TECHNICAL SPECIFICATION
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|INDRAPRASTHA GAS LIMITED (IGL) |
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|SCADA AND TELECOMMUNICATION SYSTEM FOR CNG NETWORK |
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|TRACTEBEL ENGINEERING PVT. LTD. |
|PARTCULAR TECHNICAL SPECIFICATION |
|SCADA AND RTU SYSTEM |
|ΡΕΡΤ |
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TABLE OF CONTENTS
1.0 INTRODUCTION 1
2.0 BRIEF DESCRIPTION 1
3.0 SCADA and RTU system. 2
4.0 DESIGN CRITERIA 4
5.0 SCADA SYSTEM SPECIFICATION 6
6.0 SYSTEM FUNCTIONAL REQUIREMENTS 7
7.0 REMOTE TERMINAL UNIT 20
8.0 Drawings and DOCUMENTATIONs 25
9.0 INSTALLATION & COMMISSIONING 27
10.0 EQUIPMENT INSPECTION & TESTING 29
11.0 TRAINING 32
ANNEXURE -I - SOURCE OF SUPPLY (SOS) FORM
ANNEXURE -II- POWER CONSUMPTION REQUIREMENTS (PCR) FORM
ANNEXURE -III- TYPICAL I/O COUNTS DETAILS FOR RTU SYSTEM
ANNEXURE -IV – LIST OF EQUIPMENTS AT CNG STATION
ANNEXURE -V – TOTAL PHASE STATIONS
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1. INTRODUCTION
1. THIS SPECIFICATION COVERS THE BASIC REQUIREMENTS OF SCADA AND TELCOM SYSTEMS ALONG WITH ASSOCIATED EQUIPMENT PURCHASED AS A "SINGLE POINT RESPONSIBILITY PACKAGE UNIT" FOR CNG STATIONS.
2. This Project is an important tool for IGL to maintain control over its exponential growth of CNG stations across the periphery of Delhi & NCR and upgrade existing products and maintain competitive position in the market with the existing infrastructure, human resource etc.
2. BRIEF DESCRIPTION
1. DESIGN, ENGINEERING, SUPPLY, INSTALLATION, INTEGRATION WITH EXISTING CNG SYSTEM & ITS ASSOCIATED ANCILLARY AND COMMISSIONING OF RTU, SCADA AND TELECOMMUNICATION SYSTEM. REFER “SCOPE OF WORK” ENCLOSED WITH TENDER DOCUMENT FOR DETAILED SCOPE.
2. System shall ensure safety and reliable operation of the equipment as per following functionality.
• Change price level remotely (dispenser) at IGL discretion from its Head Quarters/ Central Control Station with one-layer authentication.
• Valve ON/OFF operation.
• Motor/compressor ON/OFF operation
• Preventive and predictive maintenance fo RTU, SCADA and Telecom system.
• Remote diagnostic and configuration of RTU
• Modem (placed at Central Control Station) with router (1W+1S) having capability to connect on MPLS network and compatible with SCADA system with switchover facility to achieve uninterrupted data transfer from RTU station.
3. Master station, SCADA system shall be located at IGL Kakanagar office, New Delhi for monitoring and controlling.
4. In additional to local servers at MS, SCADA vendor shall development or kept all the data to cloud server for monitoring and controlling from anywhere. Cloud server may be from vendor’s own and from any service provider. Vendor shall analyze the space requirement and ensure data must available at any moment of time for controlling and monitoring with proper authorization. This cloud station will also work as a disaster recovery system.
5. CNG station RTUs shall be located inside the local control station. The system shall be rugged in construction and suitable for working in non-AC ambient. RTU shall be designed by considering required Inputs & outputs and future expansion. All the inputs & outputs including spares shall be fully wired upto the terminal blocks.
6. RTU shall be interfaced with telecommunication system for transferring data to Master control stations. Telecom system shall be redundant wireless 3G/4G MPLS type (Refer PTS- Telecom for details). Telecom modem at RTU end shall be compatible of dual SIM cards and can be inbuilt/ integrated with RTU or separate modem linked with RTU.
7. RTU shall be comprised of CPU, Power supply card, communication cards/ports, input cards, output cards, controller card, interface cards, wall mounted IP 54 cabinet and required internal accessories such as fan, illuminating lamps, barriers, relay MCBs, terminal blocks etc.
8. It is the prime responsibility of vendor to establish the communications between field instrument, RTU, Telecom and SCADA. If any additional items are required to make the system fully functional during interfacing stage, that shall be made available to Client by vendor without any price implication even though it was not considered during bid submission.
9. The system shall meet the requirements of interoperability, portability and scalability as per the international standards (latest version).
10. Vendor shall submit duly filled in and signed SCADA source of supply (SOS) and power consumption requirement (PCR) form during bid submission.
11. Vendor shall undertake full responsibility for providing a complete and evolutionary state of the art SCADA System with Open architecture, meeting the objectives, functional and specific requirements described in the tender.
12. Vendor shall submit the drawings and documents of the complete system as indicated in MR. Vendor shall submit as-built documentation, drawings of the complete system. These submissions shall be made in hard copies and in CDs
13. Execute civil works associated with the installation of supplied equipments at various stations and at master station.
3. SCADA and RTU system.
1. SCADA HARDWARE
a) SCADA system shall be inclusive of two number data polling Servers (real time server) on latest Windows (OS)/ Linux (OS) (one working and 1 standby) along with one number of 21” monitors (Common for real time server, web server and history server), keyboard, mouse and KVM switch. All SCADA software require for successful operation, SMS facility and OPC (both client & server) with license.
b) One number archive server (History server) for providing offline storage of historical archive files.
c) One number Server cabinet for mounting all the servers, monitor, key board, mouse, KVM switch, GPS, network switches etc.
d) One number GPS with NPT server, antenna and cable min 30 mtrs for time synchronization.
The GPS clock envisaged at master station shall be used to synchronize the clock of servers, workstations, engineering workstation on the dual SCADA LAN at master station and to synchronize the RTU time with MS.
e) Two number 24 port LAN switch L2.
f) One number 10 port router/L3
g) One number 8 port KVM Switch: Keyboard, Video and Mouse.
h) A4 size printer
i) Fire wall security with cyber security
j) Vendor’s own Cloud server
k) One number engineering work station (EWS), 21” monitor, mouse and keyboard. EWS operating system shall be windows based. EWS shall have latest software with license like HMI/MMI development, Microsoft office, antivirus etc. EWS is required for configuration, MMI development, maintenance and engineering aspects of the SCADA system. EWS can also serve the purpose of operator workstation.
l) Two number operator workstation (OWS), 21” monitor, mouse and keyboard. OWS shall have latest software with license like HMI / MMI run time, Microsoft office, antivirus etc. Operator workstations are required to allow the plant operator to monitor and control safely.
m) Redundant LAN: The redundant LAN consists of two distinct Ethernet segments; each segment has its own dedicated Ethernet switch. Critical components including SCADA servers, archive servers, GPS, EWS and OWS will be provided with dual Ethernet ports allowing connection to both segments of the LAN. Non-critical items including printers connect on single segment of the redundant LAN.
2. SCADA System software
a) The SCADA software with main SCADA database shall be in SCADA server resident. Operating system for SCADA server shall be Windows latest.
b) EWS and OWS shall be loaded with Application software MMI and Microsoft office. Operating system shall be built around latest windows based.
c) SCADA shall be web enable functionality for remote monitoring /maintenance/diagnostic. It shall be accessed by diverse set of external users through commercially available web browser e.g. Microsoft Internet explorer, Mozilla etc. It shall also be possible to access the data and display by using mobile phones/ tablets on various OS i.e. Android, iOS, windows etc.
d) The networking shall support OSI TCP/IP network connectivity.
e) The LAN shall meet IEEE 802 standards.
f) The Communication protocol with SCADA and RTU’s will conform to IEC 870-5-101/104 or DNP3 over TCPIP, OPC.
g) The Servers will be loaded with OPC (UA) software (both client and server.) with license for data exchange (reading and writing) with other system like APPS, SAP, Business Analytical Platform, existing SCADA system etc.
OPC UA shall Open Platform Communications Unified Architecture (OPC UA) for machine-to-machine communication protocol and shall be the following requirement
• Security Model
• Mappings
• Profiles
• Data Access-Real time
• Alarms and Conditions
• Event
• Programs
• Historical Access
h) The solution shall be able to interoperate with:Multiple RDBMS platforms like Oracle, MS SQL, MY SQL, DB2, Informix, Sybase or any other RDBMS confirming to ANSI/ISO SQL-200n standards
i) System shall support with all three Operating systems Linux, Windows & Unix.
j) The system shall support on multiple hardware such as Dell, HP, Cisco, etc.
3. Remote terminal Unit
The RTU shall comprise the following subsystems:
• Central processor with system software.
• Analogue input
• Contact (digital) input
• Contact (digital) output
• Modbus Serial ports (RS 232)
• Modbus Serial ports (RS 485) two wire connection type
• RTU shall support all Protocols like MPI/PPI/Profinet/profibus/Ethernet etc for Siemens PLC's and MODBUS RS485 for another devices at stations like Dispensers, Flow Meters, Soft starters, VFD's etc.
• IP port(Redundant)
• SMPS Power supply
• Diagnostic port
• USB Port
4. RTU software
• Programming software as per IEC 61131
• Cyber security as per IEC 62443
• Local and remote Diagnostic tool
5. Any additional interfacing device if required to achieve the functionality as per the philosophy mentioned elsewhere in this document shall be provided or consider during bid stage.
6. Third party interface provision/compatibility shall be available in the SCADA servers for APPS system, any other SCADA system, SAP system, Business Analytical Platform etc.
4. DESIGN CRITERIA
1. SCADA SERVERS SHALL OPERATE ON A DUAL REDUNDANT CONFIGURATION. BOTH THE SCADA SERVERS ARE OF IDENTICAL CONFIGURATION AND EACH SERVER SHALL HAVE CAPABILITY OF PROVIDING THE FULL SCADA FACILITIES IN THE EVENT OF FAILURE OF THE OTHER MACHINE. THESE SCADA SERVER(S) SHALL BE RACK MOUNTED WITHIN THE EQUIPMENT CABINETS.
2. The servers with a redundant network connection interface card and connected to both segments of the redundant LAN. In addition, both servers shall be connected via a dedicated connection so that the standby server to remain in synchronization with active server.
3. Operator control functions shall include alarming acknowledgments and suppression, request for printouts of logs & reports, open-close-stop type discrete controls and controlling of set points at remote.
4. RTU shall have capability of updating process parameters data and configuration data in its own built-in memory. Time stamping of all field values shall be required at RTU. In the event of failure or break of communication link, the RTU shall continue to scan all parameters and update its database. RTU must retain complete database analog & digital information of the field until it completely and correctly read by SCADA Station to take care of no loss of data in case of failure of communication. The memory buffer is to be sized (by considering min 15 days down time of SCADA system or communication between RTU and SCADA) to store all the changing data (i.e. exception report for the data every poll time). SCADA system shall receive the same without any loss of data after resuming the communication.
5. For “offline” storage of archive files , Network Attached Storage (NAS) device shall be attached to each SCADA server. The NAS device provides a high capacity, fast access storage system allowing archive files. Archive server shall store the data upto to minimum 12 month , automatic backup shall be initiated before overwrite to cloud server. This will be used for preparation of reports, historical trend and for detailed system analysis. The archive server shall be located in the SCADA cabinet. The server shall have the feature to store, configure and display the user defined trends /historical data of the operating parameters of the machines in graphical / table format to facilitate the predictive maintenance.
6. Functionality for Important alarms and messages through email / SMS servers to concern person. The email server shall also send daily reports/messages automatically or on event trigger basis. It shall be possible to configure the users to whom the SMS and e-mails are sent. The mobile no and e-mail addresses shall be editable/configurable as and when required.
7. System shall have provision to escalate the levels for sending the SMSs / emails based on the time elapsed from occurrence of alarm. In case of occurrence of a critical alarm, a SMS/email shall be sent automatically to concerned maintenance persons. If the alarm does not return to normal within a specific time of occurrence of alarm e.g. 1 hour (configurable), then the SMS/email shall be sent to some higher officials (configurable) also. If the alarm does not return to normal within a specific time of occurrence of alarm e.g. 6 hour (configurable), then the SMS shall be sent to some further higher officials (configurable).
8. Facility for remote price in CNG Dispensers at CNG stationschange from SCADA system Server/SCADA at administrative access level with One level of authorization.
9. Web site information as per Mimic Graphic and flow chart section as a minimum. During contract period, vendor to attend all additional web site viewing features as per IGL process requirements at his cost.
10. Engineering workstation shall have the ability to undertake key system wide engineering functions such as:
• Configuration of the RTUs networks incl. Programming of devices
• Database generation, point ID and on-line modification
• HMI /MMI graphical development and/or modification
• Report development and/or modification using MS Excel
• System network administration
• System security
11. Specifications mentioned above are basic minimum requirements. However, Vendor shall upgrade / resize (on higher side) specifications of offered system to meet functional requirements specified in this tender. At any stage of system implementation, if it is found that Servers, HMI workstations and RTU and Telecom by Vendor are not having adequate processing power, main memory etc to meet system performance requirements of this specification, Vendor shall replace these with higher end machines with no cost and time implication.
5. SCADA SYSTEM SPECIFICATION
1. SCADA PHILOSOPHY
1. The system shall have complete SCADA database including the real-time database and integrated alarm/ event management summary for overall operations management & control for the entire network.
2. Two Servers i.e. Server # 1(Active as primary) and Server # 2 (standby as secondary) shall be configured in hot standby mode. Operator shall have privilege to select any one server as active and standby initially. Each SCADA server shall be fully adequate to fulfill the entire monitoring, operation and control requirements of the entire network and sizing of each server CPU such as, average Memory, disc utilization do not exceed 60% in the implemented system.
3. SCADA system shall run on redundant LAN configuration LAN A (Primary) and LAN B (Secondary). Both the servers shall have dedicated ports for primary LAN and secondary LAN.
4. Normally, Primary server shall poll all the RTUs on primary path. In case of any problem on primary path, the Primary server shall poll the RTUs on secondary path. In case of problem in both primary and secondary paths of primary server, Secondary server shall poll the RTUS on the primary path. In case of problem in primary path of secondary server, RTU shall poll on secondary path of secondary server. Therefore, in case of primary server failure, Secondary server shall Poll all the RTUs. The changeover to secondary server shall accomplish within 1 minute automatically without causing any loss of data and control without any effect on SCADA functionality. System shall inform the operator by flashing or pop of message on MMI screen about the failed system by active SCADA server/standby server.
5. When RTU being poll through one path, the system shall continue to obtain health status of the RTU as well as path status through the other path. On restoration of a failed path, system shall revert to the earlier preferred path for polling as described above automatically without any human intervention whatsoever or manually.
6. All the databases including Real time database, historic database, archive database and configuration database shall be synchronized between Primary & Secondary Server. The interchange of health messages between Primary & Secondary Server shall be implemented through Local Area Network (LAN). Health status of each of the SCADA Servers, system nodes and RTUs shall be updated at both servers in real-time.
7. Normally secondary server shall be in hot redundant standby mode but incase operator or engineer decide to put in cold standby mode, it should be possible to switch over secondary server in cold standby mode manually when primary is in active. Once secondary server is online, the data in secondary server shall be synchronized with active server automatically.
8. In case any modification or creation of new points in database, it should be possible to use the standby server for database creation and same shall be updated in active server without any interruption or data loss.
9. The Contractor shall have the option to implement the features of Alarm generation, association of the alarm priority and engineering unit conversion at the RTU level or at the SCADA host level. However, in case of RTU level, operator shall have privilege to modify or create new alarms in RTU from master station.
10. Operator/supervisory shall have privilege to update manually the Primary Server database such as (manual inputs, online SCADA database, alarm acknowledgements, alarm inhibit, digital controls, set-point controls etc.) to database of Secondary Server to maintain database synchronization between Primary & Secondary.
11. History database and archiving files between Primary Server and Secondary Server shall remain synchronized to maintain database consistency.
12. When the SCADA Server starts up after recovery from failure, the real time and historical SCADA database shall become identical to the active SCADA Server. The event indicating that this recovered SCADA Server has become STANDBY shall denote that SCADA databases have been synchronized.
13. Indication shall be provided in MMI for identifying the active and standby server
14. As a minimum requirement, SCADA software shall have the following facilities:
a) System and Database configuration.
b) Data Acquisition from the RTUs, generation and management of real time database.
c) Generation and management of historic data for trending and archival.
d) Alarm handling, including storage, display and printout.
e) Generation, storage, presentation of mimic diagrams with dynamic information on MMI monitor.
f) Display Management for Alarm, Alerts, Mimic diagrams, Analog and digital values, Trend graphs, Bar charts in high-resolution colour graphic modes.
g) Free format report generation, storage and printout.
h) Data logging at periodic intervals, on operator request and automatically on occurrence of an event.
i) Transmission of control commands and configuration parameters to outstations.
j) Redundancy, fail-over and recovery processes.
2. System sizing
1. Contractor shall size both the servers and MMI capability considering as per tender requirement, future requirement and data archiving period as per Annexure 1 SOS.
3. Input/Output Requirement
1. Contractor is required to incorporate the complete requirements of telemetered points for SCADA system taking the inputs from the I/O point list. The RTUs I/O cards shall be considering the complete I/O requirements of RTU I/O count.
2. Contractor shall furnish the poll time calculations during detail engineering considering the requirements of 50% I/Os parameter changes every poll. The calculation shall be carried out by properly and evenly distributing the RTU over the communication channels.
4. Real Time Database Access :
The supplied SCADA system shall be OPC compliant and have necessary provision for interfacing (data interchange) with third party applications.
6. SYSTEM FUNCTIONAL REQUIREMENTS
1. PRIMARY FUNCTION
The primary function of the SCADA system shall have operational interface to support the operation of the complete pipeline network. This interface shall provide the capability to acquire pipeline data from pipeline facilities operating conditions and status, show abnormal or alarm conditions and remotely operate the valves and execute pipeline shutdown and permissive.
2. Data acquisition
The data acquisition function shall provide all the aspects needed to support data collection from the field including the requesting of data from RTU and the processing of analog and digital data received from the RTU.
The data items listed below are representative of the data required from the various types of stations.
a) Pressure
b) Temperature
c) Corrected Volumetric flow rate, mass flow rate
d) Totalized mass & volume flows
e) Pressure/Temperature high/low alarms
f) Valve controls
g) Valve position
h) Flow computer
i) Flow meter
j) CNG Dispenser
k) CNG compressor
l) VFD & Soft starter
m) Multifunction meter
n) Gas generator set
o) Gas chromatograph
3. Report by exception
All analog and status data shall be requested on a report by exception basis to avoid unnecessary processing when the analog dead band has not been exceeded or no status changes have occurred. This is to avoid unnecessary data communication between RTU & SCADA. Depending on the database downloaded to the individual RTU, an RTU will scan the I/O points and determine the points to be reported when polled by SCADA and communicate it along with time stamp.
The analog dead band, debounce time, backup report update time etc. shall be configurable as part of database definition.
4. Data requests
The SCADA system shall be capable of periodically polling all RTUs with data request messages according to polling information in polling tables developed by the Contractor. It shall be possible to define an RTU or RTUs/PLCs more than once in a polling table per data channel.
5. Data updation
a) Report by exception data shall be updated maximum within 10 seconds or faster.
b) Backup update report updation for all parameters shall be every 5 minutes (user configurable).
6. Data priorities
The retrieval of status data shall have a high priority than the retrieval of analogue data and check back execute indications of just completed control actions shall have the higher priority.
7. Data validity
The SCADA system shall include data validity analysis function. This validity analysis shall be for out of range, Instrument Bad, scan failure, point on test, RTU on test, manual input, point in alarm, alarm inhibition, point off-scan, RTU off-scan, point in manual mode etc. Database qualifiers shall be indicated in database, displayed in the graphics and logged in the reports. These quality tags shall be implemented on all tags in SCADA system.
8. Poll modes
In addition to the general polling requirements outlined above, several other poll modes [user configurable] shall be implemented as below:-
- Poll Inhibit - to enable individual points or complete RTUs from the polling function.
9. Control functions
The control function shall include the basic start/stop/open/close and set point capabilities. The basis of all control actions shall be the select-check back-execute sequence.
Typical controls functionalities are as follows:
• Remote Price Change in Dispensers
• Valve open [Device start]
• Valve close [Device stop]
• Set point control
• Station shutdown,
• Electrical devices Start/ Stop
10. Device control selection
Control requests initiated by the operator, SCADA system shall validate the control point and the control the action according to system status, defined interlocks, permissive and assigned responsibilities. System shall display the error messages in case the operation is not permitted. Contractor shall incorporate the required changes in the operation as desired by COMPANY during the site implementation phase. It shall also be possible to override all interlocks /permissive under suitable password control and execute control. It shall also be possible to configure from SCADA station the width of the digital output pulse used for remote opening / closing of valves etc
11. Select-check back-execute
After verification of selected point and control action, the software shall initiate a select-check back-execute control sequence with the selected RTU.
When the control action is initiates, the software shall set a flag showing that a device change-of-state is expected. Failure to receive a status change within a predefined period shall show a faulty control action and initiate a timeout alarm at SCADA. It shall also applicable for all the digital controls.
12. Telemetry fail and poll inhibit
Reliable detection and correction mechanism shall be implemented for data communication. If valid data is not received from control device in response to a poll request, the software shall attempt to obtain the valid data from that control device. The number of re-tries to be attempted shall be configurable.
If control device fails, or its communication channel fails, or control device is on test/masked, then all individual points at that RTU shall be marked in the database to indicate telemetry failure but only one alarm shall be generated linking with the corresponding failure status. The database shall retain the last good value or status for every point affected until the telemetry returns to normal. Return to normal event shall be generated and RTU shall update (when polled) w.r.t all points.
The operator shall have the capability to inhibit any point from scanning or an entire RTU from poll processing. In this situation, the operator may substitute values for the data for points with defective telemetry or which have been inhibited for poll processing. In addition, a point taken in manual mode shall automatically put the point off scan. The substitute value shall retained until poll processing on that point or station is restore.
13. Callup & Updation times
a) Call-up time of any graphic display on color monitor: not to exceed 5 sec.
b) Updation time of any graphic display on color monitor: not to exceed 2 sec. and Updation time of Historical trend graphics not to exceed 10 sec.
c) Call-up & Updation time of Historical trend graphics: not to exceed 20 sec.
14. System diagnostics & test facilities
Comprehensive diagnostics and the test facility for each sub-system shall be an integral part of the SCADA system.
15. MAN Machine Interface (MMI)
1. Features
The Man Machine Interface (MMI) system is the primary interface to the SCADA functionality. It is critical to the operation of the SCADA system and the Contractor shall provide a secure, flexible and "User-Friendly" interface by which engineers, supervisors and the operators may interact with the system and pipeline network by way of the computing equipment, database and software.
The MMI shall exploit the best characteristics of colour graphic monitors, keyboards, cursor control devices, and printers.
The graphic displays shall be windowed, fully supported with appropriate graphics and symbolic diagrams. All procedures shall be selectable by menu and context sensitive help displays shall be available.
The SCADA MMI shall support the feature of full screen data entry update wherein changes made to the number of tags/ fields/ parameters on the graphical display shall be buffered and updated in the database of SCADA.
2. The MMI shall, as a minimum, include the following functions:
- Display requests
- Supervisory control
- Alarm and event message display
- Alarm message acknowledge
- Alarm inhibit, poll inhibit, point scan inhibit
- Report and log output request
- Monitor hard copy printout
- Monitor analogue trending
- Bar graph display
- Manual data entry
- Free form text entry (scratch pad)
- Device warning indications (tagging)
- Assignment of console or workstation operating modes
- Calculated variable definition and modification
- Display page definition and modification
- Report and log definition, modification and control
- Alarm and event message definition and modification
- Display and modification of system parameters
- Database management
- System configuration management
- Error statistics acquisition and management
- System resource utilization
- Daily alarms and operator actions
- System status displays including all system nodes.
3. The MMI shall be equipped with full-fledged graphic editor. The graphic editor as a standard shall contain large no. of objects such as meters, bar graphs, slide bars, `Chart recorders', trend windows, alarm annunciators control buttons and other such items which the user can create for placing in the library. Objects shall include database links for alarm/mode/state/value fetching, for alarm coding and for animation & dynamics.
Facility shall be provided to easily generate and edit the graphic displays, and to move, delete, change symbols, characteristics, color, dynamic field assignments, copying etc.
4. Supervisory Control
Control to command a change of the state of CNG network devices from the console shall be supported. In addition, control of the SCADA system functions for starting & stopping, network management, diagnostics, maintenance & house keeping itself shall be supported.
5. Alarms and Events
The MMI shall support the presentation of alarms and events, on displays and printers, to provide information regarding the behaviour of the pipeline network system. Facilities shall be provided to acknowledge alarms and to inhibit alarms.
6. The facility to manually enter numeric and status data from an MMI.
7. Situational Awareness tool shall have advanced features such as Drag and Drop, Advanced Alarming, 3D visualizations, world/India/Delhi maps, contouring, use of widgets, meters, dials, and other objects enhance operations and significantly enhance situational awareness in the control room. There shall not be any limitation in number of user-based desktops. Some of the Out-of-the-box Objects and Widgets shall include Meters, Dials, Gauges, LEDs, Knobs, Buttons, Pie, Bar, Line and Plot Graphs.
a) Situational awareness tool shall use Drag and Drop technology to perform tasks such as:
• creating executive dashboards with graphical and dynamic widgets,
• creating switching orders,
• applying tags,
• creating calculations,
• Assigning and building trends,
b) All graphical displays in the proposed system shall support the following key features:
• Annotations/Notes
• Panning, zooming (via mouse scroll wheel, buttons, rubber banding, hot keys, etc.), layers, and decluttering
• Multiple navigation tools including alphanumeric display call-ups, main menus, pull down menus, and more
• Support for projection map-board view and remote control
• Support for embedded graphics and bar charts
• Designation of Action Objects for program executions and other linkages
• All Tabular style displays have advanced searching, sorting, filtering and grouping capabilities.
• Support for dynamic pressure/temperature graphs.
16. Displays
1. Features
Displays shall be in a window format and standardized to the extent that fields necessary for effective operational communication with the SCADA system are fixed. This shall provide efficient and standard MMI procedures across all system functions and serve to reduce the risk of operating errors. However, display support shall be flexible with regard to the presentation of data and customization with maintenance utilities to suit the specific operating requirements shall be available. The operators shall have easy operational access for data from hierarchy of display pages, using `point and click' cursor actions.
Using ‘command scripts' it shall be possible to automate many of the operators procedures such that mouse click operation is all that is required to open/close valves, , change set points, while performing logical checking permissive, authorization checking, check before execute security functions and time out functions. The control points shall be selected by clicking their related symbols on the graphic display. The Contractor shall supply standard set of control panel script and these shall be user configurable as well.
2. Display Requirements
a. The SCADA MMI shall support a comprehensive range of displays to enable maximum operational, engineering, maintenance and planning benefit to be obtained from the system.
b. The Operator/Engineering Work Station displays to be split in such a manner to ensure proper view ability and legibility covering all the facilities and covering all the signals & controls as per SCADA telemetry database document.
c. The soft keys/buttons for accessing P&ID diagrams, station schematic displays, SCADA system status displays, SCADA reports shall be available at all the time for direct access. Further displays shall have navigation built-in covering Page forward, Page backward, Page up, Page down facilities indicating the corresponding names of the displays for navigation.
The following types of graphics shall, as a minimum, be made available as applicable.
• Master and Sub Index Displays
• CNG stations overall status display
• Pipeline single line diagram Displays for all CNG stations
• Network and Station Overview Displays (google Geographical map).
• Station Displays
• Alarm and Event List Displays
• Data Trending
• Bar Graph Displays
• Electrical parameters
• Configuration Management Displays
• Database Review Displays
• RTU status display
• Communications status Displays & Communication statistics displays
• SCADA System Utility, Support & Diagnostic Displays
• System Resource [CPU, Memory, Disk loading]
• SCADA reports
d. The dynamic field values along with engineering units shall be indicated next to the analog tag numbers and serial link data. The tag numbers are to be displayed only wherever necessary and the remaining tag nos. may be displayed in another layer of graphic. The attributes viz. change of colour, flashing shall be done with the numeric value to show alarm on these tags in the displays.
e. The station displays having Flow computers shall constantly display the dynamic field values in engineering units. The corresponding display to be obtained by clicking the “Poke point” associated with the flow computer symbol & gas chromatograph symbol. This shall include the field values in engineering units for all the flow computer & gas chromatograph parameters telemetered through serial link along with corresponding tag nos.
f. The digital points along with their tags and alarm & normal status shall be shown in the displays.
g. The hot spots shall be configured in all the displays for further navigation/ selection and direct access.
h. The remote/ local status of ON/OFF valves shall be indicated by the static text 'R/ L' respectively, with 'R' in green and 'L' in red colour in all the station schematic displays.
i. Valve displays shall be Green open, red when closed, flashing red when bad, flashing green travel.
3. Display Requests
It shall be possible for the user to quick access to any required display with one or two mouse ‘clicks' using the feature of inter page links (poke points) plus associated display links. .
At least the following types of display requests shall be provided:
• Select window
• Activate window
• Move window
• Re-size window (including maximize, minimize)
• Close window
• Zoom and pan windows
• Page forward/ backward/ left/ right
• Display requests via dedicated function pushbuttons
• Display requests via cursor selection points
• Display request via manual entry of a display page identifier.
1. Colour coding of device symbols and numeric values on the display pages shall be used to show the status of the corresponding device or numeric value. Colour codes shall be subject to CLIENT/CLIENT’s representative approval prior to implementation.
2. Contractor to note that pipe to soil potential analog input signal will have compound range (from negative to positive side). The alarming mechanism to be suitably implemented with under-protected alarm configured as less negative signal and overprotected alarm configured as more negative signal.
3. The display hierarchy to be built to permit overview of the station (terminals etc) with alarms and important parameters & controls and linking with the detailed displays of various sections of the station with complete details of all parameters & controls. All the displays will be linked by properly implementing the display navigation mechanism through clicking the mouse.
17. Alarms & Events announcements
These fall into two categories:
- ALARMS
- EVENTS
Functions classified as monitored states shall present on the display for all possible states. It shall also be required to announce the change of states as they occur and such change of state shall display discretely identifying the function changing from one state to the other for operator interaction.
All the alarms shall be available in a consolidated alarm list. The event list shall also contain all alarms, return to normal of alarms and change of state.
18. Alarms & Events processing
The SCADA station shall facilitate the alarm reporting to alert the system operator of abnormal conditions.
It will be required to give alarm on the absolute value of measured variable, rate of change of measured variable, deviation high and low, change in discrete status to abnormal state, sensor bad, system related alarms. The system shall also be capable of generating alarms on the computed variables. The user shall be able to acknowledge the alarms either from the alarms list (single alarm, full page or own selection of alarms in a single go) or by selecting the point or object on the process graphics. It shall be possible to assign points in various alarm categories differentiated through colour combination. Alarms shall be flashing in respective colours before operator acknowledgment. Dedicated alarm summary page shall be provided giving chronological information of tag no., set point, time/date of occurrence, text descriptor etc. of the unacknowledged alarms and acknowledged but existing alarms in the system.
The alarms, which are returned to normal before operator acknowledgement, should continue to remain flashing on the alarms display. The alarms, which are acknowledged and also return to normal should be cleared from alarms summary. Also when the field conditions are abnormal and operator acknowledges the alarm, the alarm message should go to steady state from flashing. Facility shall be provided to acknowledge alarm on point/ page basis. Daily alarm/ event file should be available for further processing purpose.
The alarm manager shall provide alarm filtering current alarm/ historic alarm presentation group/ point alarm acknowledgment plus enables/ disable alarm history logging & printing specifying start time, plus audible and visual alarm presentation. Alarm list shall support sorting/grouping of various columns either by adding or deleting (through drag and drop) any alarming attributes. Operator shall be able to attach a note, photo or a document to any alarm or a group of alarms in the system. The system shall allow filtering of alarms in a parent-child arrangement. Operator shall be able to select any set of alarms either continuous or random and paste to any Microsoft applications such as MS Excel or Word etc. for providing reporting function to an operator.
Alarms filter mechanism to be provided to screen the alarms and show specific alarms for review purposes. A filter shall be able to operate based on:
• Logical division of pipelines.
• Various stations wise like metering stations, repeater stations and terminals with selection of alarms, events.
• Various class of point database types like AI, DI, accumulators, calculated points, manual inputs etc.
• The associated process related point group type.
• Priority wise for various categories of alarms like unacknowledged alarms, acknowledged alarms etc.
• Reason code such as command, manual entry, acknowledgement, unsuccessful command etc.
• RTU wise alarms & events
• SCADA system/equipments related alarms
Typical events to be stored/printed with proper ID are:
• Commanded device changes
• Uncommanded device changes
• Device time out alarm
• Alarm enable/disable messages
• Control set point(SP) initiation for change, SP actually changed
• Alarm Return to normal
• Every operator action w.r.t configuration and database changes, ACKS, control commands etc.
• SCADA system events
• All alarms shall also be events
• The change of Alarm limits and Set-point changes shall be logged on SCADA system as events.
Alarm and events summary displays shall be different.
Alarm and event history shall be maintained in the system disk file indicating all the alarms and events that occurred and acknowledged within the system in circular file retaining the latest 500 entries.
A procedure shall provide to inhibit individual points from all or partial alarm processing. Inhibited alarms shall not annunciate or display although an inhibited alarm list shall display all these points having inhibited alarms. The action of inhibiting or enabling alarm shall be logged as event.
19. Barchart Display of Measurement
Telemetered analog measurement values shall also be capable of display as horizontal and vertical Bar charts, in which the length/height of the bar shall vary according to the current telemetered value of the measurement function.
20. Trending
1. Real time trends and historical trends shall be possible on any parameter or variable as measured variable, set point, output, calculated variable and digital parameters, results etc., which shall also be capable of being drawn out on printers as hardcopy. Contractor has to ensure that all analog inputs, analog outputs and calculated parameters in SCADA database are configured in both real time and historical database with correct telemetry tag names and engineering units & ranges.
2. Trend displays shall be single line type or bar graph type with additional information like tag no., engineering units, span, present value of the trended point, alarm status etc. displayed. The display of trending parameters from the screen should be user configurable with up to 8 parameters.
3. Selection of the tag no. and sampling time for real time and historical trending shall be possible from operator keyboard.
4. It shall be possible to select number of measurements for sampling and storing over selected polling intervals.
5. The time interval shall be selectable up to one month for all parameters (for pipe to soil potential up to one year if applicable).
6. Facility to select using mouse, the required period of displayed trend for zooming and to fall back to previous trend screens. It shall be possible to see the value at a particular time on the trend curve by clicking the mouse on the curve. The trends shall be displayed in graphical form as column or curve diagrams with a maximum of 128 trends per screen. Adjustable time span and scaling ranges must be provided. The system shall have the ability to have an unlimited number of windows on a monitor. Trend shall have the ability to superimpose two different time frames in a single window for comparison. It shall be possible to drag and drop any values into the trend board.
21. Report and logging requirements
1. General
The SCADA System shall support the definition, generation, scheduling, buffering, spooling and printing of both logs and reports.
2. LOGS
A log is defined as a continuous and generally chronological listing of spontaneous messages such as alarms and events. Logs shall contain no summations or other calculations using the logged quantities.
A log shall comprise single line alarm and event messages printed one at a time as they occur. Each message shall have the same format as the corresponding message in the list displayed on the screen.
Operator interaction (commands, set points etc.) shall be logged with tagging of user ID of the operator and shall be viewable at any time through the MMI.
3. Reports
a) Reports define as an output of preselected data organized in a specific format. Report software to support output to all the three defined destinations-screen, printer and text file. Reports shall print on demand or on the occurrence of predefined trigger events, such as the time of the day, shift wise, daily, monthly. All reports shall be viewable on monitors prior to printing on demand.
b) Shift reports shall give hourly-metered values of parameters for the previous 8 hours from the time of scheduling of these reports. These reports shall be printed three times a day on predefined times. Definition of shifts to be incorporated in the shift definition screen and data to be sorted out accordingly. For status shift reports, the ‘Abnormal state’ to be maintained for the complete hour even though the status returns to normal within the same hour.
c) The SCADA shall allow the definition of new report formats and the modification of existing report formats as “system maintenance mode function”. The report generator tool of SCADA package shall be able to access real time database and history database. The reports software shall also support embedded arithmetical functions.
d) All shifts & daily reports shall generate automatically at predefined time (configurable) and automatically stored on hard disk (if ‘printing of reports’ option is enabled). The user shall be able to enable or disable the “printing of reports” option.
e) At the end of define time (configurable), the system shall automatically move all report files of that duration from archive to cloud, to free the hard disk storage space.
f) Files from archive & cloud database shall be able to access by defining report name and shift/ day/ month/ year for printing on demand.
g) The following types of reports (configurable as per Client/company requirements) shall, as a minimum, be made available covering all the requirements of the P&IDs and not limited to:
• Metering data reports (shift, daily, and monthly) with various metering and related parameters for all the metering runs.
• Station/ terminal data reports (shift, daily, monthly) with parameters as parameters and related station parameters
• Electrical parameters reports (shift, daily)
• Stations pressure & temperature reports (shift, daily)
• SCADA System status reports
• Other daily/ monthly/ yearly/ on demand operational reports such as SCADA system abnormality report, Operator tracking report, abnormal instrumentation report, station availability report etc.
• The monthly report will be generated every day containing the data from the start of the month to the latest completed day.
• The yearly report will be generated every day containing monthly data up to the current month. The current month data will be from starting of the current month up to the latest completed day.
22. Data archiving
The Contractor shall provide, as an integral part of the system, data archiving, reports archiving functions and facilities.
The archiving process shall be automatic except for those tasks where manual operation is a fundamental requirement.
The archiving function shall not interfere with the operational functionality of the SCADA.
23. Operator and engineering functions
1. All operator and engineering functions shall be initiated from the keyboards and mouse associated with the works stations.
24. Access security
1. The facility shall be provided for restriction of access. Using this facility, the names, authorized access level, access codes shall be entered.
2. Each workstation shall have no. of defined authorization for process control and for control system interaction along with login capability with password protection. Each operator login account shall define the level of access and the control for various pipeline(s). The password security shall be built on all SCADA MMI. , broadly within the following levels from SCADA MMI. These shall be finalized during FDS stage.
Manager : Top level limited to persons authorized to modify software and allocate access authority.
This is in addition to Engineer, Supervisor and Operator privileges.
Engineer : Allowed to access and modify anything in the database and display & report formats (database, display & report configuration).
This is in addition to Supervisor and Operator privileges.
Supervisor level : Allowed to adjust configuration parameters during system diagnostics/ maintenance level (Manual override, Alarm inhibit, take point in/ out of scan, Take point in/ out of Test mode, Take RTU in/out of scan, Take RTU in/out of Test mode, initiate demand scan of RTU, etc.)
This is in addition to Operator privileges.
Operator level : Allowed to do day to day operation (access displays, Generate reports, Alarms acknowledge, Supervisory digital controls and set-point controls, pipeline shutdown etc.)
3. Operator functions
a) The operator functions shall be comprehensively covering all aspects of information call up, assignment of display, function select, panning, and windowing for quick display call up and navigation from the keyboard and mouse.
b) Operator control functions shall include alarming acknowledgments and suppression, request for printouts of logs and reports, open-close-stop type discrete controls and set point controls by transmission of set points to remote outstations by telemetry.
c) Operator control functions shall also include entering non-telemetered values, constants, limits, set points and manual entered text messages for display on selected frames. These values shall be retained until changed to new values by operator entry and erased as would be the case for manually entered text messages. Manual data entry under password control shall be available on all the displays with validity/limit checking feature.
4. Engineering functions
The system shall facilitate on line SCADA system configuration, compilation, modification of configurable parameters i.e. Report by exception value, alarm limits, analog display range, addition and deletion of points for installed I/O modules, display, logs and reports.
Engineering function shall include running of system diagnostics for on line system testing.
25. Supervisory control
1. Supervisory control functions shall comprise a multi-step interactive procedure to avoid accidental operation of plant items.
2. Start/ Stop/ Open/ Close Control
This control function shall be used to control multiple state devices in the pipeline system and the SCADA system. All these control functions shall utilize the select-check back-execute control sequence and Digital output subsystem of RTUs/PLCs shall recognize two commands associated with device control.
3. Set point Control
The set point control function shall be used to provide a set point for controllers. Operator shall have a facility to change flow, pressure & speed set points manually from SCADA.
26. Real time variable calculations
The system shall have capability of defining computed variables (including host resident analog accumulator points) by arithmetic and logical operators from the real time parameters. The arithmetic operators will include as a minimum +, -, *, /, SQRT, MAX, MIN. and logical operators will include AND, OR, NOT functions on the real time operational parameters.
The calculation tool shall also include all types of database access and starting of programs with features of specifying customer specific formulae.
These calculated results can be embedded for the purpose of display, reports etc.
27. TIME SYNCHRONIZATION
The GPS timeserver shall be connected with the SCADA system at Master station(MS). The primary SCADA server at MS shall be the "Master Clock" for the overall system Date and Time Facility utilizing GPS time reference and all the nodes on the LAN at MS.
In case of failure of Master clock, the redundant SCADA server shall receive the signals from GPS timeserver and shall have the Master Clock. Whenever the MS Date and Time is set or reset, an automatic synchronizing signal shall be transmitted by telemetry to all remote stations. Any remote station subject to a "Station Failure" shall automatically sent a synchronization signal on restoration of the same.
The RTUs shall also be synchronized with the master clock with the resolution of 100 msec.
28. SCADA centric network monitoring tool shall be supplied to monitor the IT infrastructure such as servers/workstations, CPUs, memory usage, etc. inside the control centre using SNMPv3. There shall be provision to configure network monitoring tool in SCADA dashboards and ability to build system maintenance display in SCADA display editing tool. This system architecture display shall be linked to real-time values obtained from the network monitoring tool through SNMP”
7. REMOTE TERMINAL UNIT
1. RTU SHALL BE RUGGED IN CONSTRUCTION, CAPABILITY TO IMPLEMENT CONTROL LOGICS, INTERLOCKS & FUNCTIONALITY AS SPECIFIED IN TENDER SPECIFICATION AND SUITABLE FOR WORKING IN HAZARDOUS AREA & OPEN ENVIRONMENT CONDITIONS.
2. This shall be microprocessor based programmable units with both erasable ROM and RAM memory. Control device shall have its own processor, memory, power supply unit & communication processors and I/O cards complete in all respects. All RTUs shall be modular and from the same model product line with identical capabilities.
3. USB port shall be provided to collect the storage backup from RTU in pen drive/USB drive, in readable format i.e. MS Excel.
4. The complete system shall be supplied with all its components including the cabinets.
5. The I/O cards shall not be combined for the functionalities i.e. each card shall perform dedicated functionality w.r.t analog input, analog output, digital input, digital output
6. The entire supplied control device shall be with same make & model no., differing only in number of I/O cards and communication ports. Three type of RTUs are considered for this proiejct. Refer Annexure III for details.
7. Configruable Communication ports master or slave (RS 485) as per requirement.
8. Digital inputs
Typical specification of Digital Input Modules is as given below:
Input Type : Volt free contacts (2 wire isolated)
Contact Wetting : 2-4mA per input at 24V DC
Resistance recognized : Not exceeding 1 Kilo Ohms as a closed contact
Resistance recognized : Not less than 50 Kilo Ohms as an open contact
Isolation : Using optocouplers or vendor specific.
Insulation resistance : 20M ohms at 500V DC inputs
Debounce circuitry : 10 m/sec
Indicators : Loop & state LEDs for each DI point
Voltage withstand : 1.5 KV RMS Capability
9. DIGITAL OUTPUTS
Typical specification of Digital Output Modules is as given below:
Output Type : Relay contacts
Indicators : LED indication for each DO point
Relay Type : Miniature power relay
Contact arrangement : 1 NO + 1 NC relay contacts configuration to be provided up to the RTU terminal block
Contact Rating : Potential free contact rating of output interposing relay for each DO point
(Contact rating 48 V DC, 2A; 230V AC, 5A)
(Vendor to provide interposing relays for each digital output point)
Isolation : 2KV RMS Contacts to Logic
DO command activation : Configurable Pulse duration
Security : Output contacts shall be monitored via opto-isolators, shall be short circuit proof and protected by suitable mechanism like fuse with suitable visual fuse blown indication provided.
10. Analog inputs
Typical specification of Analog Input Modules is as given below:
Input Type : Isolated, Current Inputs
Ranges : 4 - 20 mA
Multiplexer : Vendor standard
ADC Type : 12 bit binary (exclusive of sign bit)
Series Mode rejection : Greater than 30 db at 50 Hz
Common Mode rejection : Greater than 100 db at 50 Hz
Roll over error : 1 bit
Temperature : 0.005% per degree C
Coefficient
Accuracy : ± 0.1% of range including drop in resistor
11. The control device shall be configured such that failure of any part of an RTU subsystem (module) except the CPU, power supply module shall not directly affect the integrity of the unit, as a whole.
12. COMMUNICATIONS
The RTU shall support both internal and external communications functions.
The communications network internal to the RTU shall be designed and implemented in such a way that the passing of data and commands between modules shall not be prevented by the failure of any module not directly involved in the communication exchange. In addition, the internal network shall not become overloaded under the heaviest traffic possible in RTUs ultimate expansion configuration.
Each RTU shall recognize its own unique address. The LED indication shall be provided in the RTU to check the health of RTU communication.
13. RTU FEATURES
1. The RTU sub-system shall support the following:
a) Scanning of Input and Output
b) Fast Scanning of selected I/O points.
c) Field input initiated discrete control action
d) Discrete control action corresponding to Remote Control command reception.
e) Operator initiated discrete control action with check before execute and time out feature.
f) Operator initiated discrete control with sequencing and interlocking.
g) Derivation of calculated digital points based on logical functions AND, OR, NOT etc. from digital and analog points.
h) Derivation of calculated analog points based on arithmetic functions +, -, /, *, sq, root etc. and driving external hardware. Calculation shall be performed in RTU in engineering units with 16 bit floating point accuracy, required in case engineering conversion is being done at RTU level. (Calculations shall be performed in the SCADA host in case engineering conversion is being implemented in the SCADA server.)
i) Derivation of counter values using Integration of hardware and software generated Analog points.
j) RTU resident accumulator points driven by analog points.
k) Remote configuration of RTU from SCADA station through PDT/PC.
2. Automatic time synchronization of Remote telemetry units shall be implemented from master Station with a resolution of 100 msec.
3. The RTUs shall have a self diagnostic feature and software watchdog timer devices to monitor & report the healthiness of CPU, memory, power supply, comm. interfaces and Input /Output modules at the local level. Further, the RTUs shall support remote diagnostics from different station so that all these status shall be transmitted to master station and displayed in the RTU status graphic.
4. The analog input card shall generate an event, if it is out of calibration, which shall be sent to SCADA station. Further, if analog output card is not self-calibrating type then all analog outputs shall be wired back as analog inputs and calculations performed on each channel to detect AO card out of calibration. This out of calibration shall be available as part of RTU status graphic along with set point value displayed in the graphic, next to the corresponding controller symbol.
5. It shall scan and acquire parameters from process as per programmed scan cycles.
6. RTUs shall be intelligent in support of the following:
l) It shall process the analog data for high-low limit violations as per stored limit tables and communicate the same to SCADA station along with time stamping.
m) Linear conversion to engineering units and input filtering, in case engineering unit conversion is being done at RTU level [conversion of raw data to normalized value (e.g. 0 to 1.0) for communication shall also be acceptable].
n) To support remote reconfiguration and downloading of parameters i.e. addition, deletion, modification and reassignment with different range, limits etc. from SCADA station to avoid local engineering at RTU level. The following requirements of RTU configuration from SCADA station shall be fulfilled:
• Analog alarm limits
• Analog scaling factor for engineering unit conversion
• Threshold value
• Smoothing factor (filter time constant) etc.
7. RTU shall be capable of updating process parameters data and configuration data in its own built-in memory. Time stamping of all field values at RTU shall be required. In the event of failure or break of communication link, the RTU shall continue to scan all parameters and update its database.
o) RTU shall retain in its database the complete analog & digital information of the field till it is completely and correctly read by SCADA Station in order to take care of no loss of data in case of failure of dispatched, SV, and Receiving Station. The RTU shall scan the field and the memory buffer is to be sized to store all the changing data (i.e. exception report for the data every poll time) without any loss of data and alarms in the SCADA system to take care of channel, SCADA server switchover times.
8. Further to take care of long term communication outage with SCADA system , RTUs shall be designed to scan the field and store in the memory upto 1000 field exception reports during the period of communication outage for retrieval by Master Station subsequently.
9. The RTU system shall have the facility to attach to each digital event signal a time tag generated by the RTU local clock to enable the occurrence to be recorded and transferred with a resolution of 100 ms.
10. Every control associated with RTU shall report the status of the point after control execution. In case the status has not changed within fixed specified time it shall report to SCADA station for not having executed the control.
11. RTU shall not generate any false control signal due to power supply on-off conditions.
12. RTU shall support communication protocol supporting report by exception to prevent unnecessary data communication when the data is not changing.
13. It shall provide error detection and control feature for data communication with SCADA Station to ensure data integrity.
14. It shall have feature of connecting a pluggable Programmable Diagnostic Test unit (PDT) with keyboard & monitors diagnostic and programming aid to trouble shoot and configuration tool for RTU and I/O boards. It shall be possible to exercise all the functions of the RTU without disconnecting the RTU from process.
15. RTU shall have provision of applying filtering on the input signals and scaling for engg. units conversion.
16. In case of failure of complete RTU or off-scan of complete RTU, only one alarm shall be generated and the RTU analog & digital points shown in various graphics and printed in reports shall correspondingly have data integrity qualifier flag.
17. RTU shall operate from power supply as indicated in the tender. Separate on/off power supply switch and fuse shall be supplied with each RTU. Adequate isolation of input, output and power supply circuits shall be provided along with over voltage and short circuit protection.
18. Terminations for connections of power supply should be of standard industrial type. The PDT as diagnostic aid to RTU shall be a notebook (laptop) with proper enclosure and shall operate on integral battery which shall be rechargeable type. Also the PDT shall operate on 230 V AC power supply. Vendor shall provide all the necessary converter/adaptor along with PDT.
19. The I/O point wires shall not be directly terminated on the RTU I/O boards. Screw less Terminal blocks/ shall be provided in the RTU cabinet. I/O termination blocks shall have both male and female portions so that to isolate the field wiring at RTU level, male/ female termination block attached to the field wiring can be pulled out instead of removing the wiring. Cross ferruling shall be done.
20. The electronics in the RTU shall consist of plug-in PCB's or units with Gold plated edge connectors that utilize a wiping action for connection for PCB's to the back frame wiring. SCADA Vendor shall detail the shelf and inter-shelf wiring and the termination of the wiring harness between the RTU and the terminal block area. Easy access to cabinet wiring, for maintenance purposes is essential. The PCBs and RTU components shall be designed for high temp rating and low power consumption so that air exchange with the ambient environment will not be required.
21. The RTU shall be immune to radio frequency interference generated by any nearby source meeting the latest international standards in this regard (MIL, VDE etc.).
22. The RTU equipment shall function continuously without requiring any preventive maintenance.
23. SCADA Vendor to ensure that the open/ close status of valves (open state first wired and thereafter close state) be wired consecutively in the RTUs.
24. Identification labels for RTUs, RTU card files, power distribution boards, terminations etc complete in all respects properly correlating with the drawings is to be ensured by the SCADA Vendor.
14. SCAN Rates
The local scan rates for individual I/O modules shall be such that the time-tagging resolution and system performance requirements are achieved.
The consideration of scan times shall include the acquisition of data, processing and updating of the RTU database. The overall local scan shall be defined as the time required to acquire field data and update the RTU database and the same shall be much faster than RTU poll time by SCADA station. It is expected that scan rate shall not exceed 100 msec.
15. RTU Scanning philosophy
All the RTUs shall have two Ethernet communication for primary LAN and Secondary LAN, port A and Port B respectively. Port A and Port B shall be reachable from Master station LAN A and LAN B
Generally, MS tries all the RTU on Port A from LAN A. In case of any problem in that path, the RTU shall be tried on Port A through LAN B. In case of RTU not accessible through Port A from MS end, it shall try through Port B from either LAN A or LAN B from MS.
Switch over from Port A to Port B or via-a-versa shall automatically without loss of data. Appropriate fault message shall be generated on SCADA system about failure of fault port.
16. SET-Point Controls
a) All analog output control functions shall utilize the select-check-operate control sequence associated with set point control.
b) At the RTU, failure of a module in a subsystem shall be identified by an individual LED display.
c) Each I/O protected against the reversal polarity of the power voltage to I/O.
d) All the data shall be available in the engineering units in the RTU database. The Contractor has the option to implement the feature of engineering unit conversion at the RTU level.
17. Serial Link Requirement
a) RTU vender shall provide appropriate number of RS 485 & RS 232 serial ports for each RTU as per tender requirement.
b) Vendor shall provide all the software tools and programs (source code) used to interface RTUs with different IEDs. CLIENT shall integrate other IEDs with the RTU in future. Hence, RTUs shall have all necessary software, compilers, tools that makes device compatible with third-party IED device. Integration of IEDs (of any protocol and not just MODBUS) with the RTUs shall be totally end-user configurable.
c) The alarms for power supply/ serial link failure/ malfunction through serial link.
d) The RTU memory sizing shall be adequate for required nos. (As applicable) of IED system & serially connected with the RTU including the spare ports.
e) All RTUs shall be user programmable for interfacing with any kind of IEDs like Flow Computers, flow meter EVC, Gas Chromatographs etc.
8. Drawings and DOCUMENTATIONs
1. THE LANGUAGE USED IN ALL CORRESPONDENCE, DOCUMENTATION, LITERATURE, DRAWINGS, MARKINGS ETC., SHALL BE ENGLISH.
2. Contractor shall furnish all relevant technical manuals, literature and other technical data as required at the various stages of the project indicated in MR.
3. All the drawings and documents shall be verified by the Contractor before presenting the same for review.
4. All these documentation shall be furnished in hard cover loose ring folders in A4 size (210mm x 297 mm).
5. All documents shall also be supplied in “SOFT COPY” form.
6. Review/approval of documents by CLIENT’S/CLIENT’S REPRESENTATIVE does not absolve the Contractor of their responsibilities to satisfactory completion of the project as per the requirements of contract document. Contractor is required to make necessary rectification in the system to meet the requirements of the contract document at any stage of system implementation, without additional implication of cost and schedule to the CLIENT.
7. It is Contractor’s responsibility to incorporate all the comments of the CLIENT’S/CLIENT’S REPRESENTATIVE in the next revision itself. Contractor shall be responsible for incorporation of additional comments at any stage of the system implementation, without implication of extra cost and schedule to the CLIENT. If any comment is not incorporated in the revised document, the same shall be brought to the notice of the CLIENT’S/CLIENT’S REPRESENTATIVE with justification for review before submission of revised documents.
8. Contractor shall take care of the complete requirements of designing, generation and implementation of SCADA displays for monitoring & control, SCADA reports, SCADA alarms/ events, SCADA trending taking care of P&IDs and list of electrical parameters and covering the requirements outlined in this specification for SCADA implementation.
9. The review code will be furnished by CLIENT’S/CLIENT’S REPRESENTATIVE only when the complete document is furnished by Contractor.
10. Contractor shall furnish point wise response to CLIENT’S/CLIENT’S REPRESENTATIVE comments indicating the document section/clause/page no. reference where the same has been included in the revised document. The body of the document and corresponding pages will show the revision bars only at the places where the revision has been carried out. CLIENT’S/CLIENT’S REPRESENTATIVE will be required to check the revised document w.r.t. these changes only, while considering that rest of the document has remained unchanged.
11. Contractor to note that all programming langauges, commands, display langauges etc. for the entire SCADA system shall be in ENGLISH langauge only.
12. Latest anti-virus software shall be provided by the Contractor for all SCADA server and it shall be upgraded by the Contractor ( as and when required) during warranty period.
13. Documents
1. Factory acceptance test (FAT) plans and procedure documents
FAT document for SCADA systems and shall contain test sections to test all the aspects of SCADA System integrated with RTU as covered in FDS and MMI documents.
2. Site acceptance test (SAT) plans and procedure documents
SAT document for SCADA systems and shall contain test sections to test all the aspects of integrated SCADA System.
Test Run Plans and procedure documents.
3. RTU Documentation
RTU documentation shall be covering engineering manuals, user manuals, installation, operation & maintenance manuals for all software, hardware and equipments.
4. SCADA Documentation
SCADA documentation covering engineering manuals, user manuals, installation, operation & maintenance manuals for all software and hardwares.
5. Other Documentation
Bill of Material, Quality assurance plan, Billing procedure, Installation & Test procedure (which also includes the mounting arrangement of each cabinet), Site execution plan.
6. Functional Design Specifications (FDS)
1. Contractor to note that the SCADA System completely covers the operational and functional requirements of this project and the requirement of FDS shall focus on the implementation aspects of these requirements.
2. FDS shall be custom defined for this project and include the implementation aspects of tender requirements.
3. FDS document shall cover SCADA implementation aspects such as complete details of systems configuration, Flow controlling, changing of set points, flow control philosophy, Redundancy and backup (system failovers & fail backs). Also covers the implementation aspects of tender requirements, Integration between various subsystems such as telecom system, RTU system, description of SCADA/ third party software interface, System resource sizing basis and performance parameters covering CPU, disk and main memory utilization, memory mapping, system timeouts, computers switchover timings, Display updates, Display call-ups, poll time calculations etc.
4. Man Machine Interface (MMI) Document
The MMI documents shall cover all the displays, graphics and reports, in colour printouts ensuring proper view ability and legibility. The colouring scheme for various displays taking care of the colours for the titles/ headings/ sub-headings, background color, static text, dynamic values, pipeline, Sectionalizing Valves and other equipments etc. shall be highlighted in the dedicated section of the MMI document.
5. SCADA telemetry points database document.
Contractor is required to incorporate the complete requirements of telemeted points for SCADA system taking the inputs from the I/O point database (I/O Point list). The information like engineering units, ranges, alarm limits, set points, and digital contact configuration shall be taken care of by Contractor during detailed engineering.
6. All the calculated, server resident points and system status related points are also be included in this document.
14. Drawings
1. Engineering drawings/ documents: -
This document shall be submitted covering the following drawings:- interconnection diagrams, supplied RTU cubicle typical layout and GA, RTU internal layout and interconnection drawings for each type of IO cards, PDB internal layout, Internal layout of RTU cabinets,.
2. Construction drawings/ documents: -
This document shall also be submitted covering the following drawings: - Mounting arrangement of each cabinet, cable schedule, IO Termination & Wiring diagrams, grounding schemes/ diagrams.
9. INSTALLATION & COMMISSIONING
1. THE INSTALLATION AND COMMISSIONING OF ALL THE EQUIPMENTS ASSOCIATED WITH SCADA,TEELCOM AND RTU SYSTEM AT VARIOUS SITES INCLUDING THE ACTIVITIES OF INSTRUMENTATION SIGNAL INTERCONNECTIONS, ELECTRICAL WORKS WITH POWER SUPPLY DISTRIBUTION AND GROUNDING WORKS AND OTHER NECESSARY FACILITIES AND COORDINATION/ INTERFACING WITH VARIOUS SUB-CONTRACTORS IS THE RESPONSIBILITY OF THE VENDOR.
2. Contractor shall be responsible for proper selection of the communication cables [with suitable cable properties, shielded cable with low capacitance (8-10 pF/foot)] for ensuring good quality communication with telecommunications & other panels.
3. Contractor shall bring all installation aids, test equipments and qualified and experienced personnel, in order to carry out the job successfully. A list of the same shall be submitted to the CLIENT’S/CLIENT’ REPRESENTATIVE for review.
4. Contractor shall carry all the necessary tool and tackles like 4-20 mA current source, multimeter, RS232/RS485 converters, protocol analyser and other diagnostic tools as required during testing and commissioning.
5. All technical personnel assigned to the site by Contractor must be fully conversant with the specific system and its software packages. The Contractor’s field personnel shall have both hardware and software capability to bring the system on line quickly and efficiently and with a minimum of interference with other concurrent construction and commissioning activity.
6. The commissioning spares for all the items/ equipments is included along with commissioning services as required to commission the complete system. The consumables required during commissioning of system is included as part of commissioning spares.
7. Contractor shall at his own expense supply and provide all the equipment, tools, temporary works materials both for temporary and for permanent works, labour, supervisors, engineers and specialists, movement of the supplied equipment at the site, required for installation, commissioning, execution and completion of the works. The Contractor shall make his own arrangements at his own cost for the transport where necessary of his staff and labour to and from the Site of the works.
8. The Contractor shall provide and maintain an office at the Site, during Installation, Testing & Commissioning phase, for his staff, and such office shall be open at all reasonable hours to receive instructions, notice or other communications as per the permission granted from CLIENT’S.
9. Appropriate storage of the materials to be supplied in this contract will be arranged at the site by the Contractor at the various stations after the materials have been delivered by the Contractor. The Contractor shall be responsible for the storage, security and safety of all other materials, tools etc. brought by the Contractor for the installation and commissioning of the system at the site.
10. The Contractor's responsibility at site shall include all the activities necessary to be performed to complete the entire job as per the contract requirements including the following as a minimum.
a) Receipt of hardware, software and checking the adequacy and completeness of supply.
b) Storage, safety and security of the equipments and other materials including software at site.
c) Installation of the complete system including power supply, earthing, cable terminations, calibration, civil & electrical works. Obtaining information/ Coordination/ interfacing with various other contractors (Electrical, Instrumentation, Telecom etc.) through CLIENT’S/CLIENT’ REPRESENTATIVE.
d) Checking of equipment installation.
e) Checking of interconnection and overall system functionality.
f) Online/ offline debugging of the system.
g) Coordination/ interfacing (including obtaining relevant details) with Instrumentation contractor and Electrical contractor through CLIENT’S/CLIENT’ REPRESENTATIVE.
h) Coordination/ interfacing (including obtaining relevant details) with Metering contractor through CLIENT’S/CLIENT’ REPRESENTATIVE
i) On line testing and commissioning of SCADA & RTU system.
11. Contractor to note that there could be minor database changes & logic changes during site commissioning phase as required by the CLIENT’S. The same to be taken care by the Contractor as part of the project requirements.
10. EQUIPMENT INSPECTION & TESTING
1. INSPECTION
a) All factory tests will be witnessed by CLIENT’S/CLIENT’ REPRESENTATIVE.
b) CLIENT’S/CLIENT’ REPRESENTATIVE shall have free entry and access at all phases of the project to all parts of Contractor's facilities associated with manufacturing and testing of system.
c) Contractor shall invite CLIENT’S/CLIENT’ REPRESENTATIVE well in advance with minimum 1 month notice of the date at which the system is ready for testing.
d) The equipment will not be shipped before they have been officially released in the form of release notes by CLIENT’S/CLIENT’ REPRESENTATIVE.
e) Contractor shall provide CLIENT’S/CLIENT’ REPRESENTATIVE with all reasonable facilities necessary to determine compliance to the system specification.
f) Contractor to note that acceptance of the equipments and the system by CLIENT or exemption of inspection & testing shall in no way absolve the Contractor of his responsibility to deliver the system meeting all the requirements specified in the specification. Contractor shall be responsible till the completion of the warranty, for any corrections/ modifications including supply and implementation of hardware & software to fulfill the requirements of the contract/ up gradation including supply and implementation of hardware & software to meet the functionality and performance of the contract.
g) Contractor personnel shall be actively involved during factory acceptance and site acceptance testing.
h) All the RTU tests as per the approved documents shall be carried out at the Contractor's works, testing laboratory and work sites at Contractor's cost. The Contractor shall provide assistance; instruments, labor and materials as are normally required for the examining, measuring and testing any workmanship as may be selected and required.
i) These tests will encompass all the material, equipment delivered, and software pertaining to SCADA system including the equipment and software supplied by Contractor. Pre-FAT report duly witnessed and cleared by Contractor shall be available for reference during FAT.
2. Testing
Testing of SCADA system shall consist of:
a) Pre-Factory Acceptance Test (Pre-FAT)
b) Factory Acceptance Testing (FAT)
c) Pre SAT & Site Acceptance Testing (SAT)
d) Test Run
1. Pre-FAT
Pre-FAT shall be conducted based on the approved FAT document and the same shall be duly witnessed & cleared by the system engineering group of the Contractor.
During the Pre-FAT testing phase, the Contractor shall ensure that the SCADA and RTU system performs according to the requirements of tender, FDS & other finalised engineering documents and furnishes the written undertaking to the CLIENT in this regard, prior to offering the system for FAT to CLIENT.
Contractor shall submit pre FAT report for our review before FAT call. Pre FAT shall be conducted as per the approved FAT procedure and on real or project specific component with observed results. Pre FAT test shall covers minimum aspect as specified in FAT clause. Pre FAT result shall be verified during FAT.
2. Factory acceptance testing (FAT)
The FAT document shall be prepared covering all hardware, software and system functionalities including system expansion requirements of tender & FDS. Factory acceptance test will be done based on the stipulations in the approved FAT document, which shall completely fulfill the contract requirements and approved RTU FDS documents.
FAT shall be carried out in Contractor’s premises.
The system testing shall cover the following aspects as a minimum:
a) Visual and mechanical testing to ensure correct, proper, good and neat workmanship.
b) Demonstration of the complete system functionalities, hardware & software compliances wrt all the equipments including RTUs.
c) Checking of complete database definitions for the proper system configuration.
d) Testing of system passwords and security features.
e) Checking of various log formats, reports, archiving functions.
f) Checking of system loading w.r.t CPU, memory, disk, as per the requirements.
g) Checking of system diagnostics for all the equipments as per the requirements, power failure and system restarts.
h) Redundancy check for dual communication channel.
i) IO & Serial communication checking by simulation
j) System building procedures and verifications.
k) Pipeline shutdown and various sequences and interlocks as per pipeline Operation and Control Philosophy.
l) Checking of monitor updates of HMI, database updates and display call up timings.
3. On line testing, Commissioning
a) Prior to SAT, Contractor shall test all the stations hardware & software such as correctness of complete SCADA database, complete checking and testing of I/O database, testing of serial interfaces as applicable.
b) Prior to SAT, the activities of installation, system on-line testing and commissioning shall be performed by Contractor as per their Company standard & established practices & procedures to ensure that good techniques and best engineering practices had been followed, while ensuring correctness & completeness of the same.
c) Contractor shall conduct the SAT after successful integration & commissioning of the complete system and after interfacing of all actual field signals with the system including the successful completion of on-line testing of all the system.
4. Site Acceptance Testing (SAT)
a) The SAT document shall be prepared for RTU system and SCADA system and Contractor to submit it one month in advance to CLIENT’S/CLIENT’S REPRESENTATIVE for review and approval.
b) SAT shall involve integrated testing of complete system including third party devices. Site Acceptance Testing will be done based on the stipulations in the approved SAT document. Once the test is successfully performed, then the system would be ready for commencement of test run.
c) SAT shall be conducted by the experienced system-engineering group of the Contractor (earlier involved in system design, engineering, integration & FAT).
d) Checking of hot standby functions, switchover of data channels to meet the system functional requirements without any loss of data and operation.
5. RTU Testing
Testing shall be carried out as per the following stages:
• Real data testing of all the serial interface signals and hardwired interface signal, third party signals to RTU with SCADA.
• Time stamping, storage capacity during communication failure, off loading data after communication recovers, set point changing from remote, flow control function, tuning of PID controller etc.
Contractor shall submit to CLIENT’S/CLIENT’S REPRESENTATIVE detailed test plans and procedures, three months prior to actual testing for all factory and site acceptance tests and test run for review.
6. Test Run
a) Test for continuous functional operation of the system with the required system reliability and availability. This test aims at keeping the complete integrated system operation for a period of 21 days for all the 24 hours a day.
b) In case of failure, the tests will be restarted again till the system operates without failure of any system functionality for 21 days. Failure of tests shall be limited to such system failures which will affect system availability & reliability and shall not be dependent upon established failure of third party supplied items. CLIENT’S/CLIENT’S REPRESENTATIVE shall have the right to reject the complete system or part there of in the event of the acceptance tests failing in two attempts.
c) Test run shall be carried out as per the approved test plans and procedures. The 'Test Run' shall be carried out after successful SAT, duly witnessed by CLIENT’S/CLIENT’ REPRESENTATIVE.
d) The observations, exceptions and test results obtained during the test run shall be documented and produced in the form of a report by the Contractor within seven days of the completion of Test Run which shall be subsequently reviewed / approved by CLIENT’S/CLIENT’ REPRESENTATIVE within ten days of submission of test report by Contractor. After that the PRE WARRANTY COMPLETION CERTIFICATE shall be issued by the CLIENT’S and thereafter Warranty phase will start.
7. Failure of Components
a) During test run a log of all failed hardware and software modules shall be maintained which shall give date and time of failure, description of the failed components & cards/ software along with designation, effect of failure on the system, cause of failure and number of hours of operation of the part before it failed.
b) Upon failure of the components/ cards/ modules, the same shall be replaced by better-graded components/cards and the test shall be restarted from the beginning or the previous logical point as the case may be. If after this one replacement the unit of sub-system still fails to meet the specifications, the Contractor shall replace the complete unit or sub-system with the one that meets the requirements and restarts the test all over again.
c) At least one Contractor engineer fully conversant with the system hardware and software shall be present at SCADA station during the test run.
d) If a unit or sub-system has failed during the test, contractor is responsible to repair failure part or replace within few hours of active repair time after the failure and made successfully operational, the test shall be suspended and restarted all over again only after the Contractor has placed the device back into acceptable operation. The CLIENT’s/CLIENT’ Representative approval shall be obtained for any allowable logistic time required to replace the failed component/sub-system. All cost for repair/ replacement of defective component/ system shall be to Contractor's account.
e) The CLIENT’S/CLIENT’ REPRESENTATIVE shall be free to request any specific test on any equipment and the system considered necessary by him, although not listed in the testing documents to verify the compliance with the specifications.
f) Contractor is responsible to provide any statutory test/ inspection certificate, as may be required, under any law or directive issued by Govt. or any competent authority.
g) For operational software tests, the plans shall include summary of the method, a list of typical test cases, the sequence of execution and expected results.
h) For hardware tests, the plans shall include purpose of the test, definition of test inputs, specifications of test procedures and definition of results to be obtained.
11. TRAINING
1. SITE TRAINING :
Contractor shall train CLIENT’S operation engineers on internals and maintenance of the supplied system. The training shall include the following:
a) Operation & Maintenance of the SCADA system
b) Back up procedure-archiving & retrieving
c) Add RTUs, new tag, modification.
d) RTU configuration
e) Generation & modification Point database
f) Integration of IEDs with the system.
g) Integration of third party software usage of OPC.
h) System internals.
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|INDRAPRASTHA GAS LIMITED (IGL) |
|SCADA AND TELECOMMUNICATION SYSTEM FOR CNG NETWORK |
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|TRACTEBEL ENGINEERING PVT. LTD. |
|SCOPE OF WORK |
|RERT |
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|0 |24.10.2017 |Release for procurement |MA |SHD |BK |
|Rev. |Date |Subject of revision |Author |Checked |Approved |
TABLE OF CONTENTS
1.0 INTRODUCTION 1
2.0 PROJECT BRIEF 1
3.0 SCOPE OF WORK 1
4.0 GENERAL TECHNICAL REQUIREMENTS 6
5.0 QUALITY ASSURANCE AND QUALITY CONTROL 8
6.0 HSE REQUIREMENTS 9
1. INTRODUCTION
1. This document details the scope of work to be carried out by Contractor for “SCADA and Telecommunication system for CNG station” Project of M/s IGL.
2. PROJECT BRIEF
1. This Project is all about to build a SCADA , Remote terminal unit and Telecommunication system for collection of important data and control & monitoring from master station of CNG station and its ancillaries across the periphery of Delhi & NCR.
2. This project is divided into three phases and will be executed in phase wise. Scope of work is covered about all the phases. For total number of stations covered in phase I refer “Annexure IV List Of Equipment”. Further details such as number of CNG compressor, dispensers, metering skid etc. at each CNG station will be shared with successful bidder.
3. Phase I comprise of :
• Fully equipped SCADA system which cater the capacity of all the upcoming phases and future expandable capability with scalability in terms of tags and license, as per PTS – SCADA and RTU system.
• Each CNG station shall be equipped with RTU. Existing equipment and sub system shall be interfaced with RTU either on Modbus or hardwire. For details refer PTS- SCADA and RTU system, Input Output list and List of equipment.
3. SCOPE OF WORK
The contractor’s scope of work shall include but not limited to the following:
1. Contractor shall read this document in conjunction with material requisition and Particular specification.
2. Contractor shall collect all the necessary drawings , document and information require for interfacing for those equipment which are not in contractor’s scope of supply from Client. It is contractor’s responsibility to interact or co-ordinate with existing equipment supplier for technical details require for interface with RTU.
3. Contractor shall carry all the required Tools and Tackles require for installation, erection , testing and commissioning of SCADA , RTU and Telecommunication system. Quantities of all the tools and tackles shall be adequate as per the quantum to work. These qualities may require to enhance as and when required by Client to achieve the project schedule or to expedite the progress.
4. Contractor shall also carry all the calibration equipment/ testing equipment like multi-meter, hand held calibrator /4-20mA simulator, MODBUS Simulator, Profibus / Profinet Simulator etc.
5. Interconnection & interfacing of signals and communication cables, cabling, laying, terminations, ferruling, cable numbering, marking, testing including hot & cold loop testing. Cable shall be laid in existing cable.
➢ Between Junction box to RTU cabinet – Multi-pair cable 6P x 0.5mm² (IS &OS) for analog/Modbus serial RS 485 and 6P x 0.5mm² (OS) for digital. Tentative aerial distance between JB and RTU is 30 mtrs
➢ Between RTU to router/Switch /modem- Ethernet cable - As applicable.
➢ Between LAN switches, Router SCADA system and Telecom system-Ethernet cable – As applicable
Note – Size and Type of cable as given above is indicative. Contractor shall choose the cable size and type according to need bases to reduce the number of runs but cable size and type shall be according to PTS- Instrument cables only.
6. Required masonry works for installation of consoles/servers/PCs/RTU systems etc. shall be in contractor’s scope of supply.
7. The contractor to submit the proposed site organization to be set up for the execution of the work. It is understood that this will be augmented from time to time depending upon requirement for timely completion of work as directed by CLIENT project manager/site in charge. A chart showing the manpower allocation and deployment to this job with specific job allocations shall be submitted by the contractors to CLIENT. The contractor shall take prior approval from CLIENT/ for any change in allocation and deployment.
8. Site office set up shall be done by contractors. Power for office (in case Client premises) area at one point shall be provided by CLIENT but construction power shall be arranged by contractor at site at their cost.
9. Drinking water, construction water, lodging, boarding, transportation for all workers shall be arranged by contractor at their cost.
10. The contractor shall engage sufficient number of workforce skilled/semiskilled along with experienced and competent supervisors and engineers to ensure quality of work and also for smooth and uninterrupted progress of the works under this work order. The contractor shall arrange at its own cost the necessary consumables, accessories, equipment, tools & tackles required for execution of the job under this work order/contract. The contractor shall also arrange transportation, lodging, boarding of its personnel deployed for executions of the work at site.
11. Contractor to plan and execute their work in a phased manner as directed by Client/PMC and from time to time and fully co-operate with other agencies working at site simultaneously so as not to obstruct or retard the work being executed simultaneously by other agencies.
12. Any other equipment /material not specifically mentioned herein but required to complete the work (i.e. to install, commission and successfully run the Installation) is covered under this document.
13. Labor license has to be taken by contractor; Form-V shall be issued by CLIENT. Any other local statutory liasoning shall be in contractor scope. PF records, wages records, workmen compensation policy and any other legal compliance required shall be maintained and submitted on monthly basis to CLIENT at site.
14. Contractor shall prepare, maintain and submit inspection reports, erection/installation progress reports, material log etc. as decided by Client.
15. Daily/Weekly progress report, Documentation like procedure preparation and approval, furnish of inspection reports, handing over the documents after completion of project etc shall be done by contractor at their cost.
16. Contractor shall submit all test reports like Calibration reports, cable Megger Report, loop checking report, material reconciliation report. Contractor shall also collect the Manufacture test certificate, Inspection reports, Equipment drawing, wiring received along with equipment/packages and submit the same to Client.
17. Fabrication and installation of MS base frames, supports for Panels/cabinet, console/panel/ cabinet supports, pipes, plates etc. including welding, bolting, riveting, supply of necessary anchor bolts, grouting etc., supply of paint and applying one coat of anti-rust primer and two finished coats of approved synthetic enamel paint, breaking walls, floors etc. for structures as required and supply of all GI hardware materials as required
18. Contractor to supply the material as per recommended vendor list. If any item is not covered under approved vendor list, contractor shall take written approval of CLIENT before supply of material.
19. Necessary documentation for gate passes for man power and removal/shifting of material
20. Unloading of material/equipment related received at site shall be in the scope of contractor. Bidder shall depute requisite manpower to unload project material received on site. In addition to this bidder shall be responsible to transport the project material from IGL store to site, if needed.
21. Inspection of received material by unpacking/opening boxes at site including spares & material to be received at site in presence of Client/Engineer in charge/OEM.
22. Contractor shall store/shift the packing material at designated location decided by Client. Assistance in temporary preservation of equipment.
23. Permission for late hours working and working on Saturday/Sunday and Holidays
24. Contractor shall follow Quality and Safety requirement during construction phases of the Project.
25. Contractor shall follow permit to work system of CLIENT. All activities shall be in line with CLIENT’s HSE policy, contractor shall conduct tool box talks, safety review meetings, promotional activities, awareness programs etc., machinery and equipment shall meet with HSE requirements, contractor has to provide warning sign boards, cordoning of working area, PPE to workers. Contractor to comply observations raised by any inspection agency/Client internal audit.
26. Any special training for height work, electrical/mechanical safety, Scaffolding work, special toolbox, etc., for workers, promotional programs, motivational programs etc., shall be in scope of contractor.
27. Contractor shall be responsible for safety and security of material/equipment.
28. Correction, updating and submission of all drawings/layouts/documents. Contractor shall submit marked up drawings for final as built.
29. Scope matrix
Part A
|Sr. No|Equipment/Packages |SCADA vendor Scope of work |Free Issue Item/IGL Scope |
|1 |SCADA System |Supply, installation, testing, integrated FAT with |Master control room, console/furniture, chair. |
| | |telecom system, commissioning, test run, SAT and |Uninterrupted power supply from feeder to SCADA|
| | |handover to Client as per PTS – SCADA and RTU system |vendor supplied PDB and from PDB to system. |
| | |and “Material Requisition” | |
| | |Cloud storage server for data monitoring and | |
| | |controlling (as per administration right) | |
|2 |Remote terminal Unit |Supply, erection, installation, testing, integrated FAT|Station Control room/mounting space at CNG |
| | |with SCADA & telecom, interfacing with existing |station, |
| | |packages at CNG station, commissioning, test run, SAT |uninterrupted power supply upto RTU, |
| | |and handover to Client as per PTS – SCADA and RTU |Profibus (MPI/PPI) and Profinet(Ethernet) |
| | |system and “Material Requisition”. |protocol is available in CNG Compressors. |
| | |Erection, installation of RTU inside the station |MODBUS RS485 available for Dispenser, |
| | |control room including supply of all the required |Flowmeters, Flow computers and VFD's, Soft |
| | |erection materials and civil works. |starters etc. |
| | |SCADA Vendor shall ensure that RTU shall be compatible |Providing the all required information |
| | |with profibus and profinet protocols and RS485 ports as|regarding communication ports address, slave |
| | |per Annexure III. |ID, baud rate, parity etc to SCADA vendor. |
|3 |Telecommunication System |Supply, installation, of dual SIM modem, testing and |Supply of SIM cards from service providers |
| | |interfacing with RTU and SCADA system, co-ordination |Uninterrupted power supply. |
| | |with service provider, establish communication, test |Two broad band connections at Master station |
| | |run, SAT and handover to Client as per PTS – |MPLS Wired/Wireless 2G/3G/4G Connectivity. |
| | |Telecommunication system and “Material Requisition”. | |
| | |Calculation of bandwidth requirement at remote station | |
| | |and master station | |
|4 |Cables (Single cable, cable, |Cable laying, glanding, termination (from existing JB |Supply and cable laying of communication and |
| |communication cable, LAN cable, |to RTU), ferruling, lugging, tagging, clamping, marking|signal cables from CNG station equipment and |
| |RS-232/485 cables, OFC etc.) |etc. Scope includes supply of cable tag, Cable ferrule,|field instruments to Junction box, including |
| | |clamps and all the required items to complete the |loop testing, multi dropping etc. Providing |
| | |laying works. Cable laying from as per above clause 3.5|terminal details to SCADA vendor |
| | |SCADA & Telecom communication cable (Ethernet) |Multidrop loop testing equipment wise on |
| | |LAN cable for work stations. For LAN cable, contractor |simulator software at junction box end in |
| | |shall supply conduit of proper size and lay cable |presence of SCADA vendor |
| | |inside the conduit. |Supply and laying of profibus cable, Profinet |
| | | |cable, CAT 6 cable from CNG compressor to RTU |
|5 |Earthing pit |Provision for earth connection (IE and PE) in|Earthing pit (IE and PE) and laying of earthing strip and connectivity upto SCADA|
| | |system |and RTU system. |
Part B
| | |Scope | |
|Sr. No.|Item Description |Contractor |Client |Remarks |
|1 |Unloading the material/equipments received from |YES | | |
| |vendors to site, shifting of equipments/material | | | |
| |from store to installation location etc. | | | |
|3 |Staff and labor transportation |YES | | |
|4 |Labor accommodation. |YES | | |
|5 |Labor license. |YES | | |
|6 |Wooden sleeper as required. |YES | | |
|7 |Office container as require |YES | | |
|8 |Required material for preparation of platform |YES | | |
|9 |Obtaining statutory approval (if any) for system |YES | | |
| |of project. | | | |
|10 |Preparation Job Planning and schedule and DPR |YES | |As per approval by |
| | | | |Client |
|11 |All statutory compliance |YES | | |
|12 |Paid all government duties & taxes applicable for|YES | | |
| |contractor | | | |
|13 |Scaffolding material and installation as require |YES | |As per requirement. |
|14 |welding machines |YES | |As per requirement. |
|15 |Documentation like procedure preparation, work |YES | |Approved by PMC/CLIENT|
| |schedule, calibration reports, inspection report,| | | |
| |progress report, termination details etc. | | | |
|16 |Temporary Illumination at work site |YES | | |
4. GENERAL TECHNICAL REQUIREMENTS
1. General site equipment shall be suitable for operation under the following site conditions.
Sand & dust : With a built-up of dust on operational surface to a level such as may occur because of imperfections in the sealing of equipment, housing and conditions prevailing in sub- tropical dust conditions.
Tropicalisation : The equipment shall be fully tropicalized.
Shock & vibration : The equipment shall withstand transportation and handling by air, sea and road under packed conditions.
2. The equipment shall also be resistant to termite, fungus, rodents and salty environment. Environmental Specification of Equipment to be supplied.
3. The equipment at Stations shall be designed for non-air conditioned environment and shall perform satisfactorily under the following conditions.
Activity TEMPERATURE HUMIDITY
Design for 02 to 60°C 90% RH
Storage & transportation 02 to 60°C 90% RH
4. Area and zone classification
All the control rooms wherever available are classified as Safe Areas.
All the fields wherever available are classified as Hazardous area.
5. Power supply, Reliable and rugged redundant 24V dc power supply unit shall be provided.
6. Surge Protection, Transient Suppressors, RFI filters
Equipments shall be designed with built-in safety to protect against the effects of monitor induced high voltages.
7. Earthing
Transmitters, Junction box and control cabinets shall be provided with earthing lugs. All these lugs/ strips shall be properly secured to the electrical earthing bus.
All system grounds of various cards and equipment, shields of instrument cables shall be connected to system ground bus, which is electrically isolated from the AC mains earthing bus. The equipment shall provide separate earthing strip for the same. The system ground bus shall be connected to independent ground buses through insulated wires.
The wire and cable shielding is required to prevent the equipment from propagating interference and to protect the equipment from the effect of interference propagated by other devices. Shielding is typically floating on the device end, tied to IE at the control console.
a) System grounding (earth resistance less than 1 ohm)
b) Frame and AC mains grounding (earth resistance less than 5 ohms)
Accordingly, the equipments shall provide separate earthing strips as mentioned above.
a. Instrument earth(IE)/system ground
IE earth shall be copper earth. IE ground protects sensitive electrical and electronic device, circuit and wiring from electromagnetic interference (EMI) and radio frequency interference (RFI). IE should be free from transient voltages and electromagnetic noise. It is, therefore, normally isolated from PE ground. Instrument earth should be tied in the most direct possible path to a common earth electrode.
IE grounds resistance is less than 1 ohm to ground
b. Power Earth (PE)/AC mains grounding
PE ground provides a route to dissipate the power line transient to earth potential. PE should be tied in the most direct possible path to a common earth electrode
PE grounds resistance is less than 5 ohm to ground
8. Safety Requirements
It is the intent of the CLIENT that operational hazards be reduced to a minimum. Contractor shall use sound engineering judgment to complete installation that will perform the required function without compromise of safety.
All controls shall operate in a fail-safe mode. A fail-safe mode defines what a plant, equipment or system will do when it fails, so as to ensure a safe condition.
Provision shall be made to isolate all 230 V AC (If any) incoming signals to a cabinet, before gaining access to cabinet internals. Shrouded terminals with warning labels shall be provided, with these terminals being segregated from other incoming terminals.
9. Electromagnetic Compatibility - EMC
The equipment shall be efficiently screened against EMI, RFI and conductive interference and shall not interfere with other equipment in the vicinity or installed in the same building.
The equipment shall be required to meet one of the relevant EMC standards (IEC, MIL, VDE, BS, IEEE etc.).
10. All the electronic component shall be protected from airborne contaminants as per ISA 71.04 environmental conditions for process measurement and control system. For those equipment mounted in field shall be G3 compliant and control room mounted shall be G2 compliant.
11. Civil Works
p) Civil works required for interconnecting cabling as per scope of work.
q) Associated foundation, grouting for installation of equipment.
r) Providing and laying perforated trays etc. for point a) above.
s) Any other masonry work associated with entry and installation of equipment, painting and finishing etc.
t) Any other civil works not specifically mentioned in the tender but required as per site requirement.
12. Electrical Works
Electrical work associated at all the stations shall be consisting of (but not limited to):
u) All earth cable work associated with the installation of the supplied equipment.
v) Any temporary electrical works associated with the installation and commissioning of the system.
w) Testing and certification of all electrical works.
13. Measuring Units
1) The metric SI system shall be used for all documents. The following units of measurement as well as their multiples and sub-multiples, shall be used:
2) Flow
3) Gas : Sm3/h (15.556OC; 1.01325 bar), MSCMD, Kg/Hr
4) Liquid : m3/h (at flowing temperature)
5) L/h for flow lower than 0.1 m3/h
6) Steam, condensate and mass flow: kg/h.
7) Pressure
8) Gauge pressure : kg/cm2 (g) and Bar (g)
9) Absolute pressure : kg/cm2 (a) and Bar (a)
10) Differential pressure : kg/cm2, mm of H2O, mm of Hg and mill bar
11) Level
0. - 100 % (Process)
12) Temperature
13) Deg C
14) Other Measurements
15) Current: A or mA
16) Voltage: V or mV
17) Power: kW
18) Force: N
19) Mass: kg or t
20) Density: kg/m3
21) Time: d or h or s.
22) Scales and Charts
23) Temperature instruments shall have scales calibrated in °C.
24) Pressure + be 0 - 100 linear.
14. Cable Ties
All cable ties shall be constructed from black PVC and have a breaking load greater than 20 kg. They shall be of a self-locking style and non-slip, but shall be releasable for the addition of extra cables. Cable ties for use on trays shall fix into the tray slots (two-piece ties).
15. Nameplates Tags labels
The nameplates, tags and labels for identifying junction boxes, instruments, panels, cabinets, etc shall be made from engraved trifoliate.
5. QUALITY ASSURANCE AND QUALITY CONTROL
CONTRACTOR/ VENDOR shall be fully responsible for their Quality Assurance and associated Quality Control process.
Unless otherwise agreed by the PURCHASER, the CONTRACTOR/ VENDOR’s quality system shall meet the requirements of ISO 9001:2007 Quality System and shall be accredited by a recognized authority.
CONTRACTOR/ VENDOR are required to establish an acceptable Quality Plan, inclusive of quality manual and procedures that cover all activities of the order, in order to comply with the Quality System requirements.
CONTRACTOR/ VENDOR shall be responsible for arranging/liaising with the Third Party Inspection Agency and other agencies for design appraisal, inspection, survey and certification requirements as required by the specification/requisition.
When required, waiver and acceptance of non-conformances shall be subjected to Third Party Inspection Agency approval before COMPANY endorsement. These concession records shall be included in the Manufacturer’s Final Documentation.
6. HSE REQUIREMENTS
The contactor shall abide by all the safety and other rules and regulations of COMPANY site.
The contractor shall provide the Personal Protective Equipment to his operators / electricians / labor / helper / engineer etc. This personal protective equipment includes a minimum of coverall, safety glasses, safety hard hat, safety shoes, hand gloves and ear protection. The contractor will have to get these PPEs approved by COMPANY HSE Engineer.
All waste generated at company site due to the contractor’s equipment / personnel shall be cleared by the contractor and disposed of properly in accordance with company rules and local government regulations. A record of such waste disposal shall be maintained by the contractor for submission to Company whenever required.
Upon demobilization, the contractor shall ensure that the site is cleaned properly of all debris and waste. These shall be disposed of properly by the contractor in accordance with company rules and local government regulations.
contractor shall ensure to carry out work after obtaining "WORK PERMIT" from CLIENT/COMPANY's authorized engineer.
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