SUPPLY, INSTALLATION, COMMISSIONING OF

ON-LINE GAS DETECTION SYSTEM IN 05 NOS OF Scope of work

GGS OF ANKLESHWAR ASSET.

TECHNICAL
SCOPE AND REQUIREMENTS

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 SUPPLY, INSTALLATION, COMMISSIONING OF
ON-LINE GAS DETECTION SYSTEM IN 05 NOS OF Scope of work
GGS OF ANKLESHWAR ASSET.

CONTENTS

SL NO. DOCUMENT DESCRIPTION PAGE

NO
01 SCOPE OF SPECIFICATION

02 BACKGROUND

03 SITE DATA

04 AVAILABLE RESOURCES AND FACILITIES

05 SCOPE OF WORK

06 DESIGN PHILOSOPHY

07 WORK SPECIFICATION

08 GENERAL SPECIFICATIONS OF CABINETS &

INSTRUMENTATION
09 APPLICABLE NATIONAL AND INTERNATIONAL
STANDARDS.

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1.0 Scope of Specification :

This specification together with the attachments defines and covers the guidelines for
Design, Engineering, selection of equipment, equipment specification, scope of work,
Inspection & Testing, Installation and commissioning requirements complete with all
accessories and materials for “Installation of on-line gas detection system in following
GGS of Ankleshwar Asset.”

Sr No LOACTION Nos of detectors

1 GGS I Gandhar (GCP 1 24
Only)
2 GGS IV Gandhar 20
3 GGS Dahej 10
4 GGS Jolwa 10
5 GGS GNAQ 13

2.0 Background :
Above GGS of Ankleshwar Asset do not have online gas detection system. As per
DGMS guideline, on-line gas detection system is to be installed.

Broadly, the on-line Gas Detection System shall be to detect hydrocarbon gas
concentrations in various Installations and initiate alarm or shutdown system as the
case may be, at pre-defined levels to prevent any hazardous events and act as
independent safety layers for mitigation of consequences to achieve overall process
safety requirements . The on-line gas detection system should also have display
and printing capabilities. The system should also provide audible and visual alarm
indications in panel and field to ensure that operators and personnel are informed of
hazardous situations.
The new Gas detectors (Sensors-cum-transmitters units) should be point type,
Infrared principle.
3.0 SITE DATA
Site information shall specify the environmental condition of the project site. All
information specified herein shall be used for reference for the bidder’s sound
Engineering & Design.
a) Location of sites:

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Sl. Field Installations Approx. distance

No from Ankleshwar
Railway Station
1. Area – III GGS – I 65 kms
(South Gandhar) GGS – IV 75 kms
Jolwa – EPS 50 kms
Dahej – GGS 45 kms
2. Area – IV
(North Gandhar) GNAQ – GGS 75 kms

b) Climate: Tropical
c) Ambient temperature: 47 deg C (Maximum), 15 deg C (minimum)
d) Relative humidity (Maximum): 89% at 47 deg C
e) Basic wind speed: 44 m/sec
f) Barometric pressure: 1013 mBar.
g) Seismic consideration: As per BIS 1893

Note: All other data, if considered necessary, shall have to be generated by

prospective bidders themselves as no additional data other than as already
provided are available with ONGC.

4.0 AVAILABLE RESOURCES AND FACILITIES:

Item Pressure in Kg/sqcmg Temperature in DegC
Cooling water supply 4.5 33

Electric power:
For lighting: 415 Volts AC, 50 Hz, Three phase.
5.0 SCOPE OF WORK:
5.1 Turnkey bidder shall be responsible for all types of Civil, Electrical, &
Instrumentation work including, but not limited to the following:

Complete design, detailed engineering, preparation of drawings / documents,

sizing, selection, procurement, installation , cabling, dressing, cable tray
supporting, testing, calibration loop checking and commissioning of all gas
detectors and controls with their accessories, installation material etc., including
supply of commissioning spares, arranging all types of equipment for testing,
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GGS OF ANKLESHWAR ASSET.

calibration, as required for “ Installation of IR Sensor-cum-transmitter based on-

line Gas Detection system at various Production Installations (GGS) of
Ankleshwar Asset”, where Gas compressors are installed along with
Comprehensive Maintenance Contract for six years after completion of one
warranty.

The system will monitor the LEL on continuous basis & will display the LEL in the
SCADA room / control room for all the sensors installed in the field. The System
will generate an Alarm as soon as the LEL in the field crosses the Set Level in
either one Sensor Or more Sensors. In Alarm condition there will be an Audio
Visual Alarm in the SCADA room / control room to alert the Operator & the
Hooter should operate in the field to alert the field operator about the LEL Alarm
level. The hooter in the field & the Electronic buzzer in the control room will stop
on operating of Accept Push button installed on the control Unit installed in the
control room & the visual alarm should remain flashing till the LEL is restored
back to normal limits. When the LEL in the field is in normal the flashing of alarm
should become steady Alarm. The alarm should be reset on operating of Reset
Push button installed on the control Unit installed in the control room.

5.2 Sensor–cum Transmitter unit Type: Sensor should be of Infra-red Type

suitable for installation in for Class-I, Div.-I, Group C & D hazardous area and
Ingress protection is IP-65 / NEMA 4x or better.

The sensors shall be SMART SIL2 IR type Sensor. System should be capable to
sense and display precise & instantaneous reading of % LEL Hydrocarbon gas
present in the sensor vicinity of 03 mts with minimum time lag. System shall
measure, display and generate alarm whenever any hydrocarbon gas leaks in
the area. The sensors should be capable to detect Hydrocarbon content in the
area. The output signal from the transmitter will be 4-20 mA. The output signal
from the sensor will be used to display the % LEL in the control Unit installed in
the SCADA room / Control Room. The bidder has to Supply & Install the sensor
& transmitter. The Sensor should have local LED indications for indicating
Normal, Alarm & fault conditions. The Sensors will be installed in the field as per
the location decided during detail engineering. For the sensor cum transmitter
shall be installed on the stanchion. A typical ‘Schematic’ of stanchion is given in
this document.

Sensor Calibration: Calibration of all detectors shall be possible either from

remote location or via hand-held calibration tool / HART configurator. The sensor
should have onsite facility for Adjustment of Zero & Span using Non- Intrusive
one man calibration by correcting the instrument on spot without disconnecting it
from its power supply by using any portable hand held intrinsically safe
calibrator/configurator like HART375 etc./equivalent calibrating device or
accessory supporting specific protocol/technology without violating hazardous
area certification. The bidder will have to describe as a write-up the detail
calibration procedure with sketch for a particular detector using their quoted

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calibration device along with the bid documents for our scrutiny & approval. All
detectors shall have factory calibration certificates along with serial no.

5.3 Cable:
5.4 Between FJB to Sensor–cum Transmitter unit: Three (3) / Four (4) core cable for
carrying both Power & Signal to / from the Gas Detector.
5.5 Between FJB to Control Unit located in Control Room: Multi-core Cable with
TWO Spare SETS of Three (3) / Four (4) core cable for any future requirements.
5.6 Power Cable to power the Control unit installed in the Scada CCR. The cable will
be three core power Cable.
5.7 Cable from Control Unit to Hooter Installed in the field.

6.0 Control Panel System:

Control Unit: The Bidder has to supply & install control unit in the SCADA room /
Control room. The Control unit should be multichannel unit compatible to the Sensor-
cum-Transmitters installed in the field. The Control Unit will have a digital display with
Channel No. & LEL % indication. The unit should be freely programmable type.
Individual channel programming should be possible. The unit shall have an Audio &
visual Alarm unit installed. One potential free digital out-put contact one each for High &
Very High Alarm shall be made available. The Control Unit shall preferably be ‘Wall
Mounted’s, the location can be finalized during Detail Engineering. An independent
Control Unit shall be made available to each Compressor shed, where; there may be 2 /
3 / 4 sensors installed in the shed. In other words, every compressor shed will have its
own dedicated Sensor(s)-cum-Controller and field-Hooter and Control room buzzer
systems. Detail specification for the control panel indicated below.

i) Control Cards / modules/ Monitor Cards shall be mounted on 19” Gas

Monitor racks based on manufacturer standard.
ii) Each control card shall be connected to the HC sensor with front display
of alarms and status on channel. Gas monitor circuit shall be so designed
that any control card can be put out of service for repair, without affecting
the other. The control card shall be plug-in type permitting the removal of
the modules without disturbing the system wiring. The controllers and
detectors should be of same make.
iii) The panel mounted Gas detection controllers/ monitors shall be installed
in mating cases or mounting bins recommended and supplied by
the manufacturer for panel mounting. All wiring to these controllers shall
be terminated on terminal blocks and/or multi-pin connectors provided as
an integral part of the case.
iv) Alarm Contact: For each detector, module shall be configured to
generate minimum of 2 nos. alarm points.
v) Alarm Reset: External Alarm Reset Push Button to be available when
alarm relays are programmed for latching. Alarm Relays will be reset but
alarm status LEDs should track actual condition.
vi) Calibration: Each channel card should have individual calibration facility,
so that it will not disturb other channel during calibration. Any item
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GGS OF ANKLESHWAR ASSET.

required for calibrating the cards specific to the suppliers quoted system
will have to be provided by the supplier along with the supply of the main
items as mentioned in the tender. Card calibration procedure should be
described with all details as a part of bid documents for our review.
vii) Alarm Test: Audio-Visual Alarm test facility should be there in each
channel module. Also Alarm adjustment and relay configurations for each
individual channel cards.
viii) Other Specifications for Channel Cards:
Input Signal: 4-20 mA loop current @ 24 V DC
Display: LED/ LCD display
Resolution & Repeatability:
Single resolution: 1% of full scale
Repeatability: 1% of full scale
Accuracy: 1% of full scale
.
Control system shall have capability to display process as well as system alarms on the
console for operator’s attention and action. Alarms shall appear immediately on the
operator console as and when they occur on priority basis. It shall also be possible to
display summary of all alarms in the sequence of their occurrence and shall disappear
from display only when they are acknowledged and cleared.

Power Supply Unit should be capable of providing power supply to all channel cards,
sensors and alarm hooter.
The power requirements are:
Input Power: 230 V AC ±10%, 50Hz
Regulated Power: +24 V DC for Sensor, +24 V DC/230 V AC for Channel cards, +24
V DC/230 V AC for Alarm Hooter. (Hooter: Type: Industrial Hooter with Audible
Range of 30 meter from control room in all directions)
On-line UPS (Uninterrupted Power Supply) with minimum 04 hours backup is
required.
CONTROL PANEL:

Large clear LCD/ LED, fixed or scrolling in Master

Digital display with Channel cards

Panel shall be freestanding, self-supporting

cubicle type.
1 No. of sensors/ channel per Maximum 16 channels/ Detectors per rack.
rack
2 No. of sensors per control Max. two nos of Detectors
card
3 No. of racks per panel Based on the No. of detectors along with 10%
spare capacity and if reqd. One spare rack for
future expansion.
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4 Mounting 19 inch Rack mounted

5 Inputs 3 wire, 4-20 mA
Other features Internal LED lighting, working on 230V AC,
50 Hz shall be installed within the panel to
provide adequate lighting for maintenance of
equipment. An On/Off switch shall be provided
for this purpose in a surface mounted
enclosure near the panel doors. The lighting
fixtures must not interfere with doors or other
equipment, which must be accessible and
space shall be provided for bulb replacement.
Panel shall have redundant power supply
modules (230AC to 24 VDC) along with MCBs ,
Fuses etc.
Separate Accept and reset push buttons
common for whole gas detection system shall
be available on the panel front. Also a flasher
and hooter to be connected on top of the panel
using the group alarm contact from the gas
monitors.
Routine calibration adjustments shall be
accessible from the front of the Gas monitor/
module without removing any wiring. In addition,
total removal of the Gas monitor/ module and
replacement with a spare shall be possible from
the front of the panel.
Each Gas monitor/module shall have the following
minimum features:
Ack/Reset Button to acknowledge / reset alarm,
Inhibit function facility, configuration facility etc.
Audible-internal sounder

6.1 Power-Supply: On-line UPS (Uninterrupted Power Supply) with minimum 04

hours backup is to be supplied, installed at each installations.

6.2 Cabling: The bidder has to supply & lay Single core triad / 4-core cable from
sensor to field JB. The cable should be routed properly through existing cable
duct wherever the cable duct exist or supply & install 1” cable tray & route the
cable through the cable tray. The bidder has to provide proper supports for
installing the cable tray. The Bidder has to supply & lay Multi-core cable from
Field JB to the Control Unit installed in SCADA room / Control Room. The multi-
core cable should have provision for ‘SPARE CORES’, for future connectivity of
at-least TWO additional sensors. The Multi core cable should be laid
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underground by making proper trenching & marking the cable laid route. The
bidder shall supply & lay the power cable from Power supply distribution board to
the Control Unit within the SCADA room / control Room. The bidder has to
Supply & lay cable. The approximate details of the cable length & cable tray
requirement are provided elsewhere in this scope of work. The technical
Specification of the signal cable and control cable is also provided. The Power
Cable is also to be laid from the Controller Unit to the Field Hooter (230 VAC / 24
VDC). In case the Field hooter requires 230 VAC, should be laid separately from
the signal cable so as to avoid any interferences.
6.3 Source of Mains Power Supply (230AC): For GDS at control room, mains power
is to be taken from either electrical sub-station or SCADA room or anywhere as
specified by Engineer-in-Charge (EIC). Supply and Laying of Power cable in
underground trench/ cable tray from the electrical source is in bidder’s scope.
Wherever road crossing is there, power cables should be laid in GI pipe. Supply
of GI pipe and pipe fittings is in bidder’s scope.

7.0 Cable Termination: Bidder shall supply all cable glands required to gland the
above mentioned cables both at field instrument and at control room (local and
main) / control room devices / junction boxes. All cables glands shall be of
anodized aluminum alloy or of nickel plated brass and they shall be double
compression type suitable for armored cables. Explosion proof glands
wherever required shall be supplied. Bidder / Vendor shall supply a 20% of
cable glands of each type / size as spare. The bidder shall terminate the cables
with proper glanding & tagging in field sensor, Junction Boxes & Control Unit.

8.0 Field Junction Box (FJB): Bidder / Vendor shall supply DGMS approved
junction boxes wherever required. These shall be of die cast aluminum alloy
body and shall be weather proof only when connected to intrinsically safe
circuit. However when connected to an explosion proof instrument / circuit the
junction boxes shall be weather proof and explosion / flame proof. These
boxes shall have terminals suitable for min 4mm 2 cable terminations (clip-on)
mounted on rails. 20% spare terminals shall be supplied in each junction box.
Each junction box shall have a minimum of 10% or 2 Nos. of each size entry,
whichever is more. Each of spare entries shall be duly provided with plugs.
9.0 Mounting Accessories: All the required accessories required for mounting of
FJB, Sensors, Control Unit etc are in the scope of the bidder. All the spare Cable
entries should be provided with proper plugs.

10.0 Statutory Approvals: BIDDER shall be responsible for obtaining statutory

approval from authorities like DGMS, IBR, CCE, GPCB, Municipal Corporation,
Development Authorities, Electricity Deptt., Electrical Inspector, Inspector of
Factories and any other concerned authority; as required for the
execution/completion of the WORK.

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11.0 Product Support and Service: Bidder has to confirm the supply of at least
Seven (07) years continuously and also provide after sales service, as and when
required by ONGC.

12.0 Historization of the alarm conditions shall be maintained in the data base for
alarm history for a minimum period of one year and the alarm display and print out
shall list the following for each alarm as a minimum :
Date and time of occurrence
Point identification (i.e. Tag number) & description
Type of alarm
Time of acknowledgement
Time of return to normal
Serial number of alarm in the sequence of occurrence

13.0 Audio-Visual Alarm

The system will generate alarm as soon as the LEL in the field crosses the set level
in either one sensor or more sensors. In alarm condition there will be an Audio-
Visual Alarm in the Main Control Room to alert the Operator & the hooter should
operate in the field to alert the field operator about the LEL Alarm level. The tone
used for gas alarm horns shall be clearly identifiable and different from the tones
used for other alarms (e.g. fire alarm, plant emergency alarm etc).The hooter in the
field & the Electronic buzzer in the control room will stop on operating of Accept
Push button installed on the control unit installed in the control room & the visual
alarm should remain flashing till the LEL level is restored back to normal limits.
When the LEL level in the field is in normal the flashing of alarm should become
steady Alarm. The alarm should be reset on operating of Reset Push button installed
in the control room.
Tentative broad Bill of Material:

Sl. Item Description Quantity Remarks

No. Required
1. IR Sensor-cum Transmitters along 77 nos For Common Detectors – mounting shall
with Mounting Stanchions be in Cross I-Beam
2. Control Units 11 Nos
3. FJBs Number of Entries and Size of FJBs may
be decided based on the number of
cables coming from C/R.
4. Hooters for Field Use 20 nos
5. Buzzers for C/Room use 08 nos
6. Signal Cable 4000 mts The quantity mentioned is Approximate
7. Multicore Cable 1000 mts quantity. Exact quantity to be worked out
8. Cable for Hooter installed in field 1 lot during detail Engineering
9. Power Cable 1500 mts
10. Stanchions 77 nos
11. Cable Trays One lot

Note: In addition to above quantity, if any materials are required to complete the scope, it is to be
supplied by the bidder within the quoted price.

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Typical Stanchion Drawing

SENSOR

3 Meters 1.5 Meters

Tentative Documents to be submitted by bidder for Review/ approval /information

of ONGC:
A) During detailed Engineering:
a) Proposed cable schedule
b) Data sheets for Gas detectors
c) I/O configuration details for each panels
d) Complete bill of material.
e) Control System cabinet Wiring Details
f) Sensor locations
g) Loop diagram & loop details

B) As built documents:
a) Hazardous area certificates for all Gas detectors and junction boxes
b) Test certificates for cables.
c) Panel wiring diagram for all field inputs
d) Warranty / Guarantee certificates for all third party items.
e) Data sheets for all Infra-Red Gas detectors.
12.1 Construction & Installation:
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Execution of work shall be in a preplanned manner in consultation with ONGC.

Supply of construction material, labour, supervision, tools, tackles,
consumables etc although not specifically mentioned but necessary for
construction, installation, testing and commissioning of the complete system is
in bidder’s scope. Facilities at work shop / site or at the Engineering office of
the bidder at their own cost. For site office or for storage of material at site,
ONGC shall provide open pace if required by bidder.
Bidders are advised to make site visit to understand the plant layout, scope of
site work, and assess the logistic requirements.
12.2 Commissioning :
The bidder shall be required to prepare operating manual, arrange/mobilize all
types of calibration equipment for testing, supply of all consumables, spares
required for pre-commissioning activities. Bidder shall engage qualified and
experienced Engineers and skilled technicians for site work to avoid wrong
handling of the instruments and systems.
12.3 Project management: The bidder shall ensure deployment of very effective
and efficient project management team for timely completion of the project. The
organization chart, control, feedback, corrective measures, communication and
project execution scheme shall be submitted at the time of Kick off meeting
after award of work.

13.1 Audio-Visual Alarm

The system will generate alarm as soon as the LEL level in the field crosses
the set level in either one sensor or more sensors. In alarm condition there
will be an Audio-Visual Alarm in the Main Control Room to alert the Operator
& the hooter should operate in the field to alert the field operator about the
LEL Alarm level. The tone used for gas alarm horns shall be clearly
identifiable and different from the tones used for other alarms (e.g. fire alarm,
plant emergency alarm etc.).The hooter in the field & the Electronic buzzer in
the control room will stop on operating of Accept Push button installed on the
control unit installed in the control room & the visual alarm should remain
flashing till the LEL level is restored back to normal limits. When the LEL level
in the field is in normal the flashing of alarm should become steady Alarm.
The alarm should be reset on operating of Reset Push button installed in the
control room.

13.2 INSTALLATION, INSPECTION & TESTING:

ONGC reserves the right to involve and satisfy itself at each and every stage
of testing. ONGC shall be free to request specific tests on equipment
considered necessary although not listed here but agreed as part of FAT
procedure. The cost of performing such tests shall be borne by vendor.
13.3 The acceptance tests shall include:
 Hardware and software tests
 Factory Acceptance Test (FAT)
 Site Acceptance Test (SAT)
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13.4 The tests undertaken shall demonstrate that each of the following responsibilities
has been fulfilled:
 The system is tested as an integrated system.
 The hardware and software responsibilities are fulfilled.
 All tests are documented in a checklist fashion.
 The system is fully proven and ready for service.
The test procedures shall be developed in parallel with the system design.

13.5 The test procedures shall be developed by the Bidder as system engineering
proceeds and shall be submitted at least one month before commencement of
the first factory test.

13.6 Any component of hardware or software failed during a test shall be re-tested as
necessary to prove rectification has been completed satisfactorily.

13.7 Hardware Tests:

13.7.1.1 Comprehensive hardware tests shall be completed by the Bidder prior to

any acceptance. Bidder shall carry out the following tests as part of their
QA procedure and sign off as part of the QA requirement:
 A heat soak test of 48-hour duration shall be carried out
 All modules will be tested individually after being installed in the
purchased system.
 The Bidder shall provide documented test programs that fully exercise all
functions in the purchased system.
 The Bidder’s quality control test records shall be made available for
examination.

13.7.2 Factory Acceptance Test (FAT):

13.7.2.1 Before the system is delivered to the site, satisfactory performance of the
entire system shall be demonstrated. The system shall simulate the final
onsite configuration as closely as possible.
13.7.2.2 Detailed test schedules, including at least the tests listed below, shall be
submitted for the Company’s approval one month before the testing. The
Bidder shall have a technician and test equipment available full time
during testing. The tests shall be conducted after the 48 hours heat soak
test.
 Inspection of equipment
 Shock or vibration test (Bidder shall supply certification to
demonstrate such a test was passed for the generic system)
 Power supply variations
 Radio interference test
 Functional tests, including:
1) Operator control panel functions,
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2) Module replacement and standby changeover,

3) Operation of multiple processors,
4) Operation of communication channels,
5) Operation of power supplies,
6) Failures and interaction between different parts of the
system,
7) Systematic diagnostic test, including self-test facilities,
8) System and report alarms,

 Electrical isolation test,

 Application logic test,
 Application software functional change test as per the Logic
and / or the Cause and Effect diagrams,
 System responsiveness (e.g.: scan time, alarm
discrimination, logging and screen updates),
 SOE test, including accuracy of time-stamping,
 Spare capacity verification

13.7.3 Site Acceptance Test (SAT):

13.7.3.1 The purchaser shall take over the system from vendor after successful
completion of SAT. SAT shall be started only after all the Systems in that
particular production Installation are installed and tested by the
successful bidder at site, all loops calibrated independently and the entire
system is ready for operation..
13.7.3.2 Site acceptance tests shall be carried out in presence of purchaser’s
representative
13.7.3.3 The field inputs shall be connected and exercised to confirm the correct
connection and compatibility of the field components.
13.7.3.4 Vendor shall carry out following tests as minimum as part of SAT:
a) Hardware verification as per final Bill of material.
b) Visual & Mechanical inspection for proper workmanship, identification,
ferruling, name plates etc.
c) System configuration as per approved configuration diagram / scheme.
d) Demonstration of all system diagnostics.
e) Testing of redundancy features
f) Testing of all operational functionalities including pre-alarm and trip logic
function.
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g) System performance test.

13.7.3.5 ONGC will finally test for successful uninterrupted operation of the integrated
system for the duration of minimum 72 hours for all units. Bidder’s personnel
shall be present during the test. Any malfunctioning of the system
components shall be rectified free of cost .Once the system failure is
detected, the test shall start all over again from the beginning. ONGC shall
take over the system for regular operation once the Site Acceptance Test is
completed successfully. The warranty period shall start from the day ONGC
takes over the system.

14.0 SPECIAL NOTES :

14.1 The intending bidder is to visit the site (Group Gathering station and Gas
compressor station) and to assess ascertain primarily the number of detectors
required and their location, distance of cable from field to gas panel, trip output
from Gas panel to Main Electrical incomer and distance of cable required from
Gas panel to Main Electrical incomer, the total nos. of instrument power cable,
cable tray, trench and other requirements with the site condition before
submitting their bid. Non-Familiarity with the site condition will not be considered
a reason for extra claims or for not carrying out work in strict conformity as per
ONGC requirements/standard practices once the order is placed.
14.2 Layout diagram of each GGS, will be provided to the successful bidder.
14.3 The bidders must submit a written undertaking (along with the bid) that they
would be able to supply all the requisite spares and consumables (including
bought out items) for a minimum period of 10 (ten) years from the Certified date
of completion / successful field commissioning of the unit. Original Equipment
Manufacturer's undertaking must be forwarded for the items not manufactured by
the bidder.
14.4 The system to be under observation for minimum 72 hours for satisfactory
commissioning performance.
14.5 The Online Gas Detection system shall be Guaranteed/ warranted which must be
valid for 12 (Twelve) months from the date of successful commissioning.
14.6 All the Gas detectors along with control system to be calibrated on site and alarm
level to be checked before put into operation
14.7 All field mounted devices including gas detectors shall be provided with
canopy/sunshades for protection against rain and water. Gas detectors shall be
grounded as per the OEM’s recommendations.
14.8 Power distribution network shall be designed in such a way that single point
failure shall not cause tripping of the total system.
14.9 Bidder must confirm in writing to provide commissioning spares free of cost at the
time of installation and commissioning as well as during test run of the system.

15.0 Data sheet for Infra-Red Gas Detectors:

Sl Features Requirements
No.
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01 Function ` Shall be able to detect hydrocarbon gases like – Methane ,

Ethane , Propane , Butane & Pentane in the range of 0-
100% LEL
02 Working principle Infra Red absorption
03 Optical performance Correct operation unto 50% obscuration, with facility for dirty
optics warning above 40%, provision for heated optics to
avoid condensation.
04 Humidity range 0-90 % RH -non-condensing or better,
05 Area classification Class 1, Div1 Group B,C & D
06 Approvals CENELEC / CE Marking/ CSA / FM / UL / BASSEEFAA etc.
07 Construction As per Mfr std.
08 Output signal 4-20 mA for 0-100% LEL
09 Status indication The field unit shall have LED indication for – Normal, Fault
condition & Gas detected condition.
10 Accuracy Better than ± 3 % of gas reading
11 Repeatability ± 2% of gas reading
12 Zero drift Less than 2 % per year.
13 Response time 90% of gas reading within 10 secs.
14 Ambient temp range 10 degC to 50 degC
15 Ingress protection IP 65 or better
16 Immunity to external The unit shall be immune to all external light – both constant
light as well as intermittent.
17 Input power supply 20 – 30 Volts DC
18 Cable entry ½ “ NPT (F) or 3/4 “ ET
19 RFI /EMI protection Shall comply with EN50081-2 , EN 50080-2
20 Dimensions As per Manufacturer std
21 Weight 3.0 Kgs approx. or less
22 Housing Aluminum or Stainless steel
23 Sensor life Minimum 3 years

Note: All gas detectors shall be supplied with local inbuilt digital display (No attachment
type is acceptable), which shall provide currently detected gas concentration. In addition,
all type of detector failure/sensor failure alarms shall also be provided. The IR detector
shall have diagnostic alarms for dirty or misaligned optics and blocked beam.
The detectors shall have two levels of alarm and trip setting adjustable over the entire
range with reference to concentration of gases before the hazard level is reached.
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 SUPPLY, INSTALLATION, COMMISSIONING OF
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GGS OF ANKLESHWAR ASSET.

15.1 Data sheet for Signal cable :

Technical Specification for Cables

Description Signal Cables

1 Pair, Armoured, Shielded Signal Cable with overall
Type
sheath color - Black
Conductor Size 1P X 1.5 mm2

Make To be confirmed by bidder

Quantity As Required
Conductor Annealed electrolytic grade stranded copper conductor
No. Of Strands 7/0.53 mm'
Twists Number of Twists shall not be less than 10 Per Meter.
Insulation Grade 600V /1100V
Primary Insulation Extruded Flame Retardant Type C PVC compound.
85 Deg. C confirming to IS-5831 of minimum thickness
0.5 mm
Insulation Thickness As per BS : 5308 - II
Inner and Outer Jacket Extruded Flame Retardant, Low Smoke 90 Deg C PVC c
Insulation confirming to IS-5831 Type ST-2
Thickness shall be as per IS: 1554 - I. A rip cord shall be
Insulation Thickness
Provided for inner jacket.
Oxygen Index Over 30% (At Room Temp.)
Temperature Index Over 250 Deg C.
Fire Retardant Low Smoke As per IEC 332-3 Part 3 CAT A
Insulation Resistance ,
Voltage and Spark As per BS 5308 Part II.
Test
Armoring Galvanized steel wire / strip as per IS 1554 Part I.
Color Code:
Outer Sheath I Jacket Black
Inner Sheath I Jacket Black
Conductor Insulation As per Mfr standard

Maximum DC Resistance (of

the
Shall not exceed 12.3 ohms / km at 20 Deg C.
Conductor of the completed
cable)

Capacitance
Mutual Capacitance of the
Shall not exceed 250 Pf / Meter at a frequency of 1 kHz.
pair
Capacitance between any
Shall not exceed 400 Pf / Meter at a frequency of 1 kHz.
core and screen
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 SUPPLY, INSTALLATION, COMMISSIONING OF
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GGS OF ANKLESHWAR ASSET.

L / R Ratio of adjacent cores Shall not exceed 40 micro Henry / ohms

The drain wire shall be in continuous contact with
Drain Wire for overall screen
aluminum side of the shield.
Type Multi stranded. 7/0.3 mm'
Resistance including shield Shall not exceed 30 ohms / km.
Material Annealed tinned copper conductor.
Electrostatic Noise Rejection
Shall be over 76 dB (NA for 1 Pair Cables)
ratio
Insulation Resistance@ 20
> 100 M ohms / Km
Deg. C

Pair / Core identification shall be provided with numbers at

Pair Identification intervals of not more than
250 mm. (NA for 1 Pair Cables)

Meter Marking At every 1 Meters

Drum Length As per requirement
Diam. Over Inner Sheath As per IS-1554 part-I
Diam. Over Armor As per IS-1554 part-I
Overall Diameter As per IS-1554 part-I
Aluminum backed Mylar / polyester tape of thickness 0.05
mm bounded together with the metallic side down helically
Element Screen / Shield
applied with either side having 25% overlap and 100%
coverage.

15.2 Data sheet for cable tray

Sl Description
No
1 The Trays shall be made of GI ,(Zinc coated , Hot dipped Galvanized
), Pre-fabricated , perforated
with dimensions as follows :
50mm (W) X 30 mm (H) X 2500 mm (L) X 3 mm (Thickness).
2 The tray surfaces should be free from sharp edges, burrs and
projections to avoid damage to cables.
3 The standard length of straight run cable tray shall be 3000mm or
2500mm.The thickness of the tray and accessories shall be minimum
3mm.The width and the depth of the trays shall be selected as
indicated elsewhere.
4 The trays shall be corrosion proof for environmental, acidic, alkaline
and saline corrosion.
The trays shall be Galvanized ( Zinc Coated, Hot Dipped, Galvanized
Prefabricated Perforated )
5 MOC of the Sheet steel shall be "HRC Sheet As per IS : 1079 Gr 0"
6 Applicable Galvanizing Standards - As per IS 2629 & IS 4759
7 All offered cable trays or those of similar designs manufactured by the
same supplier

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 SUPPLY, INSTALLATION, COMMISSIONING OF
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GGS OF ANKLESHWAR ASSET.

8 Loading on the cable trays:

for tray system design, in addition to self load, following guideline for
design shall be considered.
a) Support span 1500mm
b) Cable load for 50mm (W): 10 kg/ Linear Meter
c) In addition to this, 70 Kg concentrated load at centre
span with a safety factor of 2 shall be considered.
9 The side rails and all accessories shall have the holes on each end for
fixing connector plates. The connectors between two sections of cable
trays or a section of cable trays with associated accessories shall be
done by bolting only.
10 Each coupler assembly shall consist of two coupler plates plus
requisite no. of bolts , nuts ,
washers etc.

15.3 Data sheet for Junction boxes:

Sr..No
Specification Description Requirement
.

1 Tag Numbers As Specified

2 Make/Model No. Bidder to Specify

3 Quantity As Specified
4 Material of JB Cast Aluminum Alloy (LM6)
5 Mounting Outdoor , Hazardous area
6 Enclosure Industrial , Explosion proof as per IS-2148
7 Ambient Temp 0 to 60 Degree C.
8 Colour Light grey , Epoxy coated , as per shade 631 of IS 5
Terminals Spring loaded. Vibration proof. Clip on type
Junction boxes shall have doors which shall be of
9 Construction hinged type and these shall be fixed with SS or
cadmium plated countersunk screws
10 Terminals make / size Elmex or Equivalent / Minimum 2.5 sq.mm
Required, total minimum 44 nos terminals to be
11 Terminal Numbering
provided suitable for 2.5 sq.mm conductor
.
12 Dimensions
Overall : 355 mm X 385 mm ( approx)
Bottom & side , Main cable :1 1/2:” NPT(F) or as per
13 Cable Entry requirement & branch cable entry : 12/16 nos ½ “
NPT(F)
14 Mounting Accessories Required
15 Earthing lugs one inside & one outside (Size: M6)
16 Tag Plate Required
17 Plugging of entry ports Blind plugs shall be provided to block all idle entries.
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 SUPPLY, INSTALLATION, COMMISSIONING OF
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GGS OF ANKLESHWAR ASSET.

The entry points shall be plugged by PVC caps

during transportation.

Note:
1. During Inspection, the vendor shall be responsible for completing all in - house
testing and test reports for the same shall be ready before inspection by the
clients. The Inspection will be done as per QAP approved by ONGC.
2. Vendor shall submit dimensional drawing & other technical details before
offering the JB for inspection.
3. Vendor shall submit certificate of the enclosure for compliance as per IS -2148
for suitability for use in hazardous areas.

16.0 General Specification for System cabinets & Instruments:

 The control panels for system cabinets shall be designed and built to
accommodate the instruments and instrument auxiliaries as referenced in the
specification. Control panel shall be designed to allow for at-least 20%
expansion for future changes without involving any major modification in the
system. The sharp edges and documentation shall be rounded off to protect
personnel. The final assembly shall be free warps, buckles, dents, or
blemishes. Steel strip stock shall be edge welded to the back of the panel
front face above and below the cut outs for instrument cases/ shelves, and
elsewhere as required to ensure a rigid self-supporting structure. In order to
reduce the loading on the panel face, unstructured channel or equivalent
support shall be run horizontally beneath the instrument cases/shelves to
provide rear support. The finished panel framework shall have sufficient
strength to allow transportation and lifting by a crane, with all instrumentation
installed, without causing buckling or deflection. Entry to the panel shall be
through hinged full length swing doors. Doors shall be made of C.R steel
sheets of minimum 2 mm thickness.
 Hinges shall be full piano type. Door frame shall be formed to ensure that the
door fits tightly all around. Door latches shall be the flush mounted, 3-point
type with recessed chrome plated handles.
 The panel and its internal equipment arrangement shall be designed to
provide adequate cooling of Panel instrumentation by convection alone.
Louvers shall be provided on the top and filters at the suction of enclosure for
air circulation purpose. Minimum two exhaust fans operating on 230 V AC
shall be provided on top of the Panel with control switches located inside the
Panel.
 All wiring to the instruments shall be terminated on terminal blocks and/or
multi-pin connectors provided as an integral part of the mounting case or
shelf. In addition, total removal of the instrument and replacement with a
spare shall be possible from the front of the panel. . Sufficient access shall be
provided within the panel to allow checking and/or changes to the wiring to
the instrument case/shelf. Designated spare instrument spaces shall be
covered with blank plates.

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 SUPPLY, INSTALLATION, COMMISSIONING OF
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GGS OF ANKLESHWAR ASSET.

 All wires required for Panel internal wiring shall be of minimum 1.0 mm2,
standard copper conductor, with 600 volt rated PVC insulation. Multicore
cables shall have 1.5 mm2 copper standard conductors with PVC insulation
individual pair & overall PVC sheathing Power cables shall be 3 core,
minimum 2.5 MM2 copper conductors with 600 V rated shall be tagged at
both ends with full ring type label. Tagging shall correspond to that used on
control panel schematic drawing.
 A system of flame retarding type plastic wire ducts shall be provided for
routing wiring. All wiring run outside of ducts shall be in bundles, neatly routed
in a vertical or horizontal plane only, and secured with plastic wire ties or
cable lacing. Special precautions must be observed to maintain the integrity
of intrinsically safe wiring. Separate wiring ducts, identified by color code or
labeling shall be provided for intrinsically safe and non-intrinsically safe wiring
in the Panel. Further more, the intrinsic safety barrier outputs terminal must
be covered by an insulator to protect the field wiring from coming in contact
with a high energy source. Power circuits, instrument signal circuits and alarm
circuits shall be segregated in separate wire ways. At least 20% additional
space for future wiring shall be provided in wire ways. The panel shall be
designed for field wiring entry from the bottom exclusively. Desk inside top
can be utilized for interconnection between rear of Desk and front Desk
instruments/accessories.
 Not more than two (2) wires shall be installed on any terminal of any electrical
device. Terminals shall be sized to accept lugs for the wire sizes specified.
 Terminal blocks for Desks shall be rated and break resistant flame retarding
PVC suitable for 4.0 mm2 minimum standard copper conductors. Terminal
strips shall be the spring loading, screw locked, stacking type, with all
terminals clearly labeled. Terminal blocks shall be elevated off their mounting
plate to facilitate making wire connections. Terminal strips shall be mounted
in vertical plane and shall be spaced at least 125 mm center to center.
Terminal strips shall be elevated by minimum 300 mm from the gland plate. A
minimum of 20% spare field wiring terminals, evenly distributed through put
the Desk, shall be provided.
 All wire connectors for panel wiring shall be of the compression type, with
PVC insulated sleeves. Spade type terminals shall be used. No splices will be
allowed within the Desk.
 Control Unit based system cabinets shall be supplied completely wired,
requiring only field connections at site.
 Special precaution must be observed to assure proper grounding of intrinsic
safety barriers. Two independent ground wires must be run from the dual
barrier grounding screws to the ground bus bar ground screws can be
interconnected in a multiple barrier assembly however the ground wires must
be connected so that removal of any barrier shall not interrupt the ground
circuit. The resistance between the barrier and ground shall be less than one
ohm.
 All instrument cases and housing capable of carrying current shall be
grounded to the panel structure. The panel structure will in turn be grounded
to the ground bus bar for eventual connection to main ground. Compression
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 SUPPLY, INSTALLATION, COMMISSIONING OF
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GGS OF ANKLESHWAR ASSET.

type terminals suitable to the ground for 4/0 AWG copper ground cable shall
be provided in each Desk section for the purpose.
 Panel shall be designed to accept one 240 V AC main power supply feeders
to be protected by a suitable sized thermal magnetic circuit breaker with
manual trip lever. The breakers shall be housed in suitable surface
enclosures. In addition panel shall accept a 240 V, 50 Hz, AC feeder for
internal lighting and convenience outlets.
 Indicating fuses shall be used in the power distribution to all instrumentation
in accordance with the instrument manufacturer’s recommendations and good
practice.
 All enclosures shall be clearly marked indicating voltage level contained
therein.
 Internal lighting shall be installed using fluorescent lighting fixtures to provide
adequate lighting for maintenance of equipment. The location of lighting
fixture must not interfere with doors or other equipment which must be
accessible and space shall be maintained for bulb replacement. Thermal
insulation must be provided if necessary to prevent excessive temperature
Rise.
 All instruments items and equipment to be used for Control panel, shall have
the written approval of the Company prior to procurement and fabrications.
 It shall be responsibility of the Bidder to ensure proper compatibility of all
receiver instruments with other field mounted equipment.
 Bidder shall develop and furnish the ladder / logic diagram for all the units for
review on the basis of process write up Bidder is also to provide write up for
all control systems & shut down system.
 Wherever, indicating bulbs are used in the panel etc, it should be of cluster
LED type.
 Power distribution network shall be designed in such a way that single point
failure shall not cause tripping of the total system.
 All field mounted devices including gas detectors shall be provided with
canopy/sunshades for protection against rain and water.

17.0 APPLICABLE NATIONAL AND INTERNATIONAL STANDARDS

Design & terminology shall comply, as a minimum, with the latest edition of
following codes and standard practices of reputed publications:
 American Gas Association (AGA), Gas measurement Committee Report
(latest)
 ANSI/ISA -50.02 Part 2 –1992: Field bus Standard for use in Industrial
Control systems Part 2, Physical Layer specification and service
Definition.

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 SUPPLY, INSTALLATION, COMMISSIONING OF
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GGS OF ANKLESHWAR ASSET.

 ANSI/ISA -50.02 Part 3 –1992: Field bus Standard for use in Industrial
Control systems Part s3, Data Link Service Definition.
 American National Standards Institute (ANS)
 B 2.1: Pipe Threads
 B 16.5 : Steel pipe flanges and flanged fittings
 B16.104 : Control valve leakage classification
 MC 96.1: Temperature measurements, thermocouple.
 American Petroleum Institute (API)
 RP-520: Recommended practice for design and installation of pressure
relieving system in refineries.
 Part 1 : Design
 Part II : Installation
 RP- 521 : Guide for pressure relief and depressurizing systems
 RP - 526: Flanged steel safety valves.
 RP - 527: Commercial seat tightness of safety relief valves with metal to
metal seat.
 RP 550: Manual on installation of Refinery instruments and control
system.
 S - 1101: Measurement of Petroleum liquid hydrocarbon by Positive
Displacement meter.
 S 2000: Venting Atmospheric and low pressure storage tank.
 S2534: Measurement of liquid hydrocarbons by turbine meter systems.
 American Society of Mechanical Engineers (ASME).
 Boiler and Pressure Vessel codes.
 American Society for testing and materials (ASTM).
 British Standards (S).
 Measurement of fluid flow in pipes - 1042
 Temperature VS Resistance curves for RTDs. – 43760 (DIN)
 Indian Boiler Regulations (IBR).
 International Electro-technical Commission (IEC).
 Indian Standard for Colors for ready mixed paints (IS-5).
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 SUPPLY, INSTALLATION, COMMISSIONING OF
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GGS OF ANKLESHWAR ASSET.

 Instrument Society of America (ISA).

 Standards and Practices of Instrumentation
 National Electric Code (NEC).
 NEMA: National Electrical Manufacturer’s Association ICS6- Enclosures
for industrial Controls and Systems.
 NFPA : National Fire Protection Association
 Purged and Pressurized enclosures for electrical equipment (NFPA-496).

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GGS OF ANKLESHWAR ASSET.

SCOPE OF WORK for Comprehensive AMC

The successful bidder has to carry out Annual Maintenance for six (6) years for the
complete On-Line Gas Detection System supplied, installed & commissioned against this
tender.

Annual Maintenance will start after successful completion of warranty period. Only skilled and
trained manpower has to be engaged at site for AMC works.

1. Four nos. of Preventive maintenance (PM) should be carried out in a year (quarterly).
During PM, calibration of all the sensors and system are to be carried out. A calibration
certificate along with PM report is to be submitted to ONGC. For carrying out calibration job,
calibration kit along with minimum following items shall be available at site -
(i) Pressure Regulator
(ii) Calibration Adapter (iii) Hose, Flow meter (iv) Carrying case
(v) Methane Cylinder (vi) Zero Gas Cylinder
(vii) One hand held portable intrinsically safe calibrator/ equivalent calibration device. This
calibrator should be certified by an accreditation body of National/International repute.
3. All calibration instruments, used must have NABL traceability certificates with valid date.

4. Breakdown maintenance as and when required basis as intimated by ONGC shall be

carried out.

5. Replacement of spares and Delivery Schedule :

Spares on demand by ONGC shall be supplied by the vendor at site within 72 Hrs. Supply,
Installation and commissioning of brand new spares in place of faulty/ unserviceable defective
spares with the help of skilled manpower at site is also in the scope of vendor.

6. The expenses for transportation, boarding, lodging, medical etc. for their personnel is in
the scope of the bidder.

7. Necessary PPE for their personnel is to be provided.

8. Necessary tool, test equipment etc. shall be available at site for carrying out both
preventive and breakdown maintenance of the system to complete the job in safe way.

9. For Annual Maintenance support, ONGC will liaise only with a single point of contact of
the bidder. The bidder has to mention the contact address, phone number of the contact person
who will be responsible for Annual Maintenance support.

10. Maintenance charges shall be payable QUARTERLY after successful completion of the
Maintenance services for that period and against receipt of bill from the supplier. Any penalty
amount levied on the bidder will be adjusted from that period of Maintenance charge.

11. Non Performance Deduction

In case the system at any site/ installation is not available due to non-rectification of any fault/
non-availability of spare or any other reasons , for more than 72 hours of reporting, 1% of AMC
charge of that particular year shall be deducted on per day basis for each site/ installation .

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GGS OF ANKLESHWAR ASSET.

12. The scope shall not remain limited to the above jobs but any job that may arise at time
necessary for servicing & maintenance of Gas Detection System shall also be considered in the
scope of work.

26