TAS Ref

INQUIRY SPECIFICATIONS
FOR THE UPGRADATION OF TERMINAL

AUTOMATION SYSTEM AT IP AND AN MELT
FILLING STATIONS
INQUIRY NO: INST_IPFILLING/TMV/TAS- CONTROL SYSTEM
1
INDEX OF INQUIRY SPECIFICATION
Sr. Description
No.
TAS SYSTEM
1 INTRODUCTION OF PROPOSAL
2 GENERAL TERMS AND CONDITIONS OF BID.
3 TAS SYSTEM DESIGN ASPECTS, FUNCTIONAL REQUIREMENT AND WORK
FLOW CHART FOR TANKER MOVEMENT.
4 DETAILS OF METERING SYSTEM INSTALLED.
5 BATCH CONTROL UNIT
6 ACCESS CONTROL DEVICE
7 TAS SERVER
8 TANK TRUCK ENTRY SYSTEM (TTES)
9 ETHERNET SWITCHES
10 TERMINAL SERVER
11 LIGHT INTERFACE UNIT (LIU)
12 FAIL SAFE OPERATION PHILOSOPHY
13 TAS SYSTEM BLOCK DIAGRAM
14 TAS BILL OF MATERIAL
CONTROL SYSTEM
15 INTRODUCTION
16 BIDDER’S RESPONSIBILITY
17 SCOPE OF WORK
18 SYSTEM FUNCTIONAL REQUIREMENTS
19 SUMMARY OF CONTROL SYSTEM I/O LIST
20 CONTROL SYSTEM TENTATIVE BILL OF MATERIAL
COMMON FOR TAS AND CONTROL SYSTEM
21 INPECTION AND FAT
22 INSTALLATION, COMMISSIONING AND SITE ACCEPTANCE TEST.
23 FINAL ACCEPTANCE TEST
24 WARRANTY / GUARANTEE OF SYSTEM
25 SPECIFICATIONS FOR COMPREHENSIVE MAINTENANCE SERVICE AND
CONTRACT
26 DOCUMENTATION
27 TRAINING
28 FORMAT FOR BILL OF MATERIAL AND PRICE SCHEDULE
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1. INTRODUCTION OF PROPOSAL
Sr. GNFCs Requirement Vendor’s

No. response
1. INTRODUCTION :
GNFC is having Terminal Automation System along with two nos. of CONTROL
SYSTEM based control and instrumentation systems at IP and AN melt stations
area for filling and operation of all liquid Industrial products through Tanker.
GNFC plan to upgrade these systems due to obsolescence with the latest
technology available in the market.
Bidder to study this existing system design, engineering, supply, installation and
commissioning , working philosophy including auxiliary communication
hardware and software required to integrate with GNFC SAP/ERP system
keeping existing functional requirement as it is.
The Terminal Automation system (TAS) is to be designed, engineered and

supplied by Vender for tanker loading of 13 nos. of different Industrial Products
Such as Methanol, Methyl Format, Acetic Acid, Formic Acid, Concentrated Nitric
Acid, Weak Nitric Acid, Ammonium Nitrate (AN) Melt, Ethyl acetate etc. in line
with the existing system installed.
There are 22 nos. of Bays installed at GNFC IP filling station. Out of 22 Bays, 16
nos. of Bays are located at IP filling area and 2 nos. bays located at a distance
place approx. 1.5 Km away at AN melt filling area, 2 nos. at Ethyl Acetate filling
area and 2 nos. spare bays for future expansion.
At present, there are two nos. of Distributed Control systems (CONTROL

SYSTEM) installed, one at IP filling area and another at AN melt filling area for
controlling and monitoring of field instrumentation and various Tank parameters
with required HMI, controller and engineering station. The detail system
architecture of existing system is attached as ANNEXURE- 1.
Above is the brief introduction of existing system for the reference for the bidder.
Detail information/ clarification can be obtained from engineer in charge. Bidders
are requested to visit site study the system and detail specification / GNFC’s
requirements and make clarifications before submission of techno-commercial.
After submission of bid, no clarification and changes will be entertained.
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2. GENERAL TERMS AND CONDITION OF BID:

No. response
1 Each bid shall be submitted through E-tendering. Vendor to contact our Material
Management department (purchase) for required technical detail or procedure
for E-tendering.
2 The Bid shall be submitted by person / persons duly authorized to bind the Bidder
to the Contract.
3 Vendor to fill their compliance in “Vendor’s response” Colum against each serial
number of specification clause provide in each pages/sheet. In case of any
deviation from the technical specification, the same should be clearly mentioned
against each clause.
4 Vendor has to submit all technical detail of hardware and software proposed to be
supplied in plan of up gradation. Detailed technical
catalogue/drawings/specifications from OEM with respect to each technical
requirement shall be attached as a supporting document.
M/s GNFC reserves the right to reject offer OR take any suitable action at a later
date, whenever any “undisclosed deviation” comes to knowledge of M/s GNFC,
including canceling the order or applying penalty charges that it may deem fit,
or take corrective actions at the cost of the Vendor etc.
5 GNFC reserves the right to waive any of the Technical and Functional
Specification during technical evaluation, if in the GNFC’s Opinion, it is found to
be minor deviation or acceptable deviation.
6 During evaluation of the Bids, the GNFC is at its discretion may ask a Vendor for
technical clarification of its bid. The request for clarification and the response
shall be in writing, and no change in the price or substance of the bid shall be
sought, offered or permitted. Price bid offered with this tender will be final.
7 Vendor to offer price bid in line with the format “Format for Bill of material and
price schedule” provided with this specification.
8 Vendors may be called to give technical presentation of their solutions for their
capabilities at their own cost, which will be taken into account for technical
evaluation of the Bidders.
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3. TAS SYSTEM DESIGN ASPECTS & FUNCTIONAL REQUIREMENT:
No. response
3.1 TAS system is to be deigned to ensure product loading & unloading at the Terminal
facilities takes place in a secure, orderly, timely & well-documented manner. TAS
system and software must meet following functional requirement.
1. Accurate and uninterrupted products loading will be done to carriers such as trucks.
The process includes access validation at bays; product metering with equipment
such as Magnetic / Mass Flow meters; pre-set batch control; safety interlock
checking; monitoring, control & data acquisition by TAS server.
2. Data download / upload from BUSINESS SYSTEM (SAP/ ISD)
3. Bay queuing facility is to be provided with bay reallocation 3 times.
4. Multiple levels of security for process to TAS are to be provided.
5. Issue of Touch key & Dispatch Instruction (DI) Prints at the Marketing office are to
be provided.
6. Easy to use & interactive Graphical User Interface at Operator PC.
7. The system is to be built utilizing Relational Database Management System based
TAS Applications & CONTROL SYSTEM/PLC control System components for
real-time process & data management.
8. Reports Generation in a well documented manner in Local and Remote filling.
9. Provision of filling 10 numbers of tanker compartments will be done and each
compartment capacity is max. 50000 kg.
10. Facility for manual filling in case non availability of TAS system so that filling
work is not interrupted.
11. Seal number generation facility for each compartment.
GNFC-LAN (ISD-Network) requirement:

1. IT network diagram must be provided. All the network related settings (e.g. IP
addresses, hostnames etc) must be configured in consultation with ISD.
2. Whole TAS-IT infrastructure, including but not limited to, ethernet / optical fiber
cabling, servers, network switches, routers etc. for new TAS system shall be
provided by the vendor.
3. IT security (firewall / UTM) of new system shall be provided by the vendor. Proper
documentation shall be provided by the vendor specifying details of networking
scheme, require services/ports, specific security configurations etc.
4. Currently, database used in GNFC is Oracle 11g which is going to be upgraded to
Oracle 12c in near future. So, database connectivity shall be accordingly
established and should be compatible to it.
5. If system view is required on GNFC LAN, then it must be on HTML5, Java
Applets/Java NOT ACCEPTABLE.
6. For viewing, on network computers, no administrative rights are to be given to
users. Viewing must work without administrative right.
5
No. response
3.2 DESIGN BASIS:
Storage tank for every product is available in the battery limit of the Terminal. Mass
flow meters, Magnetic flow meters and digital valves are installed and available.
Provision to be made for the following Industrial products and number of bays to be
allotted for filling, monitoring and controlling from a central located TAS system and
CONTROL SYSTEM.
(1) METHANOL
Loading capacity: 460 MT/HR. Number of tanker filling bays: 4
(2) METHYL FORMATE
(3) WEAK ACETIC ACID
(4) ACETIC ACID
(5) FORMIC ACID
(6) CONCENTRATED NITRIC ACID
(7) WEAK NITRIC ACID (61.5%)
(8) WEAK NITRIC ACID (68/72%)
(9) AMMONIUM NITRATE
Loading capacity: 120 MT/HR. Nos. of tanker filling bays: 02
(10) FORMIC ACID CARBOY FILLING
Loading capacity: 24 MT/HR. Nos. of Carboy filling stations: 02
(11) ACETIC ACID CARBOY FILLING
Loading capacity: 3.6 MT/HR. Nos. of Carboy filling stations: 01
(12) METHYL FORMATE CARBOY FILLING
Loading capacity: 01 MT/HR. Nos. of Carboy filling stations: 01
(13) Ethyl Acetate:
Loading capacity: 150 MT/Day.
Number of tanker filling bays: 2
Hazardous Area classification:

The tanker loading is located in ZONE-1, GAS GROUP IIC/T6 hazardous area class
and hence all hardware (such as local push button station, emergency stop push buttons
and batch control unit etc.) in loading area should be EX-I(a) / IIC and in weatherproof
to IP67 as per IEC529 approved enclosure.
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No. response
3.3 FUNCTIONAL REQUIREMENTS:

Tanker Loading BAYS and BCU must consist of minimum following facility :
(1) Batch Control unit are to be require for all products. Type of BCU which will
be decided during detailed engineering. Batch accuracy to be + /- 0.15% or
better
(2) Slow start and slow finish.
(3) Soft & hard switches for individual bay and common emergency stop push
buttons are to be provided to stop filling from control room a common
emergency stop push button in the control room for tanker loading bays for all
products.
(4) Each loading bay will be provided with an earth checking device with suitable
interlock. An interlock is also to be provided to disable loading in case earthing
is disconnected during tanker filling till batch completion. Also confirms
allowable conductivity for dissipation (i.e. ensures continuity of earth
connection). (Earthing relay is in scope of GNFC)
(5) Sealing systems for tankers in loading area will be provided and facility for
entering seals nos. in TAS to be provided at the gantry.
3.4 Work flow and Tanker movement.

The following flow for tanker movement to be made in TAS software once an
IP product tanker enters the GNFC complex
(1) DI preparation at North gate. Data Entry Terminal enters the details of the
truck and qty. sanctioned by Marketing Dept. after the proper verifications of
the papers, and allocates a unique DI No. to that particular order. This DI no. is
unique no. which will be a common reference throughout the entire transaction
of the tanker till Invoice Generation. The Data entered at North Gate Computer
will be updated to MIS Server from where it will be available to TAS server
which in network.
(2) The DI contains the following information: Compartment wise quantity,
Tanker number, Tanker details, Inspection certificate number.
(3) It is proposed that the DI auto - numbering system will pre-allocate a set of DI
numbers product wise. This will easily identify the product to be loaded
into the tanker.
(4) DI is verified with indent sent by IP marketing. On verification being
approved, tanker number will be announced.
(5) The tanker then proceeds to the IP weighbridge where the tare weight of the
tanker is noted & recorded on to the network computer. Based on the data base
already available with GNFC, the tare weight is compared. Any major
deviation with the previous reading is highlighted & proper approval is
required before the tanker is released for loading.
(6) When the tanker enters the filling area, it reports to the shift supervisor who in
turn allocates a bay product wise for filling.
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No. response
3.4 Work flow and Tanker movement.

(7) The shift supervisor distributes total quantity to be filled in the tanker. The
software will check the total sum quantity of all the compartments with the DI
quantity to be filled. It will allow only if the total distributed quantity is equal to
or less then the DI quantity. This will prevent the over filling of the tanker.
(8) Comparison of product code of IP products with that of DI.
(9) Field man Ensures earthling clips is in place on to the tanker. (An interlock is
also provided to disable loading in case earthling clip is not securely attached to
the tanker )
(10) The DI number is entered into the batch controller. In case of any improper
product bay Selection, further actions will be halted with an error message on
the batch controller & TAS workstation. After validation of the DI number, the
batch controller will display the compartment wise batch quantity to be loaded.
(11) The supervisor instructs his field man to insert the loading arm into the tanker
& start filling by pressing the START button on the batch controller. The field
man ensures the filling of the tanker is done compartment wise.
(12) After completion of the loading process the field man enters seal nos. into the
batch controller. This uploads all loading information along with Tanker status
to the TAS system. This finishes the loading part in the Loading Bay.
(13) The tanker then proceeds to the weighbridge for gross weight. The invoice
generation begins if the following accuracy requirements are met. In order to
investigate any abnormality, a check is introduced in network that will allow the
printing of sale invoice.
(14) In some rare case, it becomes inevitable to fill the tanker partially in Auto
mode & partially in Manual mode. System software is featured to take care of
such occasion. (It will add the qty filled in Auto mode with the quantity filled in
Manual mode & updates the total quantity to Network.
(15) In some cases, it is required to fill the tanker in Manual mode only. To take
care of this, a separate form called “Manual weighment Entry” is provided by IP
group of ISD, which will take care & updates the total quantity filled to Weigh
Bridge PC.
(16) The weighment data like tare weight, gross weight & net weight is made
available to Shift engineer for verification purpose.
(17) A software utility will archive all old records at the end of fiscal year from
local database. This is required for enhancing the processing speed of PC & to
restrict the errors caused because of duplicate DI numbers.
(18) Audio visual alerts should be available on CONTROL SYSTEM for cases like
1) over vapor pressure. 2) Low flow. 3) No flow. 4) High flow. 5) Grounding
(earthing) fail during batch operation. 6) Emergency switches.
(BCU+Field+Panel) 7) Loading arm position 8) High Temp. , etc
(19) In case of special event, tanker may be required to be emptied back. Reversal
of TAS process should be possible with due authorization.
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4. Detail of Metering system installed at GNFC site:

No. response
4.1 Detail of Metering system consists of process line equipment such as Mass Flow Meters,
Magnetic Flow Meters and ON-OFF VALVES installed at various bays shall be made
available at time of detail engineering stage. The detail of installed Metering system
is attached as ANNEXTURE- 2.
5 Batch controller (BCU):

No. response
5.1 Vendor will offer latest model available in the market to meet following
functionality: The BCU shall perform the loading function in a remote control
mode with loading quantity issued from TAS Server or operate in a stand-alone
mode with local keyboard entry of loading parameters.
Automatic truck identification through rugged integrated card reader unit.
RIT with pushbuttons & lamps for operator interaction at the bay without
the language barrier.
Facilitate stand-alone operation with security password that can be
changed from time to time in case of communication failure with TAS
Server.
Facilitate operator interaction facility through built-in keyboard and
display.
Single arm filling
Hazardous area mounting for Batch Controller Unit suitable for ZONE-1,
Gas groups IIC/T6.
Interlock checking prior to loading
Perform batch-loading operation with:
o Meter linearizing.
o Multi stage start and stop.
o Flow control.
Accurately control the amount of fluid being loaded.
Flow inputs are received from flow meters pulse output.
Earthling relay interlocks considered while loading & unloading.
Vapor pressure and temperature interlocks considered while loading &
unloading.
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Actuates a digital set stop valve that is provided with two solenoid valves
5.1 to control flow and controls on/off valves.
MAKE of BCU: Vendor has to be mentioned BCU make & model with latest
specification and it will be approved by GNFC.
Stopping and resumption of loading locally shall be
The following loading related information would be displayed on the
BCU:
o Pre-set quantity
o Product Name
o Compartment No. /Truck No.
o Volume counts up.
o Error/Alarm/Operator Messages
Capable of providing the batch accuracy of 0.5%
Configurable feature for setting the flow set point (in 10% steps) for
calibrated K factor during reduction in flow rates.
Data retrieval facility by TAS Server for locally loaded trucks to maintain
integrity of terminal operation database and reports.
Seal number entry at BCU (The number of seals shall be max 30 per
truck. After every seal number entry, the BCU shall prompt for another
entry or ending the seal nos.).
BCU must communicate with LRC server based on open communication
protocol such as profibus, modbus and or TCP/IP Ethernet and not on
proprietary communication protocol.
6 Access Control Device:

No. response
6.1
Access Control Devices (ACD):
ACDs of touch key type are provided at the Security office for registration of
touch key cards for the tank Lorries. Touch Keys are used for truck authorization
at various points. The card readers are the authorization interfaces. The touch
keys are rugged and offer high level of security and their access code cannot be
changed. The touch keys involve a stainless steel body. A microchip with a
unique code is laser etched on the touch key. When the touch key is momentarily
touched against the ACD it receives a minute power supply that is sufficient to
transfer the code in to the reader. Card Readers shall be connected to the PC for
truck registration at marketing / S&D Room.
MAKE of ACD: Vendor has to be mentioned make and model no. of ACD with
latest specification and it will be approved by GNFC.
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7 TAS SERVERS:
No. response
7.1
TAS SERVERS:
The TAS Server hosts the TAS application software and is used in co-ordination
with the all peripheral devices including control system for MMI operation.
The TAS system consist two identical redundant servers (One primary and the
other secondary hot standby) with replicated RDBMS, i.e. Are designed as a
REDUDANT for takeover by the standby server in case of a failure of the main
server. A failure is defined as an instance that makes the TAS Server unavailable
for running the TAS applications to meet the defined functionality.
When the main server is restore online, the applications can be switched back to
main server automatically after equalizing the data from standby server to main
server.
TAS Server machine should be server grade of DELL/IBM/HP with latest server
operating system and specifications shall be freeze during pre-bid meeting at
GNFC site.
7.2 The minimum features of TAS application software are:

Record and preserve truck-loading information and terminal
information using the SQL server data base.
For the truck loading process the TAS modules in TAS Server
transfers the pre-loaded truck authorization data from SAP/ISD
server through an intermediated table residing in the TAS server and
send post load truck back to intermediate table for upload to
SAP/ISD server.
Bay allocation and queuing (one + ten trucks in queue) for trucks in
general.
Card allocation for the trucks.
Authorize and monitor loading at the loading bays, using BCUs,
Touch Key card reader and RITs.
Provide terminal operator interactive access to the system through
GUI for total plant operation.
Provide multiple levels of security for access to TAS software and
plant control.
Configuration of data access through ODBC drivers.
Report generation for Daily and shift, Truck wise filling, Event
report, Bay wise report, Message log report, Truck cancellation
report, Local filling report etc. on demand.
8 TANK TRUCK ENTRY SYSTEM (TTES):

No. response
8.1
Tank Truck Entry System (TTES):
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TTES PC will be Windows 10 or latest based platform for Graphical
8.1 User interface.
The TTES PC is used to register touch key cards using the ACD, to
assign the same to the trucks in TAS forms.
The TTES PC is also used for monitoring various TAS operations
like bay re-allocation, truck status monitoring, etc.
A user interface for report handling should be available.
One of the TTES PCs is used to drive the Access control device
through the COM port.
One of the TTES PC shall have 3rd Ethernet card for GNFC LAN
Connectivity and SAP front end S/W for DI printing.
Machine shall be supplied by vendor with latest specifications with
required software and any hardware interface modules
9 ETHERNET SWITCHES:
No. response
9.1 Communication interface between TAS server, Control System at IP Filling,
Control System at AN Melt Filling and TTES at marketing.
The acquired data made available within the LRC domain, TTES domain and
Control System domain.
Ethernet Switches with redundancy will be used for TAS, Control System at
IP Filling and Control System at AN Melt Filling and TTES PC At marketing
through LIUs.
Ethernet switch make and model will be decide during pre bid meeting.
MAKE of Ethernet Switches: Vendor has to be mentioned make & model no.
of Ethernet switch with latest specifications and it will be approved by GNFC.
10 TERMINAL SERVER:
No. response
10.1 Communication interface between TCP/IP (LAN) and serial (BCU)
The acquired data made available within the TAS Server domain.
Two Terminal Servers will be required for redundancy at IP Filling and Two
Terminal Servers will be required for redundancy at AN Melt Filling.
MAKE of TS: Vendor has to be mentioned make and model no. of Terminal
server with latest specifications and it will be approved by GNFC.
11 LIGHT INTERFACE MODULE(LIU):

No. response
11.1 Light Interface Unit is required for communication between TAS &
Control System at IP Filling, TAS & Control system at AN Melt Filling
and TTES at marketing office through Fiber Optical Cable Network.
We have required total 06 nos. LIUs in Network Cabinet.
MAKE of LIU: Vendor has to be mentioned make and model no. of
LIU with latest specifications and it will be approved by GNFC.
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12 FAIL SAFE OPERATION PHILOSOPHY:
No. response
12.1 Batch Controller Unit (BCU)

The BCU controlling single loading arms is a single unit with dual
communication link to the TAS Server. In case of failure of one port,
communication is established automatically with the other port. In case of
communications failure at both the ports, the BCU can be used to continue the
loading in the local mode with appropriate software password. The BCU should
capable to keep the last 400 transaction details in its memory.
12.2 Local Loading Operation

Local loading is to be performed in case of communications failure between the
BCU and the TAS Server. In local loading the identification of the truck and
quantity to be loaded are to be entered compartment-wise in the BCU utilizing
the built-in keypad.
12.3 Local Area Network (LAN)
Local Area network is redundant. The secondary LAN is made use of for
communication in case of failure of primary LAN but with the same IP address.
Each LRC, OIC and TTES has redundant network interface cards with fault
tolerant teaming software for redundancy.
One of the TTES PC shall have 3rd Ethernet Card to connect to GNFC LAN.
12.4 Terminal Servers
Two Terminal Servers are used for redundancy for the communication between
the TAS Server and the BCU’s. If one Terminal server fails the communication
is established from the next terminal server to the BCU automatically. Four
BCUs are connected to each port of the terminal server. A pair of eight port
terminal servers is used for IP Tanker filling whereas a pair of eight port
terminal servers is used for AN Melt filling.
12.5
Light Interface Unit (LIU):
Three redundant Light Interface Units are used for redundancy for the
communication between the IP Filling, AN Melt Filling and Marketing. If one
LIU fails then communication is established by the next LIU.
12.6 MMI presentation of TAS operations on the Engineering Server

of CONTROL SYSTEM:
The information related to operations of TAS will be communicated to Control
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System Engineering station and operator Interface console, this will be done via
OPC protocol by vendor. All required information for TAS operations will be
displayed on the Control System Engineering station and operator Interface
console, including dynamic graphical presentation of filling operations and also
trend and alarm displays as required.
The vendor has to establish communication between TAS and Control System
and also participate in detail engineering of MMI functionalities. Whatever
hardware and software will be required; it is under vendor’s scope.
12.7 Communication with GNFC’s ISD Network:
Vendor will participate in detail engineering with GNFC’s ISD (Information
Systems Department) department in establishing to and fro communication with
GNFC’s ISD network over which (sale of all products) will take place through
TAS system supplied by the Vendor. Vendor will provide all required
information in the required format as specified by GNFC’s IT department for
automated sale of the all products to GNFC’s ISD network. Similarly, Vendor
will receive information in the format defined by GNFC’s ISD department over
GNFC’s ISD network as required for TAS system operations.
13.0 TAS SYSTEM BLOCK DIAGRAM
Business server
(ISD)
TAS Server data
base
GUI operation /
engineering
configuration
TAS software
BCU’s
From CONTROL
SYSTEM for MMI
of application other
ACD than TAS
Reports
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14. TAS SYSTEM BILL OF MATERIAL : Minimum bill of material with required
specification is mentioned as below; vendor’s to offer material with required hard ware and software
and quantity to full fill to meet above requirement with batter specification material.:
Sr. Vendor’s
Item description Quantity
No. response
1 LRC (TAS server) (redundant) 2+1 (Spare)
(21” LED color video display units (VDUS) server grade machine
with Intel Core-i7 or latest processor, Windows 2012 or higher
version of server Operating System. 8 GB DDR RAM and 1 TB
HDD, RAID-5 HDD hot swappable, 5 Ethernet port, 5 USB port.)
2 Ethernet Switches at IP Filling. 2+1 (Spare)
(Industrial grade MOXA Unmanaged Ethernet Switch with 28,
10/100 Base T(X) Ports, and 4 Multimode 100 Base Fx Ports with
SC Connectors, 0 to 60 Deg.C Operating temperature. And 12 V, 1
Amp. Power Adaptor 2 Nos. each for Ethernet Switch. Warranty:
5 Years.)
3 Ethernet Switches at AN Melt Filling 2+1 (Spare)
4 Ethernet Switches at Marketing 2+1 (Spare)
5 N Port Terminal Servers at IP Filling. 2+1 (Spare)
(Nport Server with Power adaptor Make: MOXA Model: N
PORT-32 port device Server, 10/100M Ethernet,RS-422/485, RJ-
45 8 pin, 15 KV ESD, 100V TO 240V AC POWER ADAPTOR.
Warranty: 5 Years)
6 N Port Terminal Servers at AN Melt Filling. 2+1 (Spare)
(Nport Server with Power adaptor Make: MOXA Model: N
PORT-4 port device Server, 10/100M Ethernet,RS-422/485, RJ-45
8 pin, 15 KV ESD, 100V TO 240V AC POWER ADAPTOR.
Warranty: 5 Years)
7 Batch Control Unit with card reader at IP Filling, AN Melt 20+2 (Spare) Vendor to specify
Filling and Ethyl acetate.
8 Remote Instruction Terminal Module. 20+2 (Spare) Vendor to specify
9 ACCESS CONTROL DEVICE at Marketing dept. 2+1 (Spare) Vendor to specify
10 TTES 1 (PC NAME-:IPDI ) at Marketing dept. 2+1 (Spare)
(21” LED color video display units (VDUS) workstation
grade machine with Intel Core-i7 or latest processor, OS
windows 10 or latest, 6 GB DDR RAM and 1 TB RAID-5
HDD hot swappable, 5 Ethernet port, 5 USB port.)
11 CABLES Qty as Vendor to specify
1. RS485 (BCU to terminal server) required.
2. TCP/IP cable from IP and AN Melt Filling to Ethernet Will be
Switch (OPC connectivity) decided
3. All TAS, CONTROL SYSTEM, Terminal server, LIU during PRE-
etc. connectivity through Ethernet switches. BID meeting.
12 Redundant Bulk power supplies As required
13 All TAS System software with license copy As required.
14 All Server and stations software with license copy As required.
15 Firewall /UTM as required ** 03 Vendor to specify
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15. CONTROL SYSTEM:
Sr. Vendor’s
GNFCs Requirement
No. response
15.0 INTRODUCTION : Existing system.
Existing CONTROL SYSTEM (DCS) panels and all system hardware are located
at cabinet room in the close vicinity of control room. This cabinet rooms are
accommodate all marshalling panels, PDB panels, CONTROL SYSTEM
hardware panels, relay panels in both plants. All the interlocks and logics are
realized in DCS/control system.
All the field instrument signal / power and control cables are brought to this
central cabinet room, from where it was catered to diff. individual destination
marshalling panels and corresponding control system hardware panels.
The relevant CONTROL SYSTEM hardware is installed in dedicated panels.

Analog input, analog output, digital input, digital output and all interposing
relays are accommodated in a same marshalling panel/CONTROL SYSTEM
panel.
All the engineer stations and operator stations of both locations are
accommodated in the central control room in the close vicinity of central cabinet
room at IP Filling and AN Melt Filling.
Above is the brief introduction of existing system for the reference for the bidder.
Detail information/ clarification can be obtained from engineer in charge. Bidders
are requested to visit site study the system and detail specification / GNFC’s
requirements and make clarifications before submission of techno-commercial.
After submission of bid, no clarification and changes will be entertained.
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16. BIDDER’S RESPONSBILITY:

No. response
16.1 1. Bidder shall prepare system architexure diagram considering that main
Control system shall be installed at IP filling control room location. All I/Os of IP
filling and AN Melt filling will be connected to IP Filling controller through remote
I/Os concept and engineering of all I/Os segregation shall be done section/unit wise
in the control system.
2. All necessary system/communication cables shall run in closed,

flexible, PVC conduit only inside cabinet/control and engineering room, below the
false flooring.
3. All the DCS/control system hardware cards, including I/O Cards shall be
provided with protective coating as per ISA G3 level protection.
4. BIDDER shall quote for the technologically superior and latest version
system. The central processor unit used in the system should not be older than 3 years.
Software / firmware used in the system should be latest. Necessary certificate and
document must be attached with the offer with life cycle policy of the hardware
/software. Minimum life of hardware and software shall be 10 years from the date of
supply.
5. BIDDER shall inform OWNER for the updates in software/hardware releases

as and when released in future. Any software / firmware release for first five year shall
be supplied at no cost to GNFC.
6. The system reliability shall be stated in terms of MTBF in years (Typically

100 years). BIDDER shall state the mean times to repair assumed in the calculation of
MTBF (The minimum mean time to repair possible shall be assumed to be 4 hours).
Where a failure rate is derived from that of more than one item, the calculation method
and supporting data shall be presented along with the results. In addition to these,
BIDDER shall provide data from MTBF hours of each single module supplied in the
system.
7. As part of their tender, BIDDER shall present a comprehensive quality plan for
the overall manufacturing and supply of the control system hardware and software
based on ISO9001, including all phases of design and constructions. OWNER reserves
the right of visit AND audit the actual implementation of the Bidder’s QA/QC
procedure from time to time.
8. UN-interrupted power supply of high integrity shall be made available

through 8 nos. of feeders, each of having 32 amp capacity at both locations.
9. Vendor will to provide the system power consumption calculations and heat
dissipation load calculation along with offer in a separate sheet.
10. BIDDER shall supply all required standard/optional software and firmware
which are necessary to built up all application software concerned with system
hardware.
17
11. All the software shall be License software and certificate of shall be
purchased on the name of GNFC and not bidder. Bidder shall provide detail software
wise list of certificate.
12. Complete database generation including dynamic graphics shall be in

BIDDER’s scope for all installed as well as ware house spare IOs. Further to this
application software shall be successfully implemented and optimized till the plant
operations are stabilized. Any modification changes required shall be done by
BIDDER’s concerned engineer.
13. System and application software shall be made available in four sets of DVD.
BIDDER shall also supply four sets of E-Doc in CD and 4 sets of hard copy for the
complete system which shall cover all standard system documentation.
17.0 17.0 : BIDDER’S SCOPE OF WORK:
BIDDER’s responsibilities shall include, but not limited to the following:
a. System engineering including commissioning, System programming and

configuration, Implementing control strategies given by the Licensor/Clients,
Configuration of various displays, Generation of history data base and reports,
Generation of logging reports and other management information reports.
b. Factory testing. (FAT), Packing and forwarding, Transport to site, Installation at site,
c. Supply and termination of various interconnecting cables between marshalling racks

and between marshalling racks and system hardware cabinets, Powering up, Loop
checking and commissioning.
d. Providing assistance in implementing control strategies and operational

requirements like , tuning of loops etc. It shall be possible to alter history function
parameters to add / delete points , change of frequency etc. Averaging for predefined
time, min, max and this type of other simple elementary calculations shall be
possible in the history. History should display either these manipulated variables or
real time variables as per user choice. There shall not be any limit on retention time
for historian, except the hard disk size. It shall be possible to scroll time forward as
well as backward without any loss of historian data. Historian files are to be
maintained on main hard disk, while the retention time is over, it shall automatically
dump the data on an archival media like HDD before rewriting that location. This
shall be scheduled as per user defined time base.
e. Integration with TAS based on ETHERNET protocol or dedicated gateways.

Engineering TAS inputs in Control system and testing.
18
18 . SYSTEM FUNCTIONAL REQUIREMENTS:
Sr. Vendor’s
No.
GNFCs Requirement
response
18.1 SYSTEM FUNCTIONAL REQUIREMENTS:
18.1.1 Detailed specifications and system architecture of Control System will be

provided by vendor. The Control system shall have the following main
components. The system shall be 100% fault tolerant and dual redundant,
except the redundancy at I/O cards levels.
All central control processors, all communication processors, all other central
rack and individual node’s(rack’s) common cards, all the communication cards,
Ethernet switches, networks and cables, etc. shall be 100% fault tolerant and
dual redundant.
Redundancy at I/O card level is not envisaged, the failure of a single card from
complete system shall not affect whole system or more than I/Os supported by
that particular I/O card. It means all the hardware except I/O cards shall be
100% redundant and fault tolerant.
All the hardware including control/communication processors, networks,

cables, all type of system cards, all type of I/O cards shall be hot replaceable
and swappable.
18.1.2 The system shall be built on the latest state-of- the-art hardware and software
platform and hardware/software/firmware revisions of complete system will be
latest at the time of supply. Vendor to attach necessary documents of OEM for the
same.
The system architecture shall be based on client/server model with windows 10.0
OS or latest version of 32 bit or 64 bit operating systems.
18.1.3 There shall be 1 (ONE) no. of Engineer station and 1 (ONE) no. of operator
station at IP Filling, AN Melt Filling and EA station each location in the
proposed system (Total quantity 3 OS nos. +3 ES nos.).
18.1.4 Apart from above control system operator stations and engineering stations,
vendor to consider 2 (Two) nos. of VIEW Only remote monitoring stations in
the vicinity of IP control room (100 mtrs). Also WEB-server facility to be
provides where all Graphics of IP Filling and AN Melt Filling can be viewed
through GNFC LAN.
18.1.5 Web client shall able to view real time and historical trends, process graphic
with real time data. All operator and engineering stations shall have
antivirus and fire wall protections in built.
18.1.6 Control system CP load shall not exceed 30% system load after the complete
implementation of project and running at pick load. This includes redundant
control processor load also. Vendor to design / select suitable system CPU for
19
the same.
18.1
18.1.7 Engineer stations and operator stations of both location consisting of, : 21”
LED color video display units (VDUS) with related system hardware like full
fledge workstation grade machine with Intel Core-i7 or latest processor, 6 GB
DDR RAM and 1 TB RAID-5 HDD hot swappable, 5 Ethernet port, 5 USB
port, DVD writer, as a minimum. Membrane Operator’s / QWERTY
engineer’s keyboards with mouse. The hardware configuration of all operator
station shall be same as that of engineering stations.
18.1.8 Vendor shall use Dell/HP/IBM make hardware for PCs and servers only with
5 years NBD warranty.
18.1.9 Both engineering station and operator station software / personalities in overall
CONTROL SYSTEM architecture will be such that from where the complete
control System project can be developed and deployed in the system
independently. This engineering station can also be used as operator station.
However non-availability of engineering station shall not affect the plant
normal operation and shall neither cause any historical/trend data loss.
18.1.10 Operator station shall be independent of engineering stations, self bootable and
do not require engineering station/intermediate server for putting back into
normal operation or restoring them after rebooting, once the developed project
is deployed.
18.1.11 System should allow on-line modification, addition / deletion or change in any
control loop or part thereof.
18.1.12 Vendor shall also consider Laser A4 printer (3 nos.) for printing application .
18.1.13 All the I/O cards shall have individual channel to channel as well channel to
field isolation. Analog input/output cards shall be galvanically isolated and
digital input/output cards shall be optically isolated. Group isolated type or bulk I/O
cards shall NOT be accepted.
18.1.14 All I/O cards shall be intelligent type with microprocessor/ micro controller based
hardware and capable of all type of signal conditioning, self diagnostic, fail safe and
time stamping value configurable (programmable).
18.1.15 All I/O cards in individual category shall be of same type model / revision only to
facilitate the interchangeability in the system. No different mix mode ( AI+DI or
AO+DO) types of I/O cards shall be used.
18.1.16 Any other device needed to implement the requirements of this specification
but not covered above.
18.2 Displays
I. All readouts and graphic displays shall be in S.I. Units and all symbols as
per ISA respectively and in English. Proper color codes, graphic density etc.
20
shall be as per OWNER’s requirement.
II. The graphical user interface ( GUI ) shall follow advanced industrial
software & hardware standards as far as possible. In case of using
18.2 Workstation - based operator and engg. Stations, the GUI shall follow
industrial standards like Microsoft Windows.
III. System shall be able to handle instrument tag numbers consisting of
minimum 12 characters.
IV. Display call up time for various displays shall be a maximum of 1 second
or less irrespective of displays’ total dynamic I/O points, density.
BIDDER to specify the display updates times.
V. Provision of display of separate system alarm and process alarm facility.
The system shall have the following types of displays graphics with their brief
requirements as explained below:
a. Overview Display :
This shall give an idea of the overall plant status with less emphasis on
details. This can either be in the form of a deviation overview, overview of
various plant units, alarm status of all tags etc. This display shall not be used
for plant control. Similarly no alarm shall be acknowledged from this
display. It should be possible to approach any other operating display from
overview with minimum of operations. All these features shall be user
configurable.
b. Group Display : Various group of display (graphics) can be configurable.
c. Detailed Loop Status Display :

This shall give in analog/digital form all the parameters of a particular loop
like alarm set points, P, I, D values bias, loop status, PV, SV, MV values,
limits on output or set point, algorithm description, controller action, other
configuration details etc. This display shall be used mainly by engineers for
changing constants, tuning a loop etc. Real time trends of PV, MV, and SV
for tuning purposes shall be available in this display. The sampling
frequency for trends in this display shall be minimum 1second with
configurable dead band for each parameter and the display time minimum
10-30 minutes.
d. Displays For Alarm Handling :

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

ii. A common list of latest 400 alarms for the whole plant in chronological
order.
iii. Ack/scrolling ALM history and most recent alarms shall be possible through
software targets on the same display.
21
iv. The alarm list in each case shall give the tag no., the service description, type
18.2 of alarm and the time of occurrence, status, acknowledgement information.
BIDDER to specify total number of alarms per page.
v. It shall be possible to assign alarms on PV, SV, MV, rate of change (PV, SV),
deviation, ratio, as well as on any intermediate computed value in case of a
complicated algorithm.
vi. The system should have minimum 3 levels of alarm priority with different
colors and tones. High, Medium & Low. Following are the characteristics
of each level:
HIGH Priority Alarms

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

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

These should be acknowledged through a separate dedicated key with LED.
It should be possible for operator to disable the alarms. However, logging of
the same should not be disabled.
vii. It should be possible to disable alarms one by one (i.e. tag-wise) or globally
in a unit of the plant through a single command.
viii. It should be possible to assign different priorities to more than one alarm for
the same tag. (E.g. it should be possible to assign different priorities to
“high” & “low” alarms of the same loop).
ix. The system software should automatically histories all alarms earlier than the
latest 100 alarms.
x. All system alarms (hardware & software) shall be available in a separate alarm
summary with its own acknowledgment key and a dedicated hooter.
In alarm system, a common list of all defeated alarms shall appear disregarding
their alarm types, priorities, grouping, unit etc.
e. Trend Displays
Trend displays shall have following minimum features:
i. Facility to group/delete a variable from a group. This should be an operator

function.
ii. Scrolling of time axis on X- axis and scrolling of range on Y-axis.
iii. Tag no., alarm status and the dynamic value of the variable in digital form on
the trend page.
iv. Facility to read precisely any value of the variable being trended by positioning
the cursor at any point on time axis.
v. Y-axis zooming facility.
vi. It shall be possible to trend any variable, analog or digital and any parameter of
22
any particular tag.
vii. For an analog tag it shall be possible to trend PV, SV, MV deviation, ratio or
any intermediate calculated value in an algorithm and any standard block
18.2 parameter.
viii. Minimum Sampling Time For Any Trend Shall Be 1s or less.
ix. It shall be possible to assign different sampling times tag wise independently
without any limitation with user configurable DB.
x. On-line archiving of trends shall be possible.
xi. Real time trends of 2 hours time base shall be generated perfectly from the
control stations. This should not need any history. In case of power failure, no
loss of real time, historical and trend data shall occur.
f. Graphic Displays :
These displays shall be used most frequently for control and monitoring of
the plant by operators. They shall have the following features as a minimum.
i. Graphics shall be fully dynamic & interactive. BIDDER to inform the

maximum number of dynamic targets any display can accommodate.
ii. Overlays feature shall be provided to superimpose windows of various types
and sizes on a graphic. The overlay can be a face plate of a loop, a part of any
graphic, a trend, a message etc. It should be possible to have more than one
overlay of different type on any graphic and they all are should be freely
movable within main graphic window.
BIDDER has to specify the maximum numbers of overlays of different sizes,

opened on a standard base graphics and any other limitations.
iii. BIDDER to confirm the total number of colors available (minimum 32). Font
size shall be freely configurable.
iv. Background color of graphic shall be freely selectable.
v. It shall be possible to build frequently used symbols and store the same in a
library through which they can be recalled for future use.
Graphics builder shall have all ISA symbols in library form, so that standard,
uniform graphics can be generated in a less time.
vi. It shall be possible to assign at least 4 modifier conditions to a graphic
character/object. By modifier conditions it is meant change of color, size,
filling & visibility of a pattern etc.
vii. Graphic builder package shall be easy to operate without any detailed
knowledge of hardware/software. In particular following features are
desirable:
- It shall be possible to build graphic through keyboard and mouse. All features
of interactive menu driven graphic builder like drag and drop , edit , copy
, paste with on line program sensitive help shall be available.
- Software shall have facilities to change/modify either at a global level or

discrete level and the same can be updated in all places with minimum
key strokes.
- Common graphic builder tools (e.g. intersection, end point, midpoint, centre,
tangent etc.) found in AutoCAD should be available for effecting quick
18.2
changes.
- Graphic builder package shall have command / script support for
23
complex graphic which can manipulate control strategy .
- Facility to “zoom” a picture for better visibility shall be available.
- Security features like masking / access lock shall be available for

graphics or parts thereof.
- It shall be possible to save pictures or parts thereof in the symbol library (to be
used again) directly from the picture being drawn & the same need not be
drawn once again for the purpose.
BIDDER shall furnish the detailed sizing calculations along with offer :
1) 40% of total nos. of analog I/O at 1 sec scans time.
2) 60% of total nos. of closed loop at 250 msec. time.
3) 60% of total nos. of digital I/O at 50 msec. time.
4) 40% of total nos. of digital I/O at 250 msec. time.
g. Configuration Displays
These shall be used for configuring a loop and shall be mainly used by
engineer. These should also be dynamic and should show the various loop
intermediate parameters in the loop in digital form. (E.g. a temperature
indicating loop should display the mV signal being received, the value after
conversion to temperature units and so on). It shall be possible to effect “on
line” configuration changes using these displays.
Online changes made in the controller sub system, shall not affect the output
of a closed loop or process. BIDDER to categorically clarify the limitations if
any.
Changing of units, ranges, alarm values, dead bands, alarm priority,
linearization etc. Of one I/O shall not affect the others. The last good values
hold feature shall be implemented in the system with alarms.
The access to these displays shall be protected by key lock switch and/ or a
password.
It shall be possible to log any tag, calculated results or any block standard
parameter in the freely formatted manner and log scheduling shall be t user
defined interval or on demand.
BIDDER to specify the total nos. of log/reports and total point per log limit.
Elementary calculations like min., max., averaging, addition, subtraction,
rounding off, division, etc. shall be possible in the free format logs with time
and date functions.
High level programming language support -
The system shall provide proper and secure facilities for developing,
modifying, compiling and running of user written programs in any high level
language like C, C++, VB or any other 3rd party optimization package etc. It
shall be possible to modify, compile and download the program without
affecting the normal controller operation. BIDDER to specify the residency
and run time platform of these programs. If it requires any extra hardware,
then BIDDER to quote for the same with full technical details and limitations.
18.2
h. System Diagnostic Displays
These shall be arranged in a hierarchical fashion such that a fault in any of the
units of the system can be traced up to module level by suitable annunciation.
Modules and individual channel level fault diagnostics with immediate alarms
24
on all operator stations are a must. The following information shall be
available through these displays as a minimum. BIDDER to give detail of
various diagnostic features/facilities available in the system including
maintenance procedures.
i. Type and location of malfunctioning unit.

ii. Nature of fault.
Internal system Security

The system shall carry out regular and extensive self testing. In general,
transient errors shall be handled either by immediate re-try or by the inclusion
of additional information within the systems which allows minor fault
recoveries. Errors which cannot recover in such a way shall result in an
audible system alarm of high priority on operator station, historian and alarm
printers and smooth changeover to the redundant unit shall occur wherever
provided. In all cases, the transfer of control, communication etc.
To the backup equipment shall be totally transparent to the control and

monitoring of the process and shall not result in any spurious bumps or
changes to process output states. In case of control node failure, the output
shall be configurable in a fail safe manner by default (or predefined)
configuration value/status. Items which shall network and regularly thereafter
shall include:
- Control processor, I/O processor and communication processors.

- System communication network modules.
- Links to other network devices.
In particular, BIDDER has to give details about system failure mode and
causes which system attains this mode.
18.3
Multiloop Controllers/Data Acquisition System/Controller subsystem :
18.3.1 In case of failure of communication of control processor with I/O subsystem

via one of the I/O link, the second link should take smooth control, without any
plant disturbance or signal, data loss. This shall also have capabilities to
execute process sequences and interlock logic using digital inputs and
outputs.The offered controllers shall be of the highest capacity from the
available product range from the vendor from processing power and memory
point of view. No small/compact controllers shall be acceptable. Bidder to
clearly highlight the total capacity of controller in terms of total nos. of I/O
modules supported, total nos. of closed loops and open loops supported, total
memory, fastest scan time possible, fastest algorithm execution time supported,
maximum loading allowed, etc. per controller for the offered controllers.
18.3.2 The system shall have the capabilities to execute the following control
algorithms as a minimum. A list of algorithms available shall be submitted
along with quotation.
a. P, PI, PID with external bias/Anti reset wind up features.
b. PID gap.
c. Two position On/Off control.
d. PID On/Off.
e. PID with cascade, ratio.
f. PID with adaptive gain & reset.
g. Lead/lag compensation.
25
h. Dead time compensation.
i. Manual loader.
j. Low/high signal selection.
k. Temperature/pressure compensation for flow.
l. Pulse inputs scaling.
m. Integration/totalizing (both resettable & non-resettable. Min. 6 digit counter)
n. Elapsed time computing.
18.3 o. Signal selector for min./max./mid value
p. Velocity limiter.
q. Self tuning for all PID loops by default.
r. Ramp generation.
s. Alarm generation on input, set point, output, deviation, intermediate computed
value, rate of change etc. (Min. 4 Alarms/PV).
t. Analog inverter
u. Input/output characterizer.
18.3.3 : Following mathematical functions shall be available in the system as a

minimum:
a. Addition.
b. Subtraction.
c. Multiplication.
d. Division.
e. Sq. rooting/square.
f. Moving average.
g. Piece-wise linearization for input/output.
h. Cold junction compensation for all T/C inputs.
i. Exponential functions.
j. Logarithmic functions.
k. Absolute value.
l. Comparator (i.e., greater than, less than, equal to etc.)
m. Pressure & temperature compensation for flow loops.
18.3.4 :Following logic operations shall be possible in the system as a minimum:

a. AND, NAND
b. OR, NOR
c. EX-OR
18.3 d. Inverter
e. Flip Flops (SR, JK, Toggle, etc.)
f. Timers (On delay/Off delay type up to 24 hours & Cyclic timer) / counters /
software flags / numeric etc.
Controller subsystem
18.3.5 :In case the system accepts only 1~5 VDC or 4~20 ma DC analog signals the
necessary terminal boards are included in BIDDER’s scope of supply. No other
signal converters like R/I converters, barriers, etc. shall be accepted in the
system. All diff. input modules shall support direct interface with various types
of signals from field transducers as specified.
18.3.6 The termination units shall be DIN rail mounting type with adjustable
zero/span and re-ranging facility. These shall have T/C linearization and cold
junction compensation functions.
18.3.7 Two wire transmitters shall be powered from 24V DC ± 0.25% supply floating
which shall be derived internally from analog input cards by the BIDDER.
This 24 V DC supply by I/O Cards to the field transmitter shall be redundant.
26
The 24 V DC power supply shall be designed with 200% capacity. Earth fault
detection circuit is a part of input card.
18.3.8 Independent channel shall be provided for each transmitter with necessary
current limiting 30mA max. Circuit to guard against short circuit/accidental
grounding of field wires.
18.3.9 It shall be possible to have latched as well as pulse outputs from the system. In
case of pulse output it shall be possible to have positive as well as negative
pulse. Pulse width shall be adjustable individually from 0 - 10 sec
18.3.10 Interrogation voltage for all status inputs shall be 24V DC and the same shall
be derived internally by the BIDDER. This shall be 100% redundant and 24 V
DC power supply shall be designed with 200% power / current capacity.
18.3.11 For 2-wire inductive proximity type sensors the necessary power supply for
interrogation (required by Isolation Amplifiers/Barriers) shall be derived
internally by the BIDDER.
18.3.12 For all types of alarms dead band shall be configurable individually between
1%~5% of span.
18.3.13 Two modes of variation of set points and output values shall be available on
controllers and manual loaders for fast/slow ramping through the keyboard.
18.3.14 A/D converter shall have a minimum resolution of 13 bits.
18.3.15 D/A converter shall have a minimum resolution of 10 bits.
18.3.16 Scan Time : It shall be possible to assign variable scan rates loop wise for all
the loops. By definition scan time means the time taken to read the field input,
A/D conversion & linearization of the same, performing control algorithms
specified as per requirement and outputting the result including D/A
conversion.
18.3.17 The scan time of all type of analog / digital / RTD / inputs & CONTROL SYSTEM
algorithm shall be better than the required scan time of the fastest running
control/closed loop However, in any case, this shall not be more than 250 msec for
any type of analog channel/loop and 50 msec for digital IO. Here the scan time is as
defined above.
18.3.18 1:1 backup is required for all data storage modules to preserve vital system
configuration and all historical / long term trend data.
18.4 Communication Networks - Comm. protocol shall confirm to

IEEE802.X/OSI standards with 7 layer open system model or 5 layer
TCP/IP Model.
18.4.1 This shall mean all the hardware and software needed for communication
between various system nodes as well as devices within a node. In general it
can be classified broadly into following categories: All the nodes of control
systems including control processor, operator station and engineering stations,
other communication gateways, etc. shall be peer to peer nodes, sitting on the
same dual redundant communication network. No double layered
communication with one common redundant gateway server is acceptable. In
the proposed system, failure of any of the peer node, shall not affect any of the
functionality of other nodes. The minimum bandwidth of main system
communication network shall be 10 MBPS.
18.4.2 Main data highway on which various nodes of the system shall communicate
will be 100% fault tolerant with 100% redundancy at all component level.
18.4.3 Internal communication bus on which various intelligent devices within a node
shall communicate and this shall also be 100% redundant / fault tolerant
18.4.4 Communication interface between a node and a peripheral device like printer,
copier etc.
27
18.5 Main Data Highway :
1. This shall facilitate peer to peer communication with all the nodes in the system
viz., operator station, control & data acquisition system, bulk I/O processing unit,
bulk data storage modules, gateways and other devices if any and peripherals like
networked printers, etc. All these nodes are referred to as peer to peer nodes. No
layered architecture is acceptable with common gateway units.This shall be a
100% redundant highway system for operational security.
2. The system diagnostic display shall indicate load and the status of active & standby
highway at any given time. The total load in worst condition shall be defined by
BIDDER.
3. In case of a fault with active highway the redundant one shall take over
communication functions automatically, instantaneously and smoothly, without any
loss of information.
4. The health of both highways shall be checked continuously and faults annunciated
through a system alarm.
5. The system architecture and software shall be such that it shall be possible to
physically add or remove a node, on/from, highway without interrupting ongoing
communication with other nodes.
6. Similarly in case of a failure of one or more nodes, the same shall be automatically
bypassed. The communication with other nodes carries on uninterrupted.
7. The communication transmission shall be fast enough so that even during plant
upsets, shutdowns or startups, the highway is not jammed.
8. Sufficient spare capacity ( min 80 % on active bus ) shall be provided for
transfer efficiency of the data highway to ensure full functionality in the event
of load fluctuation/worst conditions, BIDDER to define worst conditions.
9. Each of the communication highways shall be routed differently to prevent damage
to both in case of an accident.
18.6
Internal I/O Communication Bus
1. This will connect various I/O modules within a node to the master CPU executing
control, data acquisition, logic execution and other tasks. This shall be a 100%
redundant bus system.
2. Health of the active and standby bus shall be available on system status display.
3. In case of a fault with active bus the redundant shall take over communication
functions automatically, instantaneously and smoothly without any loss of
information.
4. It shall be possible to add, remove or change I/O modules on-line, without
interrupting ongoing communication with other modules.
5. In case of a failure of one or more modules, the same shall be automatically
bypassed. Communication with other modules carries on uninterrupted.
6. In case the system architecture is such that I/O modules can be located remotely
from the master CPU, the data transfer rate shall be fast enough to ensure that there
is no compromise on scan time.
- BIDDER to inform distance limitations if any.
18.7
Marshalling Cabinets
All the field instrument signal / power and control cables are brought to this central
cabinet room, from where it was catered to diff. individual destination marshalling
panels and corresponding control system hardware Panels. These dedicated
marshalling panels are already installed at both IP filling and AN melt Plants.
28
Marshalling panels are not in scope of vendor.
18.8
System Hardware Cabinets
These shall be used to mount the system hardware. System cabinet is already installed
at both IP Filling and melt plant. System cabinet panel size is 1200mm (W) x 800mm
(D) x 2100mm (H). Vendor has to use the same system cabinet. Remove old hardware
and installed new hardware like controller and I/O cards. This is a single panel; one
side is system cabinet and other side marshalling cabinet.
18.9 Power Distribution Cabinets
Power distribution cabinets are already installed at both plants. Vendor has to use the
same PDB panel for distributing the supply.
110VAC power distribution is scope in GNFC. Further sub distribution 24VDC is in

scope of vendor.
Interconnection Cables
18.10
All cables inside the cabinet ( e.g. power supply , internal bus etc ) as well as any
cable from cabinet to cabinet , shall be labeled properly with the cable number
on both ends as per requirement . The labellling shall include also the destination
of each cable end. No looping shall be acceptable inside any panel wiring, including
power supply wiring.
19. SUMMARY OF CONTROL SYSTEM I/O LIST:

No. response
19.1 I/O channels details at IP Filling and AN Melt Filling:
Sr. IP AND AN MELT FILLING OVERALL I/O CHANNELS
No. INFORMATION
TOTAL
TOTAL REQUIRED
INSTALLED INSTALLED REQUIRED
TYPES OF CHANNELS WITH
CHANNELS CHANNELS CHANNELS WITH
CARDS SPARE (40 %) AT AN
AT IP AT AN MELT SPARE (40 %) AT
MELT FILLING
IP FILLING
ANALOG
1 INPUT 65 45 91 63
CHANNELS
ANALOG
2 OUTPUT 20 20 28 28
CHANNELS
DIGITAL
3 INPUT 80 70 112 98
CHANNELS
DIGITAL
4 OUTPUT 60 50 84 70
CHANNELS
TOTAL 225 185 315 259
29
20. CONTROL SYSTEM TENTATIVE BILL OF MATERIAL:

No. response
20.1 CONTROL SYSTEM TENTATIVE BILL OF MATERIAL
Minimum bill of material is mentioned as below; however it will be
vendor’s responsibility to offer required hard ware and software to full fill
our requirement as mentioned in this specification:
Sr. Vendor response

Item description Quantity
No.
1 Engineer station. 2+1 (Spare)
(21” LED color video display units
(VDUS) workstation grade machine with
Intel Core-i7 or latest processor, OS
windows 10 or latest, 6 GB DDR RAM and
1 TB RAID-5 HDD hot swappable, 5
Ethernet port, 5 USB port.)
2 Operator station. 3+1 (Spare)
Ethernet port, 5 USB port.)
3 Processor/Controller with Complete Unit at 2+1 (Spare) Vendor to
IP Filling specify
4 CONTROL SYSTEM I/O Cards. (at IP 40 % Spare Vendor to
Filling and AN Melt Filling) specify
5 Spare cards and other items. As per type Vendor to
(Each model/Unit one spare is mandatory one Each. specify
for both stations.(at IP Filling and AN Melt
Filling)
6 REMOTE MONITORING CLIENT PC 2

Ethernet port, 5 USB port.
7 E-Server 1
(VDUS) server grade machine with Intel
Core-i7 or latest processor, Windows12 or
higher version of server Operating System.
8 GB DDR RAM and 1 TB HDD, RAID-5
HDD hot swappable, 5 Ethernet port, 5
USB port.)
8 PRINTERS 3 nos. “A4” Vendor to
30
size Black specify.
Laser Printer.
9 CABLES Quantity as Vendor to
1. All TAS, CONTROL SYSTEM, required. Will specify.
Terminal Server, LIU etc. be decided
connectivity through Ethernet Switches. during PRE-
2. TCP/IP cable from IP and AN Melt BID meeting.
Filling to CONTROL SYSTEM (OPC
connectivity)
3. Fiber optic cable from AN Melt Filling
and TTES (TAS to marketing PC) to IP
Filling Redundant cable.
Note:
Above Bill of Material is indicative only. Vendor to give the System
architecture along with the offer and give detailed BOM along with
make, model and detailed specification of each of the hardware offered.
Also, detailed catalogue of the CONTROL SYSTEM software offered
shall be given with the offer.
21. INSPECTION & FAT:

No. response
21 INSPECTION & FAT
21.1 System and associated components shall be inspected and tested at the BIDDER’s
works by /OWNER.
21.2 Clients/OWNER reserve the right to inspect any bought out items by the BIDDER
at the sub-BIDDER’s works.
21.3 Cost of inspecting/testing if any shall be borne by the BIDDER.
21.4 For final integrated inspection of the system, the BIDDER shall give a minimum
notice of 2 weeks to Clients.
21.5 Before Final Factory Acceptance Test at vendor’s shop, OWNER shall carry out
stage wise internal inspection of various hardware/major components of
CONTROL SYSTEM, panel wiring, etc. The test results of same shall be made
21 available to OWNER/Purchaser during these visits.
21.6 Through out the factory acceptance test, BIDDER shall provide all necessary test
equipment’s and consumables and shall make all necessary connection to all
hardwires as many times required.
21.7 OWNER shall carry out 100% functional checking of all hardware/software
modules.
21.8 BIDDER to submit format for FAT/SAT procedure for OWNER’s review and
comments.
21.9 The inspection shall briefly envisage the following:
21.10 Hardware Inspection
1. Redundancy - wherever specified shall be checked for :

2. I/O cards (if applicable).
3. Control System Processor.
31
4. Communication processor (between nodes as well as within a node)
5. Individual modules wherever possible shall be checked for their performance.
6. All volatile memory shall be checked for battery backup by tripping power
for the duration given in the BIDDER’s specifications.
7. Power supply and all other system cards may felt necessary by engineer
incharge..
21.11 Software Inspection : These shall include, but not limited to, the following:
1. Verifications of license / certificates of all types of software used in the
system.100% inspection of the generated data base. This includes checks
on:
2. Correctness of tag number and description.
3. Measuring range., Input type, input conditioning.
4. Algorithms to be executed.
5. Output type and conditioning if any.
6. Other details if required.
7. All graphics shall be checked 100% for static and dynamic details. These
include:
i. Checking all graphics for correctness w.r.t. P&ID.
ii. Checks on line thickness, colour, equipments, tags, units of
measurement.
iii. Checking of modifier conditions wherever specified.
iv. Switching between various operating pages as per philosophy frozen.
v. Operation of all graphic targets.
8. Operation of all keys on the keyboard shall be checked. Various printing
operations like, operator changes, alarms, guide messages, screen printing
etc. shall be simulated and checked at random.
9. Group displays shall be checked for correctness of grouping.
f. Alarm priorities shall be checked for all alarms.
g. All complicated loops shall be checked 100% from input stage to
output for correctness of configuration.
h. All logic & sequence operations shall be checked 100% from input to
output by forcing/enabling various I/Os through software.
i. Any higher language program shall be checked 100% either by
simulation or by feeding requisite inputs and checking the outputs.
j. Logging operation shall be checked.
k. Communication between TAS and Control System shall be checked at
site. The updation time of all the TAS input/output parameters, internal
21 global/local memory variables, etc. shall not be more than 1 second.
For site Acceptance Test, all the activities shall be similar to those outlined for FAT as
above, but shall be performed with actual and output signals from the field
instruments.
22. INSTALLATION, PRE-COMMISSIONING AND COMMISSIONING AND SAT:

No. response
22.1 INSTALLATION, PRE-COMMISSIONING AND COMMISSIONING & SAT.
Bidder shall depute a team of experienced engineers, technician and other manpower as
required for the purpose of inspection, installation, pre-commissioning and
32
commissioning of the system at site within schedule time.
Following activities are included in the BIDDER’s scope:
a. Transportation of system from stores to site control room.

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

supports in trenches if required.
d. Inter cabinet wiring/cabling for all signal, power supply and system cables. Wiring
of all console push buttons, lamps, alarm windows, etc. to/from control system
marshalling/system panel.
e. Mounting, wiring and termination of all free issue instruments given by the Clients
and as per list of project specification.
i. Routing of all data highway cables/internal bus cables for control system & TAS
through rigid GI conduits within control room below false flooring and inside all
consoles as well as between various control room/MCC rooms of the plant. This
work may involve routing in trenches, over plant pipe racks in cable trays, etc.
j. Powering up the system, loading the system configuration and carry out internal
loop checks for correctness of wiring in BIDDER’s scope. This shall be carried
out from marshalling cabinets/dummy consoles etc. up to VDUs. The completion
of this activity marks the “mechanical completion” of the system and the protocol
to this effect shall be jointly signed by the Clients / OWNER and the BIDDER.
l. To carry out 100 % loop/interlock checking of the plant with owner. This shall be
done at least at 4 points checking of all instruments range and with printer online.
m. Prepare all loop checking reports with OWNER.
n. To mark correction in all drawings and to make them “as built”.
o. Provide commissioning assistance to Clients/Licensor/OWNER in the form of
tuning of loops, implementing any configuration and graphics, interlock changes
etc. required during commissioning of the plant.
p. During this period of commissioning , if any time is lost due to fault in the system
or any other reason attributed to the BIDDER, the assistance period shall be
extended by that period at no additional cost to the client.
Tools, Tackles
1. BIDDER will arrange all necessary tools and equipment’s line welding
22.1 machine etc., for erection of system cabinets/consoles and cable laying,
gladding and terminations.
2. BIDDER will arrange for adequate number of test equipment’s like meggers,
multi meters, CROs,.
3. BIDDER shall arrange test equipment of adequate specifications to
monitor main system power supply from UPS which will be arranged by
OWNER , to establish proper power quality before system power on.
SAT (Site Acceptance Test):

1. SAT site acceptance test shall be carried out after four week of successful
running of whole system where bidder shall depute their commissioning
33
engineer, where system should run flawlessly in trial run period for its Final
Acceptance Test. If trial run flaws lead to any modification GNFC may ask re-
run of trial period depending on extend and severity of flaws and rectification
done.
2. Also, even after SAT, if problem /flaw observed in the system / sub system
components / application software which will not satisfy the function
requirements or specifications of tender enquiry, vendor will replace full
system / sub system/ components / software as required to the satisfaction of
owner.
3. SAT shall be considered completed after receipt of all AS-BUILT documents.
23. FINAL SITE ACCEPTANCE TEST :

No. response
23.1 Final Site Acceptance Test : (FSAT)
(1) The integrated system shall run uninterruptedly for four weeks from date of Site
Acceptance Test (SAT).
(2) Any loss of time due to reasons like power failures, forced shutdowns etc. which
are due to no fault of the BIDDER shall also be counted as run time. However,
if any major software/hardware failure of the system occurs due to which the
system or a part thereof has to be shutdown the test shall be conducted afresh on
the whole system. Client shall take over the system from BIDDER after final
acceptance test.
(3) Vendor shall depute their Engineer for FSAT and testing of whole system with
engineer in charge for the problem if any in the system functionality than FSAT
shall be concluded.
24: WARRANTY / GUARANTEE OF SYSTEM:

No. response
1 It is mandatory to offer two years comprehensive warranty on all items supplied.
Warranty will start after commissioning and installation at site is over or 36 months
from the date of system supply whichever is earlier. Comprehensive warranty includes
free replacement of failed parts and service for the same once fault is reported to
bidder. Also, even after SAT, if it is observed that TAS and Control system / sub
system components / application software does not meet the functional requirement or
specifications of tender enquiry, vendor will replace full system / components /
software. Vendor shall submit PBG 10% for two years of order value.
34
2 Vendor shall offer 3 years comprehensive maintenance contract after warranty period of
2 years warranty period is over. Vendor shall give detail price break up for the same as
per format given in this tender enquiry.
3 Vendor shall offer latest models of TAS and control system hardware and software.
Vendor shall give their commitment to provide minimum 10 year’s full service support
to maintain offered hardware and software without which offer shall be rejected.
In case of , non availability or obsolesce of offered software or offered Machine /

instrument / hardware at later stage /time and if upgradation is a must to maintain
functionality of system, then required component , software and or hardware shall be
upgraded by vendor at free of cost. There shall not be any cost implication on owner
side at that time for such upgradation.
Complete TAS and Control system software installed in the TAS Servers, TTES,
Operator Stations, Engineering Stations and Processors or any other device used in the
system components shall cover this clause. Cost implication if any to be to be
considered by vendor and to be included as a part of the offer.
4 M/s GNFC shall witness all the tests on all TAS and Control System as per ordered
quantity, including physical and functional check of spares and it is further
emphasized that for the inspection requirement as stipulated in this document, if
there is any price implication then vendor shall clearly mention the same in their
offer. No excuse will be accepted at the time of inspection.
Vendor shall consider this requirement and give inspection call well in advance
time so that inspection can be carried out accordingly.
25. SPECIFICATIONS FOR COMPREHENSIVE MAINTENANCE SERVICE AND

CONTRACT:
Vendor shall offer 3 years comprehensive maintenance service contract after two
1 years warranty period is over. Following service shall be included in the
comprehensive maintenance service contract.
Vendor shall depute their competent engineer for following services and shall give
their offer accordingly ;
2
(1) Routine / periodic /planed maintenance visit
(2) Break down / emergency call visit.
(1) Routine / periodic/planned service Visit: Engineer will visit on mutually
agreed date for Checking TAS and Control System Healthiness, Functionality, 4X1 = Total 4
3
Loop Modification and correctness if require. man days.
(2) Break down service Visit: On requirement basis GNFC may call service
engineer for break down visit. Visit shall be considered complete once problem
is attended and same problem does not repeat within 1 week of operation of On call basis
system once problem is attended. Vendor shall have to attend problem within 1 visit as per
4
working day once problem reported on phone / mail or else 50 % of amount GNFC’s
shall be deducted from running bill. Annual three (03) nos. of visits to be requirement
considered for the breakdown service visit, however calling on breakdown visit
shall be totally on GNFC’s discretion.
35
Major Terms and conditions :
(1) Consumable items such as System hardware shall be provided by GNFC.
(2) Vendor to arrange own lodging /boarding / transportation.
5
(3) Vendor to depute their service engineer/technician from local station.
(4) Qualified and experienced engineer shall be deputed to attend the problem who
must be capable to handle all types of TAS as well as control system problems.
Service Guarantee :
Within guarantee / warranty period, Bidder shall undertake repair / replacement of
any defective or inappropriate system hardware and software free of cost, and shall
make correction of such deficiency within 24 hours from the time it is brought to
6
notice by the owner.
The warranty period of the repaired/ replaced parts shall be counted from the date
of repair / replacement.
GNFC reserve the right to order post warranty AMC along with main order or after
7 completion of two year’s warranty period and such decision is solely at discretion of
GNFC.
26. DOCUMENTATION/DRAWINGS:

No. response
26.1 DOCUMENTATION/DRAWINGS
Documentation/drawings shall be supplied in hard copy as per
requirements given below:
SR. ITEM NO. OF COPIES
NO.
With For For info. with Final /
Quotation approval correction after As-
After P.O. PO built
OWN Client OWNE Clie OWNER Client OWNER
ER R nt
1 Architecture (one 2 1 2 1 2 1 2+1
line diagram) of
the quoted
system.
2 Detailed bill of 2 1 2 1 2 1 2+1
material up to
module level &
including all
bought out
auxiliary items.
3. Bill of material, 2 1 2 1 2 1 2+1
make/model
number, with
catalogues for all
bought out items.
(Including
commissioning
36
spares & 2 years
normal
operation)
4 Proposed 2 1 - - - - -
organization
chart for job
execution.
5 Detailed schedule 2 1 2 1 2 1 -
of job execution.
6 Standard 2 1 2 1 2 1 2+1 1 2 1
dimensional
drawings.
7 Calculation of 2 1 2 1 2 1 2+1
total power
requirement.
8. Expected heat 2 1 2 1 2 1 2+1
dissipation.
9 Typical loop 2 1 2 1
diagram for all
I/OS
10 Final loop wiring 2 1 2 1 2+1
diagrams.
11 Nest loading and 2 1 2 1 2+1
I/O assignments.
12 Logic/Ladder 2 1 2 1 2+1
drawings.
13 Printouts of all 2 1 2 1 2+1

higher language
programs/script.
14 Printouts of all 2 1 2 1 2+1
generated
graphics.
15 Software loading 2 1 2 1 2 1 2+1
calculations for
various system
nodes with spare
margins
available.
16 Factory 2 1 2 1 3
acceptance test
(FAT) plan.
17 Standard system documentation available for all system nodes like:
i) Instruction 2 2+1
manuals.
ii) Software 2 2+1
reference
manuals.
iii) Installation 2 2+1
37
instructions.
iv) Algorithm 2 2+1
library.
v) Standard symbol 2 2+1
library.
vi) System 2 2+1
maintenance
manual.
AS-BUILT DOCUMENTS/ DRAWING
Bidder’s site representative shall mark up all engineering modifications done at site
on THREE master copies to be maintained by him at site. BIDDER shall
incorporate all the changes made at site in his “master copy” and submit as-built
documentation to Clients/OWNER as per requirements given above.
As a final documentation two set shall be provided in DVD In MS
Office environment/AUTOCAD software.
27. TRAINING:
No. response
Vendor shall train GNFC’s maintenance engineers as well as operations staff at M/S
bidder’s works as well as Onsite training. The training imparted shall be done by
qualified and experienced staff available. It shall be exhaustive and aimed at making
GNFC’s maintenance & operations staff self reliant for most of the day to day
applications. For training, supplier shall make available as close a model of the
system with all the representative nodes, as the actual system to be installed. Vendor
shall prepare the teaching material and shall provide all equipment and tools
necessary including copies of course material It is envisaged that following be
covered in the training:
27.1 InstrumentMaintenance Staff Training

a. System architecture, Functions of TAS and Control system
c. Hardware in TAS and Control system
d. Complete application software training .
- Addition / deletion/ configuration of tag/loops in control
system.
- system data base building, backup and restoration in server and
PC, generation of various system nodes to advance language
programming, configuration and debugging etc.
e. Commonly occurring hardware problems and the maintenance
procedures.
f. Various diagnostic programs available and their use and
interpretation.
g. Formatting and Preparation of complete new TAS Server and
Control system engineering station, operator station as per
written / given procedure and hand on experience.
The duration for maintenance training at vendors work shall be min. 5 working
days and total qty. shall be 100 man days.
38
27.2 Operations Staff Training
This shall be restricted to the operation of the system. This shall broadly cover
the following:
a. System architecture.
b. Functions of each node.
c. Functions of various keys in the keyboard.
d. Generation of displays like graphics, group and trend groups, etc.
e. Display hierarchy, access methods for various displays, switching between
different types of displays etc.
The duration for Operation training at vendors work shall be min. 3

working days and total qty. shall be 75man days. (25 engineers x 3 man
days each)
28. 0 FORMAT BILL OF MATERIAL AND PRICE SCHEDULE :
Important note for BOM and Price schedule”:

28.1 : Above is tentative BOM of total Terminal automation system including control system. BOM
items and quantity may vary depending on technology and configuration used to achieve intended
functionality. Vendor has to submit their BOM in line with the following format only. Vendor has to
study above list in detail in line with their supply items / services and to carry out additional / deletion
of items at suitable place. No lump sum price of TAS or control system is acceptable else bid shall not be
consider for further evaluation.
28.2: Vendor to give the System architecture along with the offer and give detail BOM along
with make, model and specification of each of the hardware offered to complete this project. In
case of any item, found not offered at this stage and latter stage found that item or software is
needed to complete this project, vendor shall have to supply the same item / software at no cost
to GNFC. Detail catalogue / specification of the all offered items including TAS system software
offered shall be submitted with the offer.
39
0 FORMAT BILL OF MATERIAL AND PRICE SCHEDULE
Sr. Qty. Unit Uni Tax Total Remarks

No. Detail list of Item/ components / Short in of t Price
description Nos. Mesu Pri
re ce
A TAS System Hardware
1 LRC Servers (with Basic specifications) etc. 3 NOS
2 Ethernet Switches (with Basic specifications) 7 NOS
3 N Port Terminal Servers (with Basic 3 NOS
specifications) at IP Filling.
4 N Port Terminal Servers (with Basic 3 NOS
specifications) at AN Melt Filling.
5 Batch Control Unit with card reader (with Basic 22 NOS
specifications)
6 Remote Instruction Terminal Module. (with 22 NOS
Basic specifications)
7 Access Control Device (with Basic specifications) 3 NOS
8 TTES (PC-IPDI with Basic specifications) 3 NOS
9 Ethernet Cables and other cables requirement.
(vendor to specify)
10 Redundant Bulk power supplies requirement
(vendor to specify)
11 Firewall / UTM for TAS server, E-server, TTES 3 NOS
PC
B TAS System Software
1 All TAS System software with license copy
(vendor to specify and give break up of each
software)
2 All Server and stations software with license copy
(vendor to specify and to give break up of each
software)
C Control system (DCS/PLC) Hardware
1 Engineer station (with Basic specifications) 3 NOS
2 Operator station (with Basic specifications) 4 NOS
3 Remote viewing/monitoring (TAS+DCS) Client PC 2 NOS
(with Basic specifications)
4 E-Server ( On LAN Viewing TAS+DCS ) 1 NOS
5 Processor/Controller with Complete Unit (with 3 NOS
Basic specifications)
6 CONTROL SYSTEM I/O Cards.(with Basic
specifications vendor to specify)
7 Whatever new extra hardware excluding above
items (with Basic specifications supplied by
vendor) 40
8 “A4” size Black Laser Printer 3 NOS
9 Ethernet Cables and other cables requirement.

(vendor to specify)
D Control system (DCS/PLC) Software
1 All Control System software with license copy 1 LOT
(vendor to specify)
2 All stations software with license copy (vendor to 1 LOT
specify)
E Installation and commissioning
charges
1 Supervision for installation and commissioning
charges (vendor to specify)
F Comprehensive AMC service charges. As per 1 Lump
clause no 25. sum
1 Comprehensive maintenance service contract 1 Lump
charges. As per clause no 25. For 3 rd year sum
charges. As per clause no 25. For 4 th year sum
charges. As per clause no 25. For 5 th year sum
Total
G Delivery period. On or Before 31st July 2018, system must

reach at GNFC site.
----------------------------xxxx--------------------------xxxx-----------------------------------------------------------
41
ANNEXURE-1
EXISTING INSTALLED - SYSTEM ARTECHTURE
42
ANNEXURE-1
NEW - REQUIRED SYSTEM ARTECHTURE
43
ANNEXURE-2
ANNEXURE -2A
IP AND AN MELT FILLING FLOW METER INFORMATION
BAY TRANSMITTER
PRODUCT TAG DESCRIPTION MAKE SENSOR MODEL
No. MODEL
1 METHANOL FT 9201A Mass flow Meter Emerson CMF300M355NQBZEZZZ 1700R11ABFEZZZ

2 METHANOL FT 9201B Mass flow Meter Micromotion CMF300M425NU RFT9739E45UJ
3 METHANOL FT 9201C Mass flow Meter Micromotion CMF300M425NU RFT9739E45UJ
4 METHANOL FT 9201D Mass flow Meter Micromotion CMF300M425NU RFT9739E45UJ
5 METHYL FORMAT FT 5099D Mass flow Meter Emerson CMF200L44NQBZEZZZ 2700R11ABFEZZZ
6 WEAK ACETIC ACID FT 9102 Mag. flow Meter Yokogawa AXF040C AXFA14C
7 ACETIC ACID FT 9101A Mass flow Meter Emerson CMF300M355NQBZEZZZ 1700R11ABFEZZZ
8 ACETIC ACID FT 9101B Mass flow Meter Emerson DS 150 S 141 SU 1700C11ABFEZZZ
9 ACETIC ACID FT 9101C Mass flow Meter Emerson DS 150 S 141 SU 1700C11ABFEZZZ
10 FORMIC ACID FT 5201 Mass flow Meter Emerson CMF200H418NQBZEZZZ 1700R11ABFEZZZ
11 CONC. NITRIC ACID FT 21001 Mag. flow Meter Emerson 8705TTA020S1WOKD 8732CR12M4ED
61. 5 % WEAK NITRIC
14 FT 11001 Mag. flow Meter Emerson 8705TTA020S1WOKD 8732CR12M4ED
ACID
61. 5 % WEAK NITRIC
ACID
68 / 72 %WEAK NITRIC
ACID
17 AMMONIUM NITRATE FT 202 Mag. flow Meter Emerson IFS4000 IFC021 F/D
18 AMMONIUM NITRATE FT 203 Mag. flow Meter Emerson IFS4000 IFC021 F/D
1700R11ABFEZZZ
19 Ethyl Acetate FT3701 Mass flow Meter Emerson CMF300M356NQBZEZZZMC
PIPEMTKT
1700R11ABFEZZZ
20 Ethyl Acetate FT3702 Mass flow Meter Emerson CMF300M356NQBZEZZZMC
PIPEMTKT
44
ANNEXURE - 2B
IP AND AN MELT FILLING CONTROL VALVE INFORMATION
BAY
PRODUCT TAG DESCRIPTION MAKE SIZE ACTUATOR
No.
DARLING
1 METHANOL XV 9201A Ball valve 3 X 300 EL-O-MATIC
MUESCO
2 METHANOL XV 9201B Ball valve XOMOX 4 X 300 EL-O-MATIC
3 METHANOL XV 9201C Ball valve XOMOX 4 X 300 EL-O-MATIC
4 METHANOL XV 9201D Ball valve XOMOX 4 X 300 EL-O-MATIC
5 METHYL FORMAT XV 5099D Plug valve XOMOX 1 X 150 Rotex
6 WEAK ACETIC ACID XV 9102 Ball valve TUFLIN 1 X 150 EL-O-MATIC
DARLING
7 ACETIC ACID XV 9101A Ball valve 3 X 300 EL-O-MATIC
MUESCO
8 ACETIC ACID XV 9101B Ball valve HYTORK 3 X 300 HYTORK
9 ACETIC ACID XV 9101C Ball valve HYTORK 3 X 300 HYTORK
DARLING
10 FORMIC ACID XV 5201 Ball valve 2 X 300 EL-O-MATIC
MUESCO
11 CONC. NITRIC ACID XV 21001 Plug valve XOMOX 2 X 150 HYTORK
61. 5 % WEAK NITRIC
14 XV 11001 Plug valve XOMOX 2 X 300 EL-O-MATIC
ACID
61. 5 % WEAK NITRIC
15 XV 11002 Plug valve XOMOX 2 X 300 HYTORK
ACID
68 / 72 % WEAK NITRIC
16 XV 11003 Plug valve XOMOX 2 X 150 HYTORK
ACID
17 AMMONIUM NITRATE HV210 Plug valve XOMOX 4 X 300 EL-O-MATIC
18 AMMONIUM NITRATE HV211 Plug valve XOMOX 4 X 300 EL-O-MATIC
19 Ethyl Acetate XV3701 Ball valve TYCO 3 X 300 TYCO
20 Ethyl Acetate XV3702 Ball valve TYCO 3 X 300 TYCO
--------------------------------------------------------END----------------------------------------------------------------------
45

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INQUIRY SPECIFICATIONS

FOR THE UPGRADATION OF TERMINAL

INQUIRY NO: INST_IPFILLING/TMV/TAS- CONTROL SYSTEM

Sr. GNFCs Requirement Vendor’s

The Terminal Automation system (TAS) is to be designed, engineered and

At present, there are two nos. of Distributed Control systems (CONTROL

Sr. GNFCs Requirement Vendor’s

GNFC-LAN (ISD-Network) requirement:

Hazardous Area classification:

3.3 FUNCTIONAL REQUIREMENTS:

3.4 Work flow and Tanker movement.

3.4 Work flow and Tanker movement.

Sr. GNFCs Requirement Vendor’s

5 Batch controller (BCU):

Sr. GNFCs Requirement Vendor’s

6 Access Control Device:

Sr. GNFCs Requirement Vendor’s

7.2 The minimum features of TAS application software are:

8 TANK TRUCK ENTRY SYSTEM (TTES):

11 LIGHT INTERFACE MODULE(LIU):

12.1 Batch Controller Unit (BCU)

12.2 Local Loading Operation

12.3 Local Area Network (LAN)

12.6 MMI presentation of TAS operations on the Engineering Server

13.0 TAS SYSTEM BLOCK DIAGRAM

The relevant CONTROL SYSTEM hardware is installed in dedicated panels.

Sr. GNFCs Requirement Vendor’s

2. All necessary system/communication cables shall run in closed,

5. BIDDER shall inform OWNER for the updates in software/hardware releases

6. The system reliability shall be stated in terms of MTBF in years (Typically

8. UN-interrupted power supply of high integrity shall be made available

12. Complete database generation including dynamic graphics shall be in

17.0 17.0 : BIDDER’S SCOPE OF WORK:

BIDDER’s responsibilities shall include, but not limited to the following:

a. System engineering including commissioning, System programming and

c. Supply and termination of various interconnecting cables between marshalling racks

d. Providing assistance in implementing control strategies and operational

e. Integration with TAS based on ETHERNET protocol or dedicated gateways.

18.1.1 Detailed specifications and system architecture of Control System will be

All the hardware including control/communication processors, networks,

b. Group Display : Various group of display (graphics) can be configurable.

c. Detailed Loop Status Display :

d. Displays For Alarm Handling :

18.2 Other requirements :

i. A list of alarms based on occurrence with most recent alarm on top.

HIGH Priority Alarms

Medium Priority Alarms

Low Priority Alarms

Trend displays shall have following minimum features:

i. Facility to group/delete a variable from a group. This should be an operator

i. Graphics shall be fully dynamic & interactive. BIDDER to inform the

BIDDER has to specify the maximum numbers of overlays of different sizes,

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

- Graphic builder package shall have command / script support for

- Facility to “zoom” a picture for better visibility shall be available.

- Security features like masking / access lock shall be available for

i. Type and location of malfunctioning unit.

Internal system Security