instructions in local / bi-lingual language)
shall be defined in Attachment 01 “Contract-specific requirements”.

5.7 Document formats

The sheet sizes of drawings and documents shall correspond to ISO standards generally followed as per
the industry practice. The contractual sheet sizes are listed in Attachment 01 “Contract-specific
requirements”.
Text documents shall generally be prepared in theA4 format. Documents, consisting of several pages shall
exclusively include the A4 and/or A3 formats with cover page). Page number and total number of pages
shall generally be shown on each page of vendor’s documents. As general rule, information on the back
side of the document shall not be allowed. Exceptions shall be limited only for standard printed product
catalogues, printed manuals or large calculations or voluminous data from a software tool.
All documents greater than A4 shall be folded to A4 so that the title block shall be visible on top. The
location of the title block is given in the templates.
All documents, except the reduced sizes of documents which are implemented in the operation- and
maintenance instruction, have to be delivered in the original format.
By using colours in documents the substance of information shall not be lost in black and white copies.

5.8 Document quality

Copies of drawings and documents shall be made on white paper on good quality commercially available
paper of having minimum thickness of at-least 70g/m2 (gsm).
All documents shall have a 2 cm free margin and 4-hole punching. The 4-hole-punched paper of
documents greater than A3 shall either be fitted with hole reinforcements / adhesive reinforcing strips or
shall be submitted in transparent pouches.

6. Procedure: Handling of documents and documentation binders

6.1 Submission of documents and documentation binders

The scope of the documents to be submitted shall be as specified in the “Summary of Engineering
Documents” / “Document Request Form” attached to the technical specification of the purchase order. The
minimum number of documentation is indicated in Attachment 02 “Number of copies”. Each Equipment
Tag of a purchase order requires an independent documentation (per Tag at least one binder). Exceptions
shall be advised during Engineering Phase by tkIS.
The vendor shall submit the documents to tkIS at the dates indicated in the said annexure “Summary of
Engineering Documents“ / “Document Request Form” to ensure further engineering and proper review
and/or forwarding.
Documents and documentation binders shall be submitted with an accompanying transmittal as per sample
format attached as Attachment 05, which shall contain:
x IOCL Contract Identifier 25284124 and tkIS Contract number 66-6699, Transmittal-ID
x tkIS Doc-ID Code, Revision No., Document title of the attached documents / documentation
binders
x The category Code (i.e. purpose of transmission “for Approval”, “for Review” “for
information/action”… etc.)
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8820-PI-000-0002 66-6699

Vendor Documentation Procedure

Rev 01 Page 7 of 16

x In the case of the submission of documentation binders, the purpose of the binders. e.g.
“for construction” or “final documentation” etc.
For hard-copy submission wherever necessary a transmittal shall be prepared for documents to be sent to
tkIS clearly indicating IOCL FOA/LOI/PO, Tag No., IOCL/tkIS Document ID, Revision and document
description. Transmittal soft copy (pdf) shall be sent to tkIS by e-mail to tkIS-Task Force e-mail-ID as an
intimation of hard-copy document submittal. 1
In case of e-mail communication through authorized e-mail-ID of the vendor / contractor the e-mail size
(Total data size for drawings, documents, transmittals and any other attachments like native files etc. for
one submission) does not exceed 5 MB.
Each e-mail should contain files related to one transmittal only with transmittal number indicated in subject
of the e-mail. Separate e-mails shall be sent for separate transmittals.

6.2 Guidelines for documentation binders

In order to ensure a uniform appearance of the documentation binders, the vendor shall use binders as
specified in Attachment A01 “Contract-specific requirements”. The binders shall only be filled to a
maximum level of 90 % to leave space for revisions or amendments.
For the delivery of the documentation binders, the binders shall be placed into parcels in suitable position
and sent via courier service to the delivery address of the documentation as indicated in Attachment 01
“Contract-specific requirements”.
The vendor shall submit the first edition of the documentation binders (one set draft or master file) of the
construction/final documentation binders including index to tkIS for approval through transmittal listing the
Table of Contents.
After the review of the construction/final documentation binders, tkIS shall provide approval/review
comments, the Table of Contents and the spine labels for each approved/commented binder back to the
vendor also through transmittal listing the Table of Contents.
Only after tkIS’s approval the required number of binders shall be submitted by vendor in line with the
Table of Contents (documentation grouping and sequence) and considering tkIS approval/review
comments. Direct submission of final copies without approval from tkIS will not be accepted and the vendor
will have to submit all required number of binders again after incorporating the changes given by tkIS.

6.3 Guidelines for expediting documents

Expediting documents shall be submitted as specified and must be clearly identified. Material delivery
schedules, fabrication and construction time schedules shall be submitted not later than on the date of the
first drawing submittal for review. Updated versions shall thereafter be submitted monthly without specific
request by tkIS. The expediting document shall show all schedule-critical materials and the critical path,
regardless of whether they have been ordered or not. Moreover, the material delivery schedules of
subcontractors or manufacturers of key equipment shall be shown. The expediting documents shall show
the scheduled completion dates as indicated in the original time schedule and the actual status together
with the updated time schedule. Expediting documents are for tkIS’s information only.

6.4 Guidelines for generation of electronic files

In case documents are exchanged via e-mail or a collaboration tool, vendor shall submit only soft copies in
PDF file format to tkIS. Vendor shall ensure that PDF files shall not be encrypted or password protected to
allow access, modification and management.
Native Files shall be submitted only along with Final / As-Built Documentation if required. Native files
submission during the engineering phase for approval if any shall be as per the specific instructions of the
technical responsible Lead Engineer.
Separate pdf files shall be submitted for each individual documents identified with one Doc-ID Code.
Multiple drawings / documents with several Doc-IDs merged to one single pdf file shall not be accepted. All
drawings / documents greater than A3 shall have individual single page pdf files with individual Doc-IDs. A4
and A3 size documents can be multi-page pdf files.
The orientation of pdf files shall be in reading orientation for all sizes irrespective of the size of document
and number of pages.
Name of the pdf file shall be:
Doc-ID Code_000_Rev.pdf
For Example: 25284124-EQS-016-DZ-0003-005_000_04.pdf
Following restrictions shall be taken into account naming of pdf files for electronic transfers.
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8820-PI-000-0002 66-6699

Vendor Documentation Procedure

Rev 01 Page 8 of 16

x Length of file name must not exceed 128 characters. The whole length of path name and
file name together must not exceed 200 characters.
x Blanks are not allowed (use underscore “_“ instead of blank to separate parts of the file
name)
x Special characters (e.g. / , \ , : , * , ? , “ , < , > , !) and umlauts are not allowed

6.5 Electronic submission

Transmittal as well as drawings / documents shall be submitted electronically. The transmittal format is as
indicated in Attachment 05. Vendors to submit the drawings / documents in pdf format during Engineering
Approval Phase. Native format files and hard-copy prints shall be submitted on specific request to IOCL /
tkIS for reference and review. Transmittal to be submitted in pdf as well as native format file (MS-Word, MS-
Excel).
Vendors / Contractors shall submit the documents through tkIS document exchange / collaboration 1
platform “Workspace”. Access to tkIS workspace shall be provided to vendor / contractor representative
(document controller) on receipt of LOI / FOA copy.
Date of receipt of document will be considered only when tkIS can open and view the documents properly.
If tkIS can't open or view the documents submission will be treated as invalid / void /rejected.
All files submitted on CD / DVD or other data carrier as part of Final / As-Built Documentation must be
accompanied by a table of contents and native files. Structure description for native files shall also be
provided as applicable (Description of layer allocation, pin allocation, list of fonts applied). The files shall be
named according the file naming convention explained in this procedure (refer to chapter 6.4).

7. Approvals by tkIS
tkIS shall review the documents to be submitted by vendor with respect to the requirements specified in the
purchase order / technical specifications. tkIS will provide review comments and return the document with
acceptance code. The acceptance code will be clearly marked on the in-built CC-AC Code Block or
Electronic stamp on the drawings / document. (In case of Physical documents the documents will be
Rubber Stamped, clearly indicating the Acceptance Code).
tkIS shall check/comment the documents within a period of ten (10) working days after receipt. Vendor shall
consider this review period in his manufacturing schedule.
Once the commented Documents are received by vendor, Vendor will submit the revised Drawings/
Documents with next revision within a period of ten (10) working days.

7.1 Category Codes

Category Codes are the codes followed to indicate the Document Submission Requirements or the
Document Status. Following are the Category Codes;
1 for Approval
2 for Review / Comments
3 for Information
4 for Engineering
5 for Enquiry
6 for Order Placement
7 Final & Approved
8 Released for Construction

7.2 Acceptance Codes

Acceptance Codes are the codes followed to indicate the Document Approval Status confirmed by the
Approving Authority. Following are the Acceptance Codes;
1 Approved
2 Approved for Manufacturing / Fabrication with comments as marked
3 Not Approved / Resubmit
4 Retained for Information / Records
5 Reviewed
6 Reviewed as noted

Note: The Category Codes and Acceptance Codes will be abbreviated in the transmittal.
 Plant Client Contract Code Document ID tkIS Contract No.
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Vendor Documentation Procedure

Rev 01 Page 9 of 16

7.3 General
Approval or review of the vendor’s drawings and documents, shall not relieve the vendor of his
responsibility for the correctness of drawings and documents.
If the vendor starts the fabrication without approved drawings/documents by tkIS he has the full
responsibility without releasing him from any obligations e.g. modification or repetition of the work in a later
stage after receiving the approval of tkIS. Cost related to consequences due to the start of fabrication
without approved documents/drawings shall be borne by the vendor.
If within the period agreed no remark / approval shall be received by the vendor, he shall contact tkIS
accordingly in written form.
On the basis of all comments the vendor shall revise the drawings / documents returned to him and
resubmit them within the deadline indicated in the purchase order specification. This does not apply to
drawings / documents already finally approved.

7.4 Documentation binders as part of final inspection

Final documentation binders are part of successful final inspection by tkIS / IOCL.
A waiver of inspection with regard to equipment does not include a waiver of inspection of the related
documentation.
No purchase order shall be considered completed until data and documents/documentation required by the
purchase order have been received by tkIS.

8. Structure of documentation binders

The documentation binders shall be structured in sections A, B and C as described in the following table
(CON = Construction Documentation / FIN = Final Documentation, also refer to Attachment A04 “Structure
of the vendor’s documentation”.)

Section A, Design documents

Group Examples for the documents which are part of the Part of
No. defined group no. Documentation
01 Block diagrams, flow diagrams, piping and CON FIN
instrumentation diagrams (PIDs), process flow diagrams
(PFDs), overview diagrams (as applicable)

02 Foundation data, fixing plate details, anchoring data, CON FIN

mounting details (as applicable)

03 Overall arrangement diagrams, general arrangement CON FIN

drawings, overall layout, plot plan etc. (as applicable)

04 Detailed drawings, part lists, detailed assembly drawings, CON FIN

sectional views, calculations (as applicable)

05 Fabrication instructions / procedures, welding instructions, CON FIN

heat treatment instructions and other fabrication
instructions (as applicable)

06 Packing / transportation, storage and preservation CON FIN

instructions (as applicable)

07 Electrical and instrumentation documents, switching and CON FIN

control diagrams, interlocking diagrams, wiring / circuit
and terminal diagram, hook-ups (as applicable)

08 Special documents / product catalogues, catalogues of CON FIN

installed single components, hydraulic diagrams (as
applicable)
 Plant Client Contract Code Document ID tkIS Contract No.
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Section B, Operating and maintenance instructions

Group Current Group Description Part of
No. Documentation
09 Installation and erection instructions, sequence of CON FIN
assembly and erection, installation drawings

10 Operating and maintenance instructions or user manuals - FIN

incl. recommended spare parts and lubricants
12 Spare Parts List (unpriced) - FIN

13 List of Lubricants / Feedstocks - FIN

Section C, Fabrication verification and inspection documents

Group Current Group Description Part of
No. Documentation
11 Test certificates and inspection reports, fabrication and - FIN
inspection documents manufacturer’s declaration,
declaration of conformity, evidence of origin, test reports
and material test certificates, tkIS non-conformance report

8.1 Documentation structure for package units and heavy machinery

Package units are understood to mean independent and operative plant sections consisting of several
components. As a rule, the PU are designed, manufactured, erected and commissioned as complete units
by the manufacturer.
If advised by the responsible lead engineer, documentation structure for these units shall be as follows:
1.) All general documents of a package unit (e.g. PIDs of the unit, user instructions of the unit,
instrumentation, bulk material, equipment without TON number, etc.) shall be sorted according to the
following sections:
- Section A, Design documents
- Section B, Operating and maintenance instructions
- Section C, Fabrication verification and inspection documents

2.) The documentation for the individual equipment items within the package unit shall be sorted
accordingly as substructure within the package unit documentation or as advised by the responsible
Lead Engineer.

8.2 Test Certificates and inspection reports submitted as part of section C

Fabrication verification and inspection documents shall be submitted with a cover sheet and a table of
contents including page numbers for a completeness check.
Examples for inspection documents applicable according to Code of Process Vessels and Heat Exchangers
belonging to one TON are given below:
x Inspection release note
x Approved QAP / approved-signed test procedures
x Weld plan and WPS/PQR
x Factory acceptance test reports / certificates
x Manufacturer’s test certificate, guarantee certificate, certificate of compliance and
performance test reports, declaration of conformity etc.
x Statutory / authority approval documents / third party approval records
x Material certificates & material heat charts
x Material traceability lists
x Inspection reports
x Dimensional check records
Plant Client Contract Code Document ID tkIS Contract No.
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x UT-test reports
x MP-test reports
x PT-test reports
x X-ray-test reports
x Hydrostatic test reports
x Air test reports
x Record of production test plates
x Records of tube to tubesheet examination
x NDT drawings / logs
x Welds map indicating welders qualification
x Heat treatment diagrams
x Results of corrosion tests
x Evidence of origin
x tkIS non-conformance report
x tkIS quality certificate

Files containing documents with original notified body-sign / stamps (i.e. IBR / CCOE etc.) shall be marked
“Original” and to be hand-delivered to tkIS project manager / inspection Lead-Engineer.

***
Plant Client Contract Code Document ID tkIS Contract No.
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Attachment 01: Contract Specific Requirements

Shipping address
thyssenkrupp Industrial Solutions (India) thyssenkrupp Industrial Solutions (India) Private Limited
Private Limited (tkIS-India) IOCL BS-VI PDR Taskforce
Attn. Mr. Kaushal Srivastava - Project Manager
Uhde House, L.B. Shastri Marg,
Mumbai - 400083
India.

e-mail
To : [email protected]
CC : [email protected]
tkIS-India site office (if applicable) Site Office address to be updated in due course

Admissible sheet sizes:

A0 landscape format / separate Doc-ID required per sheet (Exceptional case only)
A1 landscape format / separate Doc-ID required per sheet
A2 landscape format / separate Doc-ID required per sheet
A3 landscape format
A4 portrait / landscape format
For drawing formats larger than A2, a minimum character height of 2.5 mm shall be used.

Contractual language of documentation:

English

Operating manual language:

Contract language (English)

Symbols / units of measurement:

Metric units

Types of lever arch files to be used for the documentation:

Black colour File (Folder/Binder), made from plastic or Cardboard laminated with polypropylene
film, 4-ring lever arch file (double DIN A5 Cross-wise storage), with edge protection and grip
holes (locking eyelets), 70 mm wide (back width), with transparent plastic spine pocket for
insertion of interchangeable labels.

Dividers:
Paper weight @ 160g/m²
Dimensions 240mm * 105mm
Colour white
 Plant Client Contract Code Document ID tkIS Contract No.
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Rev 01 Page 13 of 16

Attachment 02: Number of copies

During engineering approval the drawings / documents shall be submitted via e-mail to the taskforce e-
mail-ID or through the collaboration tool. In addition, hard-copies (paper prints) shall be submitted
according the Construction and Final Documentation requirement given below.

Minimum number of paper copies of documentation files:

Documentation Type Number of Sets

draft Construction Documentation (for approval) Electronic Submission

(pdf and native format files)
Construction Documentation (after approval to tkIS-Site-Office) 3 Sets

draft Final Documentation (for approval) Electronic Submission

(pdf and native format files)
Final Documentation (after approval to tkIS-Site-Office) 3 Sets + 1 CD/DVD +
1 CD/DVD to tkIS Mumbai office
 Plant Client Contract Code Document ID tkIS Contract No.
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Attachment 03: Instructions for submission of drawings / documents electronically to tkIS

o Vendor shall submit only soft copies (pdf) to tkIS for review through tkIS document exchange / collaboration
platform “Workspace”. Vendors to submit hard copy prints on specific instructions from tkIS / IOCL during
engineering approval. Vendors shall be advised regarding submission hard-copy prints of Final / As-Built
Documentation in due course.
o Vendor shall prepare pdf file directly from the engineering tool/application or native file. In exceptional cases
scanned pdf files shall be accepted. Care shall be taken that PDF documents shall be in PDF/A-format, as
described in ISO 19005, this means especially:
a) No passwords or digital rights management encrypting or protecting the PDF
b) All necessary fonts are embedded
c) No attachments inside the PDF-document 1
d) Do not upload any attachments inside a PDF, but always as separate files.
o The file size of an individual document shall not exceed 20 MB or single pdf document shall not contain more
than 400 pages.
o Vendor / Contractor shall provide details of authorised person/s for document exchange through collaboration
platform Workspace or for official communication through e-mail during Kick-off-meeting.
o Vendor / Contractor to maintain the Original signed copy as master copy and to be offered for verification for
tkIS’s / Third party Approval Agency’s inspector upon request / during audit.
o Name of the pdf file shall be: Document-ID_Part_Rev.pdf
For example 25284124-8430-016-VE-0001-001_000_00.pdf.
tkIS shall inform the vendor document series sequence to be followed for each itemised equipment or for
Electrical, Instrumentation and Piping items for unique FOA/LOI/PO.
Following restrictions shall be taken into account to avoid problems while transfer of documents through e-mail /
ftp server.
x Length of file name must not exceed 128 characters. The whole length of path name and file name
together must not exceed 200 characters.
x Blanks are not allowed (use underscore “_“ instead of blank to separate parts of names)
x Special characters (e.g. / , \ , : , * , ? , “ , < , > , !) and umlauts are not allowed
o Date of receipt of document shall be considered only when tkIS can open and view the documents and
transmittal properly. If tkIS can't open or view the documents submission will be treated as invalid / void.
Vendor shall ensure that pdf files are not encrypted or protected.
o After reviewing document tkIS shall return approved/commented documents review through tkIS document
exchange / collaboration platform “Workspace”. Once the commented documents are received by vendor,
vendor will submit the revised documents with next revision within a period of ten (10) working days. As far
as possible vendor shall not change the position of details in the drawing / document in next revision.
o In-case documents are not received back with approval / comments within 2 weeks of submission to tkIS,
vendor to send expediting/follow-up mail to tkIS Taskforce e-mail-ID
o Vendor shall maintain document index with tkIS Doc. ID-Code which should also indicate date of submission
& date of return. The same shall be sent for tkIS information on monthly interval.

***
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8820-PI-000-0002 66-6699

Vendor Documentation Procedure

Rev 01 Page 15 of 16

Attachment 04: Structure of documentation binder

 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8820-PI-000-0002 66-6699

Vendor Documentation Procedure

Rev 01 Page 16 of 16

Attachment 05 : Transmittal Format

***
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CONTENTS

1. INTRODUCTION ....................................................................................................................... 3
2. SCOPE ...................................................................................................................................... 3
2.1 HSE and Ergonomic Issues ................................................................................................ 3
2.2 References ......................................................................................................................... 4
3. HEALTH .................................................................................................................................... 5
3.1 Substances Hazardous to Health........................................................................................ 5
3.2 Restrictions on Substances ................................................................................................ 6
3.3 Ergonomics......................................................................................................................... 6
3.4 Control Systems Interface & Alarm System Design .......................................................... 10
3.5 Working Environment Factors .......................................................................................... 10
3.6 Occupational Health ......................................................................................................... 10
4. SAFETY................................................................................................................................... 11
4.1 HAZOP Studies ................................................................................................................ 11
4.2 SIL Reviews ...................................................................................................................... 11
4.3 Review of Layout Drawings .............................................................................................. 11
4.4 Electrical Area Classification ............................................................................................. 12
4.5 Provision of Safety Records.............................................................................................. 12
5. ENVIRONMENTAL .................................................................................................................. 12
5.1 Polychlorinated Biphenyls (PCBs)..................................................................................... 12
5.2 Chlorofluorocarbons (CFCs) and Halons .......................................................................... 12
5.3 Noise ................................................................................................................................ 12
5.4 Lighting ............................................................................................................................. 13
5.5 Life Cycle Duty of Care ..................................................................................................... 13
5.6 Source Emission and Ambient Air Quality Standards ....................................................... 13
ATTACHMENT 1 - ANTHROPOMETRIC DATA ............................................................................. 14
ATTACHMENT 2 - HUMAN FACTORS CONSIDERATIONS FOR VALVE LAYOUTS ................... 17
ATTACHMENT 3 - PREFERENCES FOR CONTROLS, DISPLAYS AND SIGNS .......................... 18

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1. INTRODUCTION

This document is intended to ensure consistency in Vendor supply of Health, Safety

and Environmental (HSE) information.

It is not a comprehensive representation of requirements but it represents the IOCL

standards, which should be regarded as a minimum to comply with.

Vendors and Contractors of equipment shall adhere to the guidelines contained

within this document to meet Project operational, HSE and Ergonomic requirements
for their scope of supply. In all cases reference to IOCL and relevant Indian
Standards shall be made to ensure complete compliance with their requirements.
This document is equally applied to supplies made through Supply and Erect
Contractors, in which case ‘Contractor’ shall be read for ‘Vendor’.

All obligations hereafter are to be construed as be Vendor or Contractor unless

otherwise specifically stated.

This document is based upon the FEED document 3210-8560-SP-0004, Health,

Safety, Security and Environmental Design Requirements for Vendors and
Subcontractors.

2. SCOPE

2.1 HSE and Ergonomic Issues

This document addresses the following key HSE and ergonomic issues relevant to
the supply of equipment:

Loss Prevention to be addressed.

Provision of data on hazardous substances.

Restrictions on materials included in the supply.

Ergonomic aspects, which shall be addressed.

Environmental aspects, which shall be addressed.

Provision of Safety Records.

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2.2 References

Reference should be made to the following documents:

Document Name Document Number

1. Engineering Standards and PDRP-8820-IN-0001

Specification Index

2. International Codes and Standards PDRP-8820-IN-0002

Index

3. Indian Codes and Standards Index PDRP-8820-IN-0003

4. Basic Engineering Design Data PDRP-8820-SP-0001

5. HAZOP Review Procedure PDRP4200-8150-PR-1004

6. SIL Review Procedure PDRP4200-8150-PR-1005

7. Environmental Design Basis PDRP4200-8150-PH-1002

8. Lighting and Small Power PDRP-8531-SP-0011

Specification

9. Ergonomics requirements for BS EN ISO 9241

office work with visual display terminals

10. EEMUA 191 Alarm Systems – A EEMUA Publication 191, 1999.

guide to Design, Management and
Procurement

11. EEMUA 201 Process Plant Control EEMUA Publication No. 201: 2002
Desks Utilising Human-Computer
Interfaces, A Guide to Design, Operational
and Human Interface Issues

12. “Extra-ordinary" Ergonomics. How ISBN 0-8493-3668-6. 2005

to accommodate small and big persons,
the disabled and elderly, expectant
mothers and children. Karl HE Kroemer.

13. Human Factors principles in the ISO 6385

design of work systems

14. Body Space: Anthropometry, ISBN 0-85066-352-0

Ergonomics and Design. Stephen

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Document Name Document Number

Pheasant.

15. Hazardous Chemicals and their OISD-STD-114

handling

16. Classification of Area for electrical OISD-STD-113

installations at Hydrocarbon processing
and handling facilities

17. Classification of Hazardous Areas IS 5572 (1994)

18. The Institute of Petroleum Area

Classification Code Part 15

19. The Institute of Petroleum

Electrical Safety Code – Model Code of
Safe Electrical Practice Part 1

20. Human Factors Specification PDRP4200-8150-SP-1002

3. HEALTH

3.1 Substances Hazardous to Health

Suppliers of equipment shall provide a list of all substances that may be hazardous to
health, which are being provided as part of the equipment or materials supply.

The Supplier is required to provide copies of each Material Safety Data Sheet
(MSDS), with full information about any substances supplied as part of the order
which could be harmful to a person during transporting, storing, installing or using in
connection with their work. These MSDSs shall contain full details of the hazardous
substance, specify the precautions that must be taken for the safe use of the
substance and the first aid and medical advice needed in case of an accident. The
format of the MSDS shall be in accordance with OISD-STD-114 (reference 15).

All containers must be properly labelled and handled according to the recommended
practices of the MSDS.

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3.2 Restrictions on Substances

The use of certain specified substances is restricted on this project as outlined below:

3.2.1 Asbestos

Asbestos or products containing asbestos shall not be used on this Project.

3.2.2 Polychlorinated Biphenyls (PCBs)

See Paragraph 5.1 of this document.

3.3 Ergonomics

Minimum ergonomic requirements for the project are contained within this Project
Specification. These requirements are extracted from the Human Factors
Specification, PDRP4200-8150-SP-1002.

3.3.1 Anthropometrics

In order to meet accessibility requirements, all work areas and workspaces within the
Paradip facility will accommodate 5th to 95th percentile Indian adult anthropometric
data – as illustrated in Attachment 1. The application of anthropometry shall also be
used in the design of all walkways, ladders, control desks, and all other key human
machine interaction (HMI) points.

3.3.2 Access and Space Requirements

In addition to applying the above anthropometric requirements, key requirements

relevant to Paradip Refinery include the following:

Sufficient space around pumps, valves, control panels, instruments and other
machinery parts, including flanges, to allow the use of tools of the correct
dimensions required for the specific part.

Sufficient space for a temporary laydown area for parts during maintenance.

Where hoists, cranes, fork-lifts and other lifting equipment may be required to
move plant items, sufficient spatial volume shall be allowed around the machinery
for the lifting equipment to be positioned and operated correctly and safely.
Sufficient space shall also be allowed for any transport required for the removal of
the equipment to the workshop/stores etc.

Main walkways and escape routes shall allow for the safe passage of people
wearing personal protective equipment.

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Main and/or regularly used operation and maintenance routes, walkways and
platforms, shall be accessible by stairs (not ladders).

3.3.3 Positional requirements

The following positional requirements for the plot areas include:

Plant items and equipment which require regular/frequent attention shall be

positioned at optimum height and reach for the user e.g. operations,
maintenance, inspection and test.

The position and arrangement of valves, pumps, other equipment parts, including
flanges, controls and instrumentation shall allow for easy access (e.g. close to
main walkway) and sufficient space for the various users of the equipment (e.g.
operations, maintenance, inspection and test) to perform their duties.

Manually operated valves shall be positioned at optimum height and reach for
operation and maintenance.

Instrument displays, gauge glasses and viewing ports shall be located, wherever
possible, at eye level for the user, while at the normal viewing position.

Instruments shall be positioned at suitable height and reach for ease of

maintenance and calibration, without compromising operational requirements.G

Sampling positions shall be set at ground level, wherever possible, and at the
optimal height for the operator (normally between elbow and shoulder level – see
Attachment 1).

Lubrication and seal buffer systems shall not obscure the space required for
operation, maintenance, inspection, testing etc. of other plant items. Greasing
points shall be easily accessible from platforms/fixed ladders. G

3.3.4 Packaged Units

The following guidelines shall be followed for the layout of packages and skid
mounted equipment:

Items requiring regular maintenance, as far as possible, shall be located on the

outside of the skid.

Items which require regular/frequent operator attention shall be positioned at an

optimal height and reach, for ease of operation and maintenance.

All instrument displays, gauges etc. shall be positioned at the normal eye level of
the operator, presented in a logical sequence and easily readable from an easily
accessible location.

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Displays should be protected from direct sunlight/glare and be suitably

illuminated, where required.

Junction boxes shall be easily accessible and be located such that terminal points
are at least 875 mm (i.e. 5th percentile elbow height) above the base-plate of the
skid. All cables shall enter the junction boxes from the underside.

Conduits, cable trays, drip trays etc. shall be arranged so as not to obstruct the
access to valves, pumps, motors and other equipment items.

Small bore piping and cabling shall not be vulnerable to damage or impede
operational or maintenance activities.

3.3.5 Pump Configurations

The guidelines given in Positional requirements, Section 3.3.3 and Packaged Units,
Section 3.3.4 shall be followed.

3.3.6 Access to Pit Equipment

It will be necessary for some equipment, such as drainage systems, to be positioned

within pits. Sufficient space should be provided within the pits to enable safe and
efficient access and working space.

The size and depth of the pit required will be determined by the requirements of the
specific equipment, and the need to provide an access margin around the equipment.

Access to the pit should be by stairs rather than a ladder. There should be two sets
of stairs on opposite sides of the pit.

3.3.7 Design of Physical Interfaces

The physical design of all valves, piping and packaged units shall ensure that all
equipment requiring human interaction is accessible and usable.

In addition, anthropometric data shall be considered in the design of Human Machine

Interfaces (HMI) (see Attachment 1 and 2 for anthropometric data which shall be
utilised to ensure that valves, pumps, machinery parts, flanges, workstations, work
benches, work spaces, etc., as well as instrumentation and controls are set at the
optimal height and within easy reach for the user).

The strength capabilities of individuals shall also be taken into account through
consideration of the forces required to operate valves and perform manual handling
tasks.

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3.3.8 Controls, Displays, Labels and Signs

The design shall consider the ergonomic requirements for usable controls, displays
and labels, etc. The design shall be compatible with all relevant IOCL standards and
guidance on control displays, labelling and signage. Generic specifications are
provided in Attachment 3 and some general requirements included below:

Instrument displays, indicator dials and gauges shall be consistent in their

logic and arranged such that under “normal” operational conditions all
indicators shall point in the same direction. The convention used shall be that
the pointer moves and the scale is static.

Displays and switches/buttons on control panels shall be prioritised according

to importance and arranged to optimise ease of operation. For example,
emergency stop buttons should be clearly identified. If appropriate, this can
be achieved through colour coding and other methods.G

Critical controls should be designed to prevent inadvertent operation. This

may be achieved through the provision of covers though it is important that
this does not impede operation when appropriate,G

The arrangements of displays and control panels shall, as far as possible,

copy the arrangement of the components on the unit/equipment and
represent a logical sequence of operations relative to the process.

All labels, displays and signs shall be easily readable at eye level from the
normal position of the range of operators.

The following factors shall be considered in relation to the readability of labels

displays and signs:

the ratio of the size of the features on the display to the viewing distance;G

the contrast of the features against the background;G

the illumination levels to ensure good readability and avoid glare from natural
light;G

the form of the display (graphic, letters, figures etc. – see Attachment 3);

the font size and type (for letters and figures);G

duration of the display (where applicable); andG

combinations of colour (see Attachment 3).G

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3.4 Control Systems Interface & Alarm System Design

The project shall adopt human factors best practice in the design of all control system
interfaces to help ensure HF and end user requirements are reflected in the design.

Generic HF requirements shall be addressed through application of the following

standards or similar:

BS EN ISO 9241, Parts 10, 12 and 14 (Reference 9)G

EEMUA 191 (Reference 10)G

EEMUA 201 (Reference 11).G

National Standards (Reference 3). G

Project specific HF requirements will emerge from ongoing project work in other
areas (e.g. development of operational philosophy). In particular, the project shall
ensure that the design supports the management of operator workload and human
error risk, and reflects the proposed staffing levels for operations and maintenance
as these are finalised. As a general principle the use of colour on the displays will be
kept to a minimum in order to present cool grey screens in normal operating
conditions.

In order to meet alarms handling best practice the project will utilise industry
guidance such as EEMUA 191 (Reference 9).

3.5 Working Environment Factors

Working environment factors including the thermal environment, noise and vibration,
and lighting shall be taken account of in the design.

3.5.1 Noise

Wherever practicable the use of noise enclosures shall be a routine requirement for
equipment generating excessive noise levels.

The provisions for equipment noise levels shall comply fully with, but not be limited to,
the requirements referenced in the Environmental Design Basis (Reference 7).

3.6 Occupational Health

Provisions for exposure protection from occupational health hazards are to be

provided.

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3.6.1 Process Fluid Sample Collection System

Process fluid sample collection systems shall be designed in such a way that the risk
of exposure to the hazardous process fluid by the operator is minimised.

These hazards may be classified into physical and chemical hazards. Physical
hazards include exposure to high level noise and inadequate lighting. Chemical
hazards include, but are not limited to, welding fumes and hazardous materials.

4. SAFETY

All equipment, as supplied, shall be designed to be safe for installation, operation and
maintenance. All aspects of the installation, use and maintenance of the equipment
shall be considered by the designers, who shall provide any appropriate lifting lugs,
guarding and ‘easy to maintain’ features. Appropriate installation, operation and
maintenance instructions shall be provided to emphasise how the equipment shall be
used safely.

4.1 HAZOP Studies

The Vendor shall, when requested by Consultant, supply appropriate information and
personnel to attend HAZOP studies, at Consultant Offices. The Requirement for
Vendor to attend HAZOP studies is likely to be for Vendors of packaged equipment,
compressors and other complex items of equipment. The Vendor shall prepare
P&IDs suitable for HAZOP study on an as required basis. Requirements for P&IDs
are detailed in the HAZOP Review Procedure (Reference 5).

4.2 SIL Reviews

The Vendor shall, when requested by Consultant, supply appropriate information and
personnel to attend SIL reviews studies, at Consultant’s Offices. The Requirement
for Vendor to attend SIL reviews studies is likely to be for Vendors of packaged
equipment, compressors and other complex items of equipment. The Vendor shall
implement the SIL level determined during the SIL review in their design. SIL
determination and implementation shall be performed in accordance with SIL Review
Procedure (Reference 6).

4.3 Review of Layout Drawings

The Vendor shall respond positively to Consultant responsibilities ensuring that all
aspects of operation, maintenance and safe spacing in the layout are addressed.
Draft installation layout drawings and piping General Arrangement (GA) drawings
shall be provided to the Consultant for review before the layout is finalised.

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4.4 Electrical Area Classification

Hazardous area classification for electrical equipment shall be in accordance with the
requirements of:

OISD-STD-113 Classification of Area for electrical installations at Hydrocarbon

processing and handling facilities.(Reference 15)

IS 5572 (1994) – Classification of Hazardous Areas

The Institute of Petroleum Area Classification Code Part 15 (where applicable)

(Reference 17)

The Institute of Petroleum Electrical Safety Code – Model Code of Safe Electrical
Practice Part 1 (where applicable) (Reference 18)

4.5 Provision of Safety Records

The Vendor shall maintain safety records to demonstrate compliance with the project
safety requirements and the local Health and Safety requirements during design,
fabrication, transport, erection and operation.

5. ENVIRONMENTAL

5.1 Polychlorinated Biphenyls (PCBs)

Purchase of new equipment, insulation materials or insulation liquids containing

Polychlorinated Biphenyls (PCBs) is prohibited.

5.2 Chlorofluorocarbons (CFCs) and Halons

The purchase of new equipment utilising ozone-depleting agents such as CFCs and
Halons is prohibited.

5.3 Noise

Ambient standards are detailed in the Environmental Design Basis (Reference 7).

The provisions for equipment noise levels shall comply fully with, but not be limited to,
the requirements referenced in the Environmental Design Basis (Reference 7).

DSN 36359
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HSE Design Requirements for Vendors PDRP4200-8150-SP-1003

PAGE 13 OF 19
and Contractors
REV F1

5.4 Lighting

Lighting requirements for the project are outlined in Lighting and Small Power
Specification (Reference 8).

5.5 Life Cycle Duty of Care

The quantities, concentrations and disposition of emissions to air, liquid and waste
generated in the construction and operation of the proposed facilities shall be
described in detail. The Vendor shall identify the nature and quantity of waste that will
be generated during the lifetime of the equipment supplied. The Vendor shall advise
disposal options for waste that will be generated, specifically considering options for
reduction, re-use, recycle and recovery. Vendor shall advise on the types of waste
facilities suitable for final disposal of wastes.

5.6 Source Emission and Ambient Air Quality Standards

Facilities shall be designed in accordance with Environmental Design Basis

(Reference 7).

DSN 36359
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Specification

HSE Design Requirements for Vendors PDRP4200-8150-SP-1003

PAGE 14 OF 19
and Contractors
REV F1

ATTACHMENT 1 - ANTHROPOMETRIC DATA

Anthropometric data (i.e. data on human physical dimensions) shall be used in the
design to ensure that the majority of people required to use or maintain equipment
are able to do so safely. The aim shall be to ensure that at least 95% of the user
population are accommodated.

The data supplied gives the main body dimensions for the anticipated user population
for the project.

In applying the data the following principles are applied:

Let the large person be able to fitG

(e.g. use 95th percentile when allowing space around/between machinery and
equipment)

Let the small person be able to reachG

(e.g. use the 5th percentile when considering heights of manual valves, workstations,
shelves, instrument displays etc.)

Locate work requiring hand operation around elbow heightG

Consider the normal operating position (e.g. standing or seated)

The following working heights are widely recommended:

manipulative tasks involving a moderate degree of force and precision - from

50mm to 100mm below elbow height.G

lighter and more delicate tasks (including writing) - from 50mm to 100mm above
elbow height.G

heavier tasks (particularly requiring downward pressure on work piece) - from

100mm to 250mm below elbow height.

lifting and handling tasks - from knuckle height to just above elbow height.G

two-handed pushing and pulling actions - a little below elbow height.G

hand operating controls - between elbow and shoulder height. (Controls with
associated visual displays should be in the upper part of this region).

DSN 36359
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Specification

HSE Design Requirements for Vendors PDRP4200-8150-SP-1003

PAGE 15 OF 19
and Contractors
REV F1

Anthropometric Data for Adults – Standing

10

11
5 4 3 2 1

All measurements are in millimetres

Dimension Indian Adults

Male Female
5th 95th 5th 95th
Percentile Percentile Percentile Percentile
1. Stature 1535 1745 1415 1615
2. Eye Height 1440 1630 1320 1520
3. Shoulder Height 1245 1445 1140 1330
4. Elbow Height 950 1110 875 1025
5. Knuckle (Grip) Height 650 780 620 740
6. Shoulder Breadth 375 455 310 390
(bideltoid)
7. Chest Depth 145 235 165 255
8. Upper limb length 680 790 610 720
9. Shoulder Grip Length 575 675 515 615
10. Forward Grip Reach 680 790 610 710
11. Vertical Grip Reach 1820 2060 1680 1910

Data from Body Space: Anthropometry, Ergonomics and Design. Stephen Pheasant.
Reference 14.

DSN 36359
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Specification

HSE Design Requirements for Vendors PDRP4200-8150-SP-1003

PAGE 16 OF 19
and Contractors
REV F1

Anthropometric Data for Adults – Sitting

22

7
12 13 14
17
15
20

18
16
19

All measurements are in millimetres

Dimension Indian Adults

Male Female
5th 95th 5th 95th
Percentile Percentile Percentile Percentile
12. Sitting Height 795 905 730 850
13. Sitting Eye Height 685 795 635 745
14. Sitting Shoulder 590 690 465 565
Height
15. Sitting Elbow Height 180 280 175 265
16. Popliteal Height 370 460 330 420
17. Elbow - Finger Length 415 485 375 435
18. Buttock - Popliteal 415 515 405 505
Length
19. Buttock - Knee Length 510 610 490 590
20. Thigh Thickness 85 135 80 135
21. Hip Breadth 275 365 270 390
22. Vertical Grip Reach 1085 1265 995 1170

Data from Body Space: Anthropometry, Ergonomics and Design. Stephen Pheasant.
Reference 14.

DSN 36359
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PARADIP REFINERY PROJECT

Specification

HSE Design Requirements for Vendors PDRP4200-8150-SP-1003

PAGE 17 OF 19
and Contractors
REV F1

ATTACHMENT 2 - HUMAN FACTORS CONSIDERATIONS FOR VALVE LAYOUTS

Positional Requirements

Ease of operation and maintenance of valves depends upon their height, reach and
clearance as well as the physical force required to operate them.

Manual valves that are:

• essential to operation of plant;

• and/or where the consequences of failure would be serious;

• and/or where rapid operation is essential

• and/or are operated/ maintained frequently

shall be placed within easy reach of a normal walkway or platform and shall be at a
height where the requirement to stretch or bend is minimised.

Whenever there is a conflict in an arrangement in trying to achieve these aims and it

is not possible to set all of the manual valves at the optimum height and reach, the
following should be applied:

Priority should be given to the valves that require the greatest physical force.

Where a large force and/or 2 handed operation is required, valves should be

placed just below elbow height – the optimum location.

Valves requiring single hand operation and low physical force may be placed
outside the optimum location indicated above, but as near to it as possible.

Where temporary access is provided to manual valves, this should be arranged to

allow operation of the valve from the optimum position, wherever possible.

Sufficient space should be allowed around all valves to allow for the use of the
correct tools during maintenance.

Operational Requirements

Ease of operation of valves depends upon the physical force required to operate
them as well as their height, reach and clearance.

Valve hand wheels requiring an operating torque greater than 29.5 N-m (40ft-lb) shall
be placed within the optimum zone (just below elbow height).

DSN 36359
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Specification

HSE Design Requirements for Vendors PDRP4200-8150-SP-1003

PAGE 18 OF 19
and Contractors
REV F1

ATTACHMENT 3 - PREFERENCES FOR CONTROLS, DISPLAYS AND SIGNS

Colour
Sign Colour Type of Message
Red Prohibition
Stop
Fire Protection
Blue Instruction (with diagram)
Mandatory
Green Prompt
Safe Condition
Pass
Yellow Warning
Yellow and Black Hatched Notice

Preferences For Legibility When Combining Colour In Signs And Simple

Displays
Legibility Colour Combination
Very good Black characters on a white background
Black on yellow
Good Yellow on black
White on black
Dark blue on white
Green on white
Fair Red on white
Red on yellow
Poor Orange on black
Orange on white
Very poor Black on blue
Yellow on white
Prohibited Green on red
Red on green

Font Sizes and Type Faces

The size, spacing and type of font used for text are all important factors which can
affect legibility.

Vertical spacing between numerals should be approximately 100% of character

height;

DSN 36359
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PAGE 19 OF 19
and Contractors
REV F1

Sans serif typefaces such as Arial, Univers, Gill sans or Helvetica should be
used;

A medium to bold typeface should be employed to ensure that the closed spaces
of letters remain open.

Ergonomic Guidelines for Displays

The following table details some generic ergonomic guidance on the use of different
types of displays.
Display Type Advantages Disadvantages
Numeric Accurate quantitative Cannot illustrate rate of
information change or approach to limit.
Quick to read Rapidly changing data is
unreadable.
Difficult to locate individual
data items in list/table.
Bar charts/ Easy to check whether data Movement can potentially
Analogue is within limits distract operators
dials Possible to mark alarm Slow read time
limits Inaccurate if numerical
Displays rate of change well value has to be derived
Easily compared to other
similarly presented data
Provides at a glance
appreciation of operating
conditions
Trend Ideal for presenting Inaccurate if numerical
Displays continuously changing value has to be derived
information Only 4 parameters can be
Presents rate of change in displayed
an easily understandable
format
Good for comparing data
plots
Provides historical data over
time.

DSN 36359
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8610-PI-000-0001 66-6699

Packing, Marking, Documentation and

Despatch Instructions
Rev 00 Page 2 of 13

Contents:
1 AIM / PURPOSE ................................................................................................................................. 3
2 SCOPE ............................................................................................................................................... 3
3 ABBREVIATION AND DEFINITIONS ................................................................................................ 3
4 REFERENCE DOCUMENTS ............................................................................................................. 4
5 PREPARATION AND PRESERVATION ............................................................................................ 4
6 HANDLING- ODC/ OWC AND SUPER ODC/ OWC CARGO ............................................................ 4
7 ROUTE SURVEYS ............................................................................................................................. 5
8 PACKING AND MARKING ................................................................................................................. 5
8.1 PACKING ............................................................................................................................................ 5
8.2 HAZARDOUS CARGO & NOXIOUS SUBSTANCES ........................................................................ 5
8.3 SHIPPING MARKS ON PACKAGES ................................................................................................. 6
9 SHIPPING DOCUMENTS .................................................................................................................. 7
9.1 SHIPPING INVOICES ........................................................................................................................ 8
9.2 PACKING LIST ................................................................................................................................... 8
9.3 BILLS OF LANDING / AIRWAYBILLS ................................................................................................ 8
9.4 CERTIFICATES OF ORIGIN .............................................................................................................. 9
9.5 HARZARDOUS MATERIALS ............................................................................................................. 9
9.6 REPORTING REQUIREMENTS- foreign points of origin. ................................................................. 9
10 GENERAL IMPORTATION ARRANGEMENTS ............................................................................... 10
11 DESPATCH ARRANGEMENTS / INSTRUCTIONS ........................................................................ 10
12 DISTRIBUTION OF DOCUMENTS .................................................................................................. 10
13 EXPORT LICENCE / END-USE CONTROLS .................................................................................. 11
14 INSURANCE..................................................................................................................................... 11
15 SITE RECEIVING ARRANGEMENTS ............................................................................................. 11
15.1 SITE GATE PASS SYSTEM ............................................................................................................ 11
15.2 SITE RECEIPT ................................................................................................................................. 12
15.3 SITE HSE REGULATIONS .............................................................................................................. 12
16 TAXES AND DUTIES ....................................................................................................................... 12
17 Appendix-A: Examples of internationally recognised marking symbols. .......................................... 13
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8610-PI-000-0001 66-6699

Packing, Marking, Documentation and

Despatch Instructions
Rev 00 Page 3 of 13

1 AIM / PURPOSE
The purpose of this document is to provide VENDORs and SUB-CONTRACTORs with instructions for
the packing and marking of GOODS. Preparation and submittal of all relevant documentation,
arrangements that must be applied in the release and despatch of goods to the BS VI Project at
Paradip Refinery, Paradip, Odisha, India.
2 SCOPE
This document is applicable in respect of all GOODS purchased:
x Within India for delivery to Paradip Refinery Project Site (PDRP) under delivery terms
“Delivered Paradip Project Site”.
x Outside of India for delivery to Paradip Refinery Project (PDRP) under delivery terms:
i) ODC/OWC cargo: CFR Paradip Port – However it must be noted that the relevant
Bills of Landing shall be free of any liability of IOCL to the carrier for demurrage, and
that transfer of property and risks occurs on receipt of GOODS at the destination Port/
Airport.
ii) All other GOODS: CFR Kolkata / Nhava Sheva Port
which are a result from placing Purchase Orders or Sub-contracts by the OWNER, and to any SUB-
CONTRACTOR’s GOODS which are required at the PDRP Site during construction.
3 ABBREVIATION AND DEFINITIONS

OWNER Indian Oil Corporation Limited (IOCL)

CONSULTANT/ tkIS/ tkIS- thyssenkrupp Industrial Solutions (India) Private Limited and other
India/ tkIS-Site offices of tkIS responsible for execution of the project wherever
applicable.
VENDOR / CONTRACTOR Vendor/ Contractor shall mean the bidder during the bidding phase
and the supplier/ contractor after purchase order award. The vendor
supplies the equipment and/ or services as specified by tkIS/OWNER.
MANUFACTURER A Company that actually manufactures GOODS.
SUB-CONTRACTOR A Company undertaking supply and/or installation of GOODS for the
CONSULTANT.
PDRP/SITE The Paradip Refinery Project, Paradip, Odisha State, India
LC Letter of Credit
CHA / CUSTOMS HOUSE A contractor undertaking Customs Clearance and inland transport
AGENT services (within India).
SHIPPING CONTRACTOR Contractor undertaking shipping and/or ‘Freight Forwarding services
for the Project (Outside India)’.
TRANSPORT CONTRACTOR A contractor undertaking inland transport services (within India).
GOODS All / various types of equipment or materials associated with the
Project.
CISF Central Industrial Security Force.
ODC Over Dimensional Cargo (individual items exceeding 11.8 metres
length, or 2.2 metres width, or 2.2 metres height).
OWC Over Weight Cargo = individual items exceeding 20,000 Kgs.
IBR Indian Boiler Regulatory Authority.
NACE National Association of Corrosion Engineers U.S.A.
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8610-PI-000-0001 66-6699

Packing, Marking, Documentation and

Despatch Instructions
Rev 00 Page 4 of 13

4 REFERENCE DOCUMENTS
1. Project Specifications.
2. IOCL General Purchase Conditions.
3. IOCL Special Conditions of Purchase.
4. IOCL General Conditions of Contract.
5. IOCL Special Conditions of Contract.
6. Indian Customs and importation regulations.
7. International Maritime Organisation latest IMDG Code.
8. International Chamber of Commerce Uniform Customs and Practice for Documentary Credits
UCP 600, ICC publication no.600 (latest revision).
9. Regulations applicable to Indian Ports, railways and roads etc.
10. INCOTERMS 2010
11. ISPM15 – Regulation of Wood Packing Material in International Trade.

5 PREPARATION AND PRESERVATION

Materials shall be protected by a suitable coat of paint and all bright parts shall be protected from rust
by application of rust preventatives as may be necessary. All machinery surfaces shall be protected.
All manufactured surfaces shall be painted with rust-proof paint or as specified in the specification.
All nozzle holes and openings and all delicate surfaces shall be carefully protected against damage
and bad weather. Flange faces of all nozzles shall be protected by blanks.
All pipe and pipe fittings (Carbon / Stainless Steel / Alloys etc.) shall be shipped with end caps
securely fitted to both ends of the pipe.
All threaded fittings shall be greased and provided with a plastic cap. All pipes and sheets shall be
marked with strips bearing progressive numbers.
All flanges shall be shipped in cases and with the flange faces protected. This shall be by means of
Plastic Flange Protectors. This also includes all flange faces on Valves/ Vessels/ Drums/ Equipments,
etc. which shall be protected in the same manner.
All Stainless Steel and Exotic Materials should be packed and protected from weather damage and
cross contamination.
All small bore Pipe & Fittings will be packed in cases.
Please refer to Material Specifications for more detailed preservation requirements.
6 HANDLING- ODC/ OWC AND SUPER ODC/ OWC CARGO
ODC cargo is defined where any of the individual dimensions of package exceed 11.8 metres length x
2.2 metres width x 2.2 metres height, and OWC is defined which exceed 20,000 kg. weight.
Maximum weight and dimensions for transportation of ODC & OWC within India are generally as
follows:
• Overall Length 30 metres
• Overall Width 4.5 metres
• Overall Height 4.5 metres
• Gross Weight 140,000 kgs Including transportation saddles.
Super ODC cargo is defined where any of the individual dimensions of package exceed 50 metres
length x 6 metres width x 6 metres height width.
Super OWC cargo is defined where the package exceeds weight of 150,000 kgs.
This type of cargo shall be shipped on geared heavy lift / Roll On – Roll Off ships from port of origin to
Paradip port, India.
Transport drawings showing all relevant Dimensions, Lifting / Securing points, Centre of Gravity must
be forwarded to tkIS/OWNER, 3 months before shipment.
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8610-PI-000-0001 66-6699

Packing, Marking, Documentation and

Despatch Instructions
Rev 00 Page 5 of 13

All ODC/OWC equipment items will be discharged by ship’s cranes directly to suitable trailers, and
transported by road directly to the required Site locations.
Super ODC/OWC equipment items that for technical reasons cannot be transported within the Port
area by road are to be discharged by ship’s cranes on to a suitable barge and rolled-off at a purpose
built jetty on the South side of the Port, from where road transport on suitable trailers directly to the
required Site locations can be accomplished.
7 ROUTE SURVEYS
To ensure feasibility of transportation, it is advised that route surveys will be undertaken by the
Vendor for the movement of ODC/OWC equipment items in/around Paradip and from other locations
of import / Port or supplier’s location to Paradip Site. Details shall be made available to tkIS/ OWNER
as and when required.
8 PACKING AND MARKING
8.1 PACKING
All materials shall be suitably packed in weatherproof roadworthy / seaworthy /airworthy packing for
ocean/air transport under tropical conditions and/or for rail/road or other appropriate transport within
India. The Vendor/Contractor shall ensure that the packing is strong enough to ensure safety and
preservation of the materials up to the Project Site or other point of final destination.
For uniform goods when packed in several cases/crates, progressive serial numbers shall be
indicated on each end. In case of bundles, the shipping marks shall be embossed on metal tags wired
securely on each end.
All small pieces shall be packed in cases. All fragile and exposed parts shall be packed with care and
packages shall be marked "HANDLE WITH CARE" in English and, in case of indigenous supply, also
in Hindi.
If containers are utilised, care should be taken not to load heavy cases on top of lighter cases. For
piping and any unpacked materials, sufficient wooden dunnage should be used between the layers
and smaller heavy gauge pipe should not be loaded on top of lighter gauge pipe.
Top Heavy containers will be marked either “TOP HEAVY” or “HEAVY ENDS”, and any other direction
for special handling shall also be clearly indicated on the package
For closed containers (dry van), the weight limit per piece should not exceed 2000 kgs.
Unless authorised by the OWNER/tkIS, no shippers own containers should be used.
The Vendor shall be held liable for all damages or breakages to the goods due to defective or
insufficient packing, as well as for corrosion due to insufficient greasing/ protection, and must
therefore ensure that suitable standards are in fact applied.
In addition to the above, for imported supplies, all wood packaging materials must be appropriately
treated and marked in accordance with ISPM-15 or must be accompanied by a phyto-sanitary
certificate with the treatment endorsed. Internal packaging or wrapping materials shall be new and
clean, and shall not comprise or include any vegetable matter, printed paper, sawdust, straw, wood
chippings, or similar materials. The Vendor shall be responsible for any all costs arising from failure to
comply with these requirements.
8.2 HAZARDOUS CARGO & NOXIOUS SUBSTANCES
All packages MUST show the storage colour code box as RED The nature of any / all types of
hazardous / dangerous or noxious GOODS shall be identified and packed in accordance with
International Maritime Organisation (IMO) and IMO Dangerous Goods – IMDG code or IATA
Regulations, and applicable statutory regulations currently in India.

All packages MUST show the storage colour code box ED

All hazardous and noxious materials must be packed separately from other types of hazardous and
non-hazardous GOODS and be packed according to International and National transportation
standards.
Manufacturer’s Material Safety Data Sheets (MSDS) must be submitted to OWNER/tkIS well in
advance before the shipment.
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8610-PI-000-0001 66-6699

Packing, Marking, Documentation and

Despatch Instructions
Rev 00 Page 6 of 13

8.3 SHIPPING MARKS ON PACKAGES

All pieces and packages must bear shipping marks indelibly marked in BLACK on three sides of the
packages, in BOLD with a minimum letter height of 5 cm. This can be done on packed case or crate
by means of two metal tags secured to each end of bundles, and affixed by use of secure waterproof
labelling on items deemed appropriate to be transported loose and unpacked.
Such markings shall not be directly applied to prepared or painted surfaces.
When packing is clean and light coloured, a dark black stencil shall be acceptable. However where
packing is dark, a coat of flat Zinc white paint shall be applied and allowed to dry before applying the
specific markings
All packages must bare international trade practice symbols as appropriate and marked on all four (4)
sides of all packages (see examples in Appendix-A).
Packages which require special handling / transport shall include Centre of Gravity, Lifting Points, and
any other marks as required shall be clearly marked.
Any special handling instructions must be notified to OWNER/tkIS before delivery to PDRP.
Storage Colour Code Storage Conditions
150 mm Yellow Square Equipment to be stored in a totally enclosed air
conditioned/heated building.
150 mm White Square Equipment to be stored in a totally enclosed
building / container not heated
150 mm Green Square Equipment to be stored outside, provided it is
kept clear of the ground and waterproof sheeted.
150 mm Black Square Equipment to be stored outside, un-sheeted,
provided it is kept clear of the ground.
150 mm Red Square Inflammable and hazardous material - flash
points are to be shown on case in accordance
with International Agreements.
The storage colour code box must be marked alongside the shipping marks shown below.
Å (Storage colour code, as above).

Colour codification shall be used to identify different items e.g. IBR, NACE, Fire Safety items etc.
In case of large equipment’s like vessels, heat exchangers etc. documents contained in a waterproof
envelope shall be fastened inside a shell connection with an identifying arrow sign “Documents”
applied with indelible paint.
Vendors /Contractors may arrange additional marking of goods, but shall ensure that the above
details are always clearly applied by all of their sub-suppliers or sub-contractors as indicated.
Goods that are presented for delivery with inadequate marking and PO Item no. / HSN Code
may be rejected upon arrival at the site security location.
All other documents associated with a particular delivery shall be separately despatched by reputable
Courier services, on a "Delivered at Place" basis.
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8610-PI-000-0001 66-6699

Packing, Marking, Documentation and

Despatch Instructions
Rev 00 Page 7 of 13

FROM: - Vendor Name

TO: - INDIAN OIL CORPORATION LTD.

BS VI PROJECT AT PARADIP REFINERY, INDIA.

PURCHASE ORDER NO: ........................Rev. No:...............

HSN Code:……………..
Equipment nomenclature:……………………………….
Nett weight: ............Kgs.
Gross weight: .........Kgs.
Package no: ..... of .... packages.
Dimensions: ........(L) X .........(W) X ...........(H) Cms.
IMPORT LICENCE NO: ..............................

FOR: - tkIS/OWNER-India
VENDOR/SUB-CONTRACTOR REFERENCE NO: ..................................

9 SHIPPING DOCUMENTS

If a Letter of Credit (LC) has been established, then the Vendor shall comply with the conditions of the
LC. Any discrepancies / problems shall be notified in writing to IOCL, and copy to tkIS/OWNER.
All documents must be completed in accordance with the conditions stated in the LC, and submission
of these documents must be followed to ensure full compliance with the LC requirements is essential.
All documents shall be in completed in English.
Vendor’s to ensure that GOODS are shipped and documents presented to Bank by the dates stated in
the LC.
Consignee / Buyer name to be shown on all Shipping documents as:-
Indian Oil Corporation Limited
[Name of Refinery / Project] and address to be confirmed.
All documents must include a statement that the described GOODS are destined for the BS VI Project
at IOCL Paradip Refinery, the 10 digit item code (HSN Code), the description as stated in the
Purchase Order and Letter of Credit.
All documents must be duly signed by an authorised representative of the Vendor/ Sub-Contractor.
If there is no LC then Vendor shall provide documents as directed by Purchase Order and IOCL
General Purchase Conditions, as shown on list below:-
Invoice
Packing List
Bill of Lading / Air Waybill
Freight memos
Certificate of Origin
Export Certificate (wherever applicable)
Railway / Truck Receipt
Third Party Inspection Certificate
Release / Inspectors Certificates
Test / Composition Certificate, wherever applicable
Drawings / Catalogue
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8610-PI-000-0001 66-6699

Packing, Marking, Documentation and

Despatch Instructions
Rev 00 Page 8 of 13

See Section 12 for Distributions of Documents.

9.1 SHIPPING INVOICES
All shipping invoices must show IOCL as the BUYER and CONSIGNEE.
Invoice for Shipping & Customs purposes in English language shall be completed in strict accordance
with the following instructions and should be addressed as follows, See Section 12 for Distributions
of Documents.
Supplier's Commercial Invoice shall contain:-
x Purchase Order Number of IOCL
x IOCL SAP Coding number
x Whether item is 'Part'/'Balance'/’Complete'
x Quantity and full description of goods as specified in the LC & Purchase Order without
abbreviation of each item, including any Tag No.
x Import Licence (if applicable & advised by tkIS/OWNER)
x Country of Origin
x Currency, Net unit price of each item and extension
x Net value(s) totalled.
x Customs HS Code Number 10 Digit Item Code for goods.
x Shipping Mark, Number and Type of Packages, Gross / Net Weight (in metric units)
x Delivery Terms (e.g. FOB …named Port)

The following statement shall be added at the end of each invoice:

Where a packaged unit is being supplied then the value of the total package may be shown as one
invoice line, with the details of what makes up the package itemised on the Packing List.

Where Material has a tag number this must be clearly shown on the invoice against the relevant line
item.
9.2 PACKING LIST
Supplier's Packing List shall be made out to IOCL, and shall contain:
x Full description with out abbreviations of goods contained in the package giving packing list
with code, description and qty for all the items contained in the package.
x Type of package, e.g. wooden case, drum, bundle etc.
x Gross weight, Net weight and dimensions of Each package (in metric units)
x
3
Total Gross/Net weight and total shipping volume (m )
x Shipping marks and package number(s).
x Purchase Order Number of IOCL
x IOCL SAP Coding number

FULL DETAILS OF ANY HAZARDOUS GOODS INCLUDED IN ANY PACKAGE MUST BE

IDENTIFIED ON THE PACKING LIST.

Shipping documents must be prepared to be fully compliant with the requirements of relevant Letter of
Credit, and the relevant IOCL Terms and Conditions of purchase.

Descriptions (nomenclature) used in respect of imported GOODS, and all GOODS in general, shall be
aligned with those correspondence to the International Customs Harmonised System (HS) coding, for
which the correct 10-digit item code must be stated.
9.3 BILLS OF LANDING / AIRWAYBILLS
All Bills of Lading / Airwaybills must show IOCL as the BUYER and CONSIGNEE.
x All columns in the body of the Bill of Lading/Airway bill, namely marks and numbers, material
description, weight particulars etc. should be completed accurately and such statement
should be uniform on all of the shipping documents.
x The freight particulars shown ( either on Bill of Lading/Airway bill or on a separate “Freight
Memo” signed and stamped by the carrier) should mention the basis of Freight tonnage and
 Plant Client Contract Code Document ID tkIS Contract No.
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Despatch Instructions
Rev 00 Page 9 of 13

rate, heavy lift charges and/or other surcharges/discounts etc. (if any) clearly and separately,
and the net total freight payable shown at the bottom.
x The Bill of Lading/Airway bill should be free of any liability of IOCL to the carrier for demurrage
and the transfer of property and risks occurs on receipt of the GOODS at the destination
Port/Airport- both of which must be recognised as important variations in the interpretation
and application of INCOTERMS 2010.
In all instances the VENDOR/SUB-CONTRACTOR shall obtain the shipping documents in the
required number of sets, including three original stamped copies of Bills of Lading, immediately
after the shipment is made.
The VENDOR/SUB-CONTRACTOR shall be responsible for any delay and/or demurrage in
clearance of the consignment at the port due to delay in forwarding the shipping documents.
9.4 CERTIFICATES OF ORIGIN
Separate certificates of origin – in the standard international trade format, stamped and signed by a
Chamber of Commerce or Notary Public, shall be submitted in English for each shipment effected
under each purchase order/sub-contract, corresponding to each shipping invoice.
9.5 HARZARDOUS MATERIALS
Vendors are responsible for providing Material Safety Data sheets for any hazardous materials and
are responsible for completion of the necessary Dangerous Goods documentation for International
and Indigenous transportation.
Refer to Section 8.2 Hazardous Cargo & Noxious Substances.
9.6 REPORTING REQUIREMENTS- foreign points of origin.
Vendors will provide reports of planned / confirmed shipment details, comprising the following:-
x Supplier name and location.
x Purchase Order number.
x Assigned Consignment Identification Number (CIN).
x General equipment / materials description.
x Total number of package, total gross weight (kgs), total volume (CBM).
For seafreight- (one week prior to planned shipment date):-
x Total number and type of containers, or confirmation of breakbulk shipment.
x Weight / dimensions of any / all items exceeding 20 tonnes weight and / or dimensions of
11.8m X 2.2m X 2.2m.
x Name of the intended Carrier and ship, Port of shipment, planned shipment date and ETA at
Port of discharge.
x In respect of containerised shipments, the routing / transhipment points.
x Confirmation of shipment as planned (or new plan details)- not more than one week after the
advised shipment date.
For airfreight- (one week prior to planned shipment date):-
x Name of the intended Carrier and Airway bill number.
x Airport of despatch and Indian Airport of importation.
x Planned flight, despatch date, routing and ETA.
x Confirmation of shipment as planned (or new plan details)- not more than one week after the
advised shipment date.
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8610-PI-000-0001 66-6699

Packing, Marking, Documentation and

Despatch Instructions
Rev 00 Page 10 of 13

10 GENERAL IMPORTATION ARRANGEMENTS

IOCL will appoint a Customs House Agent (CHA) to undertake all required arrangements concerning
Customs and other importation and handling formalities. Each vendor shall be responsible to provide
all required documentation and information necessary to ensure that the CHA is able to complete all
formalities in time to avoid delays and associated costs, and to manage all relevant importation and
handling arrangements.

11 DESPATCH ARRANGEMENTS / INSTRUCTIONS

Details of all OWC / ODC and Super OWC / ODC shipments shall be pre-alerted to tkIS/OWNER at
least ONE month before proposed vessel departure.
Refer to Section 6 ‘Handling – ODC / OWC and Super ODC / OWC Cargo.’
Unless otherwise directed by tkIS/Owner in writing, no GOODS shall be despatched from the point of
origin without satisfactory inspection and/or testing having been fully completed as required - for which
written evidence must be submitted before despatch of the particular goods shall be authorised.
For all GOODS a pre-alert of scheduled shipments (Sea / Rail or Road) / flights, with copies of all
relevant shipping documents and freight forwarder contact details / references are required to be sent
electronically to the nominated tkIS/OWNER before departure, and regular vessel position and status
reports shall be provided on request.
If GOODS are transported by rail from other Ports within India the Vendor shall exercise due care to
ensure that the consignment are booked under appropriate railway classification, failing which result in
any additional freight incurred by IOCL due to incorrect classification shall be borne by the Vendor.
The Vendor shall exercise due care to ensure that the consignment are booked under appropriate
railway classification, failing which results in any additional freight incurred by IOCL due to incorrect
classification shall be borne by the Vendor.
The Materials shall be transported only through bank approved transporters by the most economical
and expeditious mode of transport to the destination as applicable for respective mode of despatches
as follows.
i. By Rail in wagon load consignment to : Paradip Refinery Project Site
ii. By road transport to: Paradip Refinery Project Site
iii. By sea transport to: Paradip Port for ODC / OWC shipments and Kolkata/Nhava Sheva for
other cargo
Material shall be consigned in the name of the Consignee:-
Indian Oil Corporation Ltd, BS VI Project, Paradip Refinery, Odisha State, India.
The tkIS/Owner shall retain the option to direct the Vendor / Contractor to change the despatch point
and/or means of transportation. If this option is applied, additional costs incurred by the
Vendor/Contractor in compliance with such directions shall be reimbursed by IOCL or the
tkIS/OWNER upon receipt of satisfactory supporting evidence of the costs.

12 DISTRIBUTION OF DOCUMENTS
The Vendor shall obtain the shipping documents in required number of sets including three original
stamped copies of the Bill of Lading/Airway Bill immediately after the shipment is made and airmail the
shipping documents in the manner stipulated hereunder to ensure that the documents so forwarded
are received at least one week before the arrival. The Vendor shall be fully responsible for any delay
and/or demurrage in clearance of the consignment at the port due to delay in forwarding the shipping
documents. If in terms of the Letter of Credit , the complete original set of documents are required to
be sent to IOCL through the bank, the distribution indicated below will be confined to obtaining copies
of documents only.
 Plant Client Contract Code Document ID tkIS Contract No.
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Despatch Instructions
Rev 00 Page 11 of 13

IOCL (Office that IOCL (Port IOCL (Project

Documents
issued the PO) Office) Site)
Bill of lading/Airway Bill 3 (including 1 original) 1 1
Invoice 2 2 1
Packing List 2 2 1
Certificate of Origin 2 2 1
Test/Composition Certificate 2 2 1
Third Party Inspection
Release Certificate 1 1 1 (Original)

Drawing/Catalogue 1 1 1
Invoice of Third Party for
Inspection Charges,
2 1 1
(wherever applicable)

Export Certificate
(where applicable) 1 1 1

13 EXPORT LICENCE / END-USE CONTROLS

Vendors are responsible for obtaining any necessary Export Licence(s) which pertains to their supply
delivery terms “Delivered Paradip Project Site”.
Upon receipt of Purchase Order the Vendor shall advise tkIS/OWNER within 4 weeks if any Export
Licence / End-User Control is applicable.
14 INSURANCE
Marine /Air and transit risk insurance shall be covered by IOCL against its Open General Policy.
Vendor shall advise the despatch particulars of the Shipment / Consignment to the IOCL appointed
insurance company by fax / e-mail (Contact details to be advised), promptly after each shipment to
ensure that the Consignment is fully covered by insurance. Any failure by the Vendor to do so shall
place the consignment at the Vendor’s risk.
15 SITE RECEIVING ARRANGEMENTS
15.1 SITE GATE PASS SYSTEM
All personnel requiring access to the Project Site must obtain prior security clearance and approval by
application to IOCL site personnel. Identity cards issued must be worn at all times and be visible for
inspection by appropriate authorities.
The Central Industrial Security Force (CISF) is to provide security for the Project site, which will
include advance checks on all personnel and vehicles that will be entering and leaving the site.
In respect of vehicles delivering GOODS, a Request for Entry’ must be submitted to the Engineer in
charge for signature and submission to the CISF. Following CISF checks, a gate pass will be issued
to personnel, and a permit issued for each vehicle.
Following documents are requested to assist in obtain Personnel & Vehicle passes:-
• Valid driving licence for driver
• Other proof of driver’s identity and photograph
• Valid registration papers for the vehicle
• Valid road tax certificate and insurance
• A valid PUC certificate for the vehicle
• The vehicle shall be in good condition, carry a spare wheel, and have a spark arrestor fitted to the
exhaust
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8610-PI-000-0001 66-6699

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Despatch Instructions
Rev 00 Page 12 of 13

• A list of materials carried

• A ‘Request for entry’ signed by the Engineer In-charge
Compliance is mandatory, and any delays or costs resulting from failure to ensure compliance will be
for the VENDOR / SUB-CONTRACTOR account.
15.2 SITE RECEIPT
Upon receipt at the designated Site location, each consignment will be thoroughly checked as quickly
as possible and the tkIS/OWNER site representative will issue an official receipt document to the
respective VENDOR or SUB-CONTRACTOR.
This document has implications related to taxes payable upon the GOODS and must be retained for
production by the VENDOR / SUB-CONTRACTOR when required.
In respect of final delivery to the Project Site - always expected to be by road transport - all
Vendor/Contractors are further required to advise advance details of each proposed consignment /
shipment of goods to be delivered to the Project Site, and to provide the following details to the both
the tkIS/OWNER representative and the appointed CISF (in advised format) before the issue of
approval for despatch:-
I. Name / address / contact details of the Supplier / Manufacturer from which the goods are to
be despatched.
II. Full description of the consignment / shipment, number / type of packages, total gross weight,
and total value of the consignment for insurance purposes.
III. Method of transportation from origin and, for road transportation to the Project Site, details of
the truck number(s) and driver identification details.
IV. Planned date of delivery to the Project Site.
Vendor/Contractors shall note that trucks arriving at the Site security check-point, for which no prior
advice (as above) has been submitted, for which inadequate driver or truck documents can be
produced, or that otherwise fail to meet Project Site security and/or safety requirements, will be denied
access to the Project Site until adequate details and explanations have been reviewed and approved.
No responsibility for notifications or for any related costs will be accepted.
15.3 SITE HSE REGULATIONS
Compliance with established Site HSE regulations (as detailed in Guidelines for PPE) by all personnel
entering the site will be mandatory. In respect of drivers involved in the delivery of GOODS
requirements for Personal Protection Equipment (PPE) will apply, and both provision and use will form
part of both access Site Gate checks by the CISF and ongoing surveillance on the Project Site.
16 TAXES AND DUTIES
IOCL’s liability on account of Customs Duty shall be limited to the Customs Duty leviable on the CIF
value indicate by the Vendor/Contractor in his Purchase Order/ Contract.
The value can be reduced or increased only by a change/extra work order. In all cases, if the total CIF
value of imports is exceeded, the Customs Duty/ Penalties and other charges have to be borne
completely by the Vendor/Contractor.
Taxes and Duties payable or reimbursable by IOCL to Vendor/Contractor on the supply of indigenous
goods shall be included in and shown separately in the Vendor’s invoice for payment.
Freight payable or reimbursable by IOCL shall be invoiced separately and shall be paid / reimbursed
by IOCL after receipt of the goods at the site and satisfactory proof of payment of the related amount.
 Plant Client Contract Code Document ID tkIS Contract No.
BS-VI IOCL BS-VI PDR 25284124-8610-PI-000-0001 66-6699

Packing, Marking, Documentation and

Despatch Instructions
Rev 00 Page 13 of 13

17 Appendix-A: Examples of internationally recognised marking symbols.

FIG. 3
THIS WAY UP

FIG. 2
USE NO HOOKS

FIG. 3A
FIG. 1 EXAMPLE OF THE
APPLICATION OF FIG. 3
FRAGILE HANDLE WITH CARE

FIG. 6
FIG. 5 KEEP DRY
SLING HERE

FIG. 4
KEEP AWAY
FROM HEAT FIG. 5A
EXAMPLE OF THE
APPLICTION OF FIG. 5 FIG. 7
CENTRE OF GRAVITY