corrigendum no 4_composite works for bharatpur-13000032-hd-10129_4_signed_part 2

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HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT SPECIFICATION FOR MEDIUM VOLTAGE VARIABLE FREQUENCY DRIVE

EPMC Services for Rewari-Kanpur Pipeline Project

SPECIFICATION FOR MEDIUM VOLTAGE VARIABLE FREQUENCY DRIVE

MH2145-COOO-EL-SPC-0015

26-Dec-12

Raheja Plaza,1 st floor LBS Marg, Ghatkopar 01'1) Mumbai - 400086, India Phone: +91-22-67818000 Fax: +91-22-67818080 www.worleyparsons.com

Copyright 2010 WorleyParsons

DOC NO.: MH2145-COOO-EL-SPC-0015 Rev. A PAGE NO: 1 OF 19

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SYNOPSIS

Disclaimer

This specification has been prepared on behalf of and for the exclusive use of Hindustan Petroleum Corporation Limited (HPCL), and is subject to and issued in accordance with the agreement between Hindustan Petroleum Corporation Limited (HPCL) and WorleyParsons. WorleyParsons accepts no liability or responsibility whatsoever for it in respect of any use of or reliance upon this report by any third party.

Copying this report without the permission of Hindustan Petroleum Corporation Limited (HPCL) or WorleyParsons is not permitted.

PROJECT 513/MH-2145 - EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT REV DESCRIPTION PREPARED CHECKED APPROVED DATE CLIENT DATE

A

BY BY BY APPROVAL

Issued for Customer Review

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DOC NO.: MH2145-COOO-EL-SPC-0015 Rev. A

~??/ MAHD

26-Dec-12

PAGE NO: 2 OF 19



Abbreviations:

AC CT DOL MV PVC VFD

Alternating Current Current Transformer Direct on Line Medium Voltage Polyvinyl Chloride Variable Frequency Drive


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CONTENTS

1.0 SCOPE ........................................................................................................................................................ 5 2.0 CODES AND STANDARDS .................................................................................................................... 5 3.0 GENERAL REQUIREMENTS ................................................................................................................. 6 4.0 SITE CONDITIONS ................................................................................................................................... 6 5.0 DESIGN AND FABRICATION REQUiREMENTS ............................................................................... 7 6.0 COMPONENTS REQUIREMENTS ...................................................................................................... 11 7.0 PROTECTION, CONTROL, METERING AND INDICATION REQUIREMENTS .......................... 15 8.0 INSPECTION AND TESTING ...................................... ; ........................................................................ 17 9.0 PACKING AND DESPATCH ................................................................................................................. 19




1.0 SCOPE

This specification covers the minimum requirements for the design, material, manufacturing, inspection, testing, supply, shipment and delivery to site of MV variable frequency drive for EPMC Services for Rewari-Kanpur Pipeline Project.

The Vendor shall be fully responsible for the design, material, manufacturing, inspection, testing and delivery of MV variable frequency drive at site.

Definitions Purchaser Engineer / Consultant :

Hindustan Petroleum Corporation Limited (HPCL) WorleyParsons Sea India Pvt. Ltd.

Vendor / Manufacturer: Supplier of MV variable frequency drive

2.0 CODES AND STANDARDS

2.1 The equipment shall comply with the requirements of latest revision of following standards issued by BIS (Bureau of Indian Standards), unless otherwise specified: IS 5 IS 1248 IS 2705 IS 14901 IS 3715 IS 4411 IS 5001

IS 5469 IS 6297 IS 8623 IS 13703 IS/IEC 60529 IS/IEC 60947 IEC 61800-2

IEEE 519

Colours for ready mixed paints and enamels Direct acting indicating instruments Current transformers Semi-conductor devices - Discreet Devices and Integrated Circuits Letter symbols for semi-conducting devices Code for designation of semi-conductor devices Guide for preparation of drawings for semiconductor devices and integrated circuits Code of practice for the use of semi-conductor junction devices Transformers and indicators for electronic equipment Specification for low voltage switchgear and control gear assem blies Low voltage fuses for voltages not exceeding 1000V ac or 1500V dc Degree of protection provided by enclosures (IP code) Low voltage switchgear and controlgear Adjustable Speed Electrical Power Drive Systems - Part 2: General Requirements - Rating Specifications for Low Voltage Adjustable Frequencya.c. Power Drive Systems Recommended Practices and Requirements for Harmonic Control in Electrical Power System

2.2 In case of imported equipment, standards of the country of origin shall be applicable, if these standards are equivalent or stringent than the applicable Indian standards.

23 The equipment shall also conform to the provisions of Indian Electricity rules and other statutory regulations currently in force in the country.

2.4 In case Indian standards are not available for any equipment, standards issued by IEC/BSNDE/IEEE/NEMA or equivalent agency shall be applicable.

25 In case of any contradiction between various referred standards/specifications/data sheet and statutory regulations the following order of priority shall govern: - Statutory regulations




- Data sheets - This specification - Codes and standards

However the vendor shall bring any such contradiction to the notice of Purchaser for prior approval.

3.0 GENERAL REQUIREMENTS

3.1 The offered equipment shall be brand new with state of art technology and proven field track record. No prototype equipment shall be offered.

3.2 Vendor shall ensure availability of spare parts and maintenance support services for the offered equipment for at least for 35 years from the date of supply.

3.3 Vendor shall give a notice for at least one year to the Purchaser of equipment before phasing out the product/spares to enable the end user for placement of order for spares and services.

3.4 The MV variable frequency drive shall be an integrated system comprising of converter, converter input transformer, drive output transformer (if required), dc link reactor with associated auxiliaries, harmonic filters (if required), input power factor correction unit (if required), switches / contactors (as applicable), protection, monitoring and control devices and all other equipment/ accessories required for completeness of the system whether specifically mentioned herein or not, but necessary for completeness and satisfactory performance of the system.

3.5 The vendor shall be responsible for engineering and functioning of the complete system to fully meet the intent and requirements of this specification and enclosed data sheets. Selection, sizing and suitability of all equipment and components used for MV variable frequency drive shall be vendor's responsibility.

3.6 Vendor shall ensure proper co-ordination with the driven equipment Supplier in selection / sizing of MV variable frequency drive.

4.0 SITE CONDITIONS

4.1 The MV variable frequency drive shall be suitable for installation and satisfactory operation in indoor or outdoor installation as specified in the data sheet with humid and corrosive atmosphere.

4.2 The MV variable frequency drive shall be designed to operate under site conditions as specified in the data sheets. If not specifically mentioned therein, a design ambient temperature of 40C for indoor, 50C for outdoor and an altitude not exceeding 1000 metres above mean sea level shall be considered.

4.3 The MV variable frequency drive described in this specification is intended for continuous duty at the specified ratings under the specified site conditions.




5.0 DESIGN AND FABRICATION REQUIREMENTS

5.1 Performance requirement

5.1.1 The variable frequency drive shall be energy efficient, designed as standard product and shall provide very high reliability, high power factor, low harmonic distortion and low vibration / wear / noise. It shall be easy to install in minimum time and expense and no special tools shall be required for routine maintenance.

5.1.2 The variable frequency drive shall be designed to deliver the motor input current and torque for the complete speed torque characteristics of the driven equipment, with input supply and frequency variation as specified in the data sheet. The system shall be suitable for the load characteristics and the operational duty of the driven equipment. It shall be capable of withstanding the thermal and dynamic stresses and the transient mechanical torque, resulting from short- circuit.

5.1.3 The variable frequency drive shall be designed to operate in one or more of the following operating modes as to suit characteristics of the driven equipment or specified in the data sheet: a. Variable torque changing as a function of speed i.e. Speed squared b. Constant torque over a specific speed range c. Constant power over a specific speed range where the torque decreases when speed

increases d. Any other as specified in the data sheet

5.1.4 The variable frequency drive controller shall be equipped with microprocessor based digital regulator with programmable functions. The power control regulator logic shall provide for an acceleration/deceleration current limit curve and shall be capable of field adjustments without shutting the system down. Linear acceleration and deceleration shall be separately programmable from 0.1 to 20 seconds.

5.1.5 The variable frequency drive shall be suitable for single quadrant operation and the speed variation shall be with range 10-100 % unless otherwise specified in the data sheet with speed set accuracy of 1% of rated maximum speed and steady state regulation of 0.5% of rated speed without encoder or tachometer feedback.

5.1.6 The total harmonic distortion (THO) of the voltage and current at inverter output shall be as per I EC 61800-4.

5.1.7 Harmonics at the supply side of the variable frequency drive at primary of the main input transformer shall be restricted within the maximum allowable levels of current and voltage distortion as per recommendations in the latest edition of IEEE-519.

5.1.8 Unless otherwise specified, the overload capacity of the variable frequency drive shall be 150% of rated current of motor for one minute for constant torque applications, and 115% of rated current for one minute for variable torque applications at rated voltage. If the motor load exceeds the limit, the variable frequency drive shall automatically reduce the frequency and voltage to the motor to guard against overload. If load demands exceeds the current limit for more than 1 minute, the variable frequency drive shall shut down to prevent over heating of the motor and damage to the drive.

5.1.9 During operation, the variable frequency drive shall be capable of developing sufficient torque under all load conditions to respond to a 20% alteration in speed set point within a time limit




up to 60 seconds.

5.1.10 The integrator action of the speed set point alteration shall be independently adjustable for both an upward and a downward alteration. The minimum time interval between set point adjustments by the distributed control system shall be considered as 10 seconds.

5.1.11 The variable frequency drive shall trip in case the speed exceeds 1050/00f the maximum operational speed or reduces to 950/0 of the minimum operational speed for more than 10 seconds.

5.1.12 Variable frequency drive shall be arranged so that it can be operated in an open circuit mode, disconnected from the motor for start up adjustments and troubleshooting/ maintenance.

5.1.13 The variable frequency drive must be able to catch and take control of a spinning load if started while rotating equipment is already running. Appropriate safeguards must be included in this operation to prevent damaging torques, voltages or currents from impacting any of the equipments. The user shall have option of enabling this feature or disabling it.

5.2 Control requirement

5.2.1 The variable frequency drive shall operate on constant V/f supply with required voltage boost capability in low frequency mode of operation.

5.2.2 Short time voltage dips up to 20% of nominal voltage (e.g. in case of a large motor start up connected to the same bus as variable frequency drive) shall not cause the control system to stop functioning and shall not trip the variable frequency drive.

5.2.3 The variable frequency drive shall also be equipped with a facility which will restart the system in case of voltage dip over 20% or power interruptions for less than 2 seconds, with recovery of the voltage to its nominal value. The variable frequency drive shall have the facility to block this feature, if required by the operator. Upon restart the converter shall be capable of synchronizing onto a rotating motor and develop full acceleration torque within 10 seconds.

5.2.4 The variable frequency drive shall be suitable for number of starts as per specification for High Voltage Motors.

5.2.5 The power controller shall be controlled to always start the motor in the forward direction. Logic shall be provided to prevent the motor from being started in the reverse direction.

5.2.6 The variable frequency drive motor shall be speed controlled corresponding to 4-20 mA or 0-10 V reference input signal. Unless otherwise specified, upon complete loss of the user's speed reference signal, the drive shall automatically run at constant speed as determ ined by the last speed reference available prior to the loss of signal.

5.2.7 It shall be possible to vary the speed of the variable frequency drive motor in either manual or auto mode. Auto/manual selection shall be from variable frequency drive panel unless otherwise specified. a. With the selector switch in "manual" mode, the operator shall be able to start, stop and set

the speed through keypad, mounted on front of the variable frequency drive or start, stop and set the speed through push buttons from the field. Motor operated potentiometer shall be provided as a speed set point device.

b. With the selector switch in "auto" mode, start, stop and speed setting shall be from DOC NO.: MH2145-COOO-EL-SPC-0015 Rev. A PAGE NO: 8 OF 19



Purchasers PLC/OCS (Process Control) system. The speed setting shall be through a 4-20 mA signal. Necessary equipment required for interfacing with PLC/OCS shall also be provided in the drive panel.

5.2.8 The required provision for the interface with remote PLC/DCS system shall be either through hardwired connection (with potential free contacts and transducers as described elsewhere in this specification) or through serial communication link as defined in the data sheet.

5.2.9 Variable frequency drive shall have provision for interface with upper level automation such as Substation monitoring system or electrical control system in case specified in the data sheet.

5.2.10 The closed loop control feedback for the variable frequency drive having output transformer shall be tapped from the secondary side of the output transformer

5.3 Construction

5.3.1 The construction of variable frequency drive shall provide effective protection against electromagnetic emissions and shall meet the design requirement of integrated standards.

5.3.2 All components of variable frequency drive shall be suitably housed in sheet steel panels fabricated with 2 mm thick cold rolled sheet steel. The variable frequency drive panel shall be free standing with degree of enclosure protection as specified in the data sheet. The maxim um and minimum operating height shall be 1800 mm and 300 mm respectively.

5.3.3 Bolted un-drilled gland plate shall be provided at bottom. Clamp type terminals shall be used for connection of all wires up to 10 mm2 and terminal for higher sizes shall be bolted type suitable for cable lugs. Minimum space for power cable termination shall be 200mm clear from bottom of the cable gland plate.

5.3.4 Bus bars shall be of electrolytic copper, color coded separately for AC and DC system. All the live parts shall be sleeved I shrouded to ensure complete safety to personnel intending to carry out routine inspection by opening the panel doors.

5.3.5 All the switches, component and accessories which are essential for normal and emergency operation shall be mounted on the door and shall be operable externally. All the analogue instruments, where provided, shall be switchboard type, back connected, 72x72mm. Scale shall have red mark indicating maximum permissible operating rating.

5.3.6 All panels shall be of same height so as to form a uniform line-up, to give good aesthetic appearance.

5.3.7 All electronic modules and components shall be accessible from front of panel only. Modular assemblies for both the system control electronic equipment and power electronic equipments shall be used.

5.3.8 DC link capacitor and pre charging and discharging circuit shall be preferably mounted in the rear of the panel.

5.3.9 Suitable removable type hooks shall be provided for lifting the panel.

5.3.10 Variable frequency drive keypad, operator control panel required for control, monitoring and measurements shall be supplied and installed outside the panel on the front door. It shall be


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accessible for operation without opening the front door and shall be non-removable type.

5.4 Cooling

5.4.1 The variable frequency drive panel shall be naturally cooled. Cooling system shall include well-dimensioned panel, adequate cooling airflow path, module cooling fan and if necessary, panel cooling fan. Vendor shall ensure that the panel dimensions and flow paths have been designed for continuous running at the specified ambient without overheating. For fan cooled drives, redundant ventilating fans (N +1) shall be provided.

5.4.2 Necessary starters shall be provided with in the variable frequency drive for the ventilation fans. The system provided shall be interfaced with variable frequency drive starting and shut down such that safety interlocks such as start permit from cooling system to variable frequency drive and trip signal from cooling system to variable frequency drive in case of cooling system failure etc., shall be incorporated in the overall sequence logic.

5.4.3 MCS for motor space heater, auxiliary power supply if required for local panel, drive panel space heater etc. shall be included and mounted in easy accessible location.

5.5 Auxiliary wiring and terminals

5.5.1 The wiring for control, signalling, protection and instrument circuits shall be done with SIS approved, PVC insulated, flame retardant type, copper conductor wire. The insulation grade shall be 660 V. The wiring shall preferably be enclosed in plastic channels or neatly bunched together.

5.5.2 A minimum of 10% spare terminals shall be provided on each terminal block. Conductors shall be terminated with adequately sized compression-type lugs for connection to equipment terminals and strips. Stranded conductors shall be soldered at the ends before connections are made to the terminals. Sufficient terminals shall be provided on each terminal block to ensure that not more than one outgoing wire is connected per terminal. Terminal strips shall preferably be separated from power circuits by metal barriers or enclosures. All spare contacts of auxiliary relays, timers, etc shall be wired up to the terminals.

5.5.3 Each wire shall be identified at both ends by correctly sized PVC ferrules. Shorting links shall be provided for all CT terminals.

5.5.4 PVC insulated copper conductor of cross section 1.5 mm2 may normally be used provided the control fuse rating is 10 amps or less. For 16 amps control fuse circuit 2.5 mm2 copper conductors shall be used. Each wire shall be terminated at a separate terminal. CT Circuit wiring shall be done with 2.5 mm2 copper conductors. Shorting links / suitable shorting arrangement for shorting CT secondary shall be provided.

5.5.5 Unless otherwise specified, all control cables shall enter from the bottom.

5.5.6 Supporting facilities shall be provided for clamping the control cables.

5.5.7 All inter-panel control wiring within variable frequency drive shall be by vendor. The inter-panel wiring shall be taken through PVC sleeves or suitable grommets.

5.6 Noise level

Maximum noise level from the variable frequency drive at 1-meter distance, under rated load DOC NO.: MH2145-COOO-EL-SPC-0015 Rev. A PAGE NO: 10 OF 19



with all normal cooling fans operating shall not exceed 75 dBA.

5.7 Earthing

5.7.1 Copper earth bus of min. 30 x 6 mm size shall be provided in the panel with provision for connection to purchaser's plant earth grid. All the non-metallic components/parts shall be connected to the main earth bus bar. Separate earth bus bar and stud for electronic control system is required shall be provided.

5.7.2 All non-current carrying metallic parts of the mounted equipment shall be earthed. All doors and movable parts shall be earthed using flexible copper connections to the fixed frame of the variable frequency drive.

5.8 Name plate

5.8.1 A nameplate with the variable frequency drive deSignation shall be fixed at the top of the central panel.

5.8.2 Nameplate or polyester adhesive stickers shall be provided for each equipment mounted inside the variable frequency drive. Special warning plates shall be provided on removable covers or doors giving access to cable terminals and bus bars.

5.8.3 Engraved nameplates shall preferably be of 3-ply (Black-White Black) lamicoid sheets or anodised aluminium. However back engraved perspex sheet nameplates may also be acceptable. Nameplates shall be fastened by screws and not by adhesives.

5.8.4 Special warning labels shall be provided inside the variable frequency drive also, wherever considered necessary. Identification tags shall be provided inside the panels matching with those shown on the circuit diagram.

5.9 Painting

5.9.1 All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rust, grease and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The under surface shall be prepared by applying a coat of phosphate paint and coat of yellow zinc chromate primer. The under surface shall be made free from all imperfections before undertaking the finishing coat.

5.9.2 After preparation of the under surface, the panel shall be spray painted with two coats of epoxy based final paint or shall be powder coated.

5.9.3 Colour shade of final paint shall be as specified in the data sheet.

5.9.4 The finished panels shall be dried in stoving ovens in dust free atmosphere. Panel finish shall be free from imperfections like pinholes, orange peels, runoff paint etc.

5.9.5 All unpainted steel parts shall be cadmium plated or suitably treated to prevent rust formation. If these parts are moving elements then they shall be greased.

6.0 COMPONENTS REQUIREMENTS

6.1 Input isolator




The variable frequency drive shall be provided with input isolator (Circuit breaker / MCCB / Switch-fuse) as specified in the data sheet. Input isolator shall be lockable in off posHion and shall have minimum interrupting capacity as specified in the data sheet. Interlock shall be provided between the door, so that door cannot be opened unless the input isolator is open.

6.2 Input harmonic filter

If harmonic filters are required to meet the input harmonics requirement of this specification, then Vendor shall provide the filter, upstream filter isolation, protection and protection coordination as a part of variable frequency drive. The harmonic filters shall be isolated from other components such that they can be disconnected from power source and accessed for maintenance / repair while variable frequency drive is in operation. Harmonic filters must be located on primary side of the converter transformer and must be switchable with the variable frequency drive to avoid leading power factor condition when variable frequency drive is tripped. The complete filter must have independent protection for over current and ground fault. Any inductors used shall be iron or air core with maximum temperature rise of 115C with minimum 220C insulation and over temperature protection. Capacitors shall have balance / discharge resistors to equalize charge voltage and permit safe discharge on power outage

6.3 Converter Transformer

The converter transformer shall be dry type or oil filled type as specified in the data sheet. In case of the dry type transformer, it shall be mounted in the variable frequency drive unless other specified in the data sheet. The impedances of converter transformer with two secondary winding for 12 pulse systems shall be selected to ensure equal load/current sharing between the secondary windings, the converters and the motor windings under all operational conditions including starting and restarting.

6.4 Power Converter

6.4.1 The static power converter shall consist of a line side power converter for operation as a rectifier and a load side power converter for operation as a fully controlled inverter. Power converter shall be fast switching, most efficient and low loss type.

6.4.2 The rectifier shall employ full wave, bridge type, diodes to convert AC to DC. Where series connection of diodes is applicable, the manufacturer shall provide n+ 1 redundancy. The rectifier section shall be unaffected by phase rotation / phase sequence.

6.4.3 The inverter shall employ latest generation of IGBT power switching transistors to convert DC to 3-phase, variable frequency sinusoidal waveform using PWM technique. Where series connection of IGBTs is applicable, the manufacturer shall provide n+1 redundancy.

6.4.4 Normally for all output short circuits, the inverter shall interrupt the current before any semiconductor fuse blows. For internal short circuits, semiconductor fuse protection shall be provided and for all fault upstream of semiconductor fuses, the converter shall be able to withstand a three phase short circuit current until interrupted by normal circuit breaker operation. In case of fuse less design, the failure shall be limited to the particular device, without causing any damage to other parts of the power module. There shall be clear annunciation of the failure of the device.

6.4.5 All power converter devices shall include coordination by peak voltage protecting snubber networks and di/dt and dV/dt networks as required.



HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) EPMC SERVICES FOR REWARI-KANPUR PIPELINE ,PROJECT SPECIFICATION FOR MEDIUM VOLTAGE VARIABLE FREQUENCY DRIVE

6.4.6 The current rating of the converter's semi-conductor components shall not be less than 120% of the nominal current flowing through the elements at full load of the variable frequency drive through the whole speed range.

6.4.7 All power diodes shall be of silicon type with minimum VBO rating as 2.5 times the rated operating voltage.

6.4.8 The power converter circuits shall be designed so that motor can be powered at its full nameplate rating continuously without exceeding its rated temperature rise due to harmonic currents generated by the inverter operation.

6.4.8 The conversion devices and associated heat sinks shall be assembled such that individual devices can be replaced without requiring the use of any special precautions/tools.

6.4.9 The COOling system of the electronic components, if provided, shall be monitored and necessary alarms shall be provided to prevent any consequential damage to the power control devices.

6.4.10 All transistors and diodes shall be protected with high speed semiconductor grade fuse. 12t particulars of the power controller devices and the fuses shall be properly coordinated for the selection of the fuses.

6.4.11 Offered system shall also take in account the distance between variable frequency drive panel and motor and system shall include all material and accessories to make system suitable for a distance of 350m unless otherwise specified in the data sheet

6.5 DC Link Reactor

6.5.1 Smoothing reactors for the DC link shall be designed to sufficiently decouple the rectifier and inverter portion of the converter and to limit fault currents in this circuit.

6.5.2 Unless otherwise specified, the reactor shall be air-cooled or fan cooled type located within the panel. In case of fan cooled type, operation of fans shall be monitored.

6.5.3 Reactor shall be suitable for operation with the non-sinusoidal current wave shapes and DC components under all operational conditions of the system without exceeding its temperature limits.

6.6 Output Filter

6.6.1 Variable frequency drive output current waveform should be inherently sinusoidal at all speeds, with harmonic limits as specified in this specification. Output filter shall be provided if required. Output filter capacitors shall be provided with discharge circuits to ensure that all residual stored charge is reduced to less than 50 V DC within 300 seconds after a loss of AC voltage. All capacitor shall be maintenance free and self-healing type.

6.6.2 The variable frequency drive shall inherently protect motor from high voltage dv/dt stress, independent of cable length to motor. Output filter shall be an integral part of the variable frequency drive and included within the variable frequency drive panel.

6.7 Printed Circuit Boards




All printed circuit boards shall be new. They shall be conformably coated for moisture and chemical resistance in addition to any dielectric coating properties.

6.8 Output Isolator

Output isolator (contactor / load break switch) shall be provided for isolation between output of the the controller and motor if specified in the data sheet. The output isolator (contactor) shall be energized before speed signal is applied to the variable frequency drive and shall be de-energized after motor stopped ..

6.8 Bypass Feature

6.8.1 Bypass feature shall be provided, if specified in the data sheet.

6.8.2 All variable frequency drives having bypass feature shall have motor protection relay along with necessary control and metering etc. Three contactors / circuit breakers shall be used for this purpose, one contactor in the bypass and two contactors across the variable frequency drive, such that in case of variable frequency drive mal-operation, the motor could be taken on bypass control, while the variable frequency drive could be attended by opening its contactors.

6.8.3 Bypass feature shall meet the requirement of Type-2 coordination.

6.9 Fault Diagnostic

Fault diagnostic shall be built into the system to supervise the operation and failure of the system. The information regarding failure of any of the system including shut down of the system shall be available for a period of minimum 4 days (96 hours) after a shut down even though no supply would be available to the system. The system may be totally de- energized for maintenance or otherwise. It shall be possible to retrieve the record of events prior to tripping of the system or de-energisation. Auxiliary supply to the system components or to the electronics (firmware) for the diagnostics / display shall be taken care by the manufacturer for this purpose

6.10 Miscellaneous items

Each variable frequency drive panel shall be provided with illuminating lamp (11 W CFL) with switch - fuse and 5/15A, 240V power socket with switch - fuse. Each variable frequency drive panel shall have space heater with switch fuse and variable setting thermostat.

6.11 External Power Supply for Auxiliary and Control Circuit

6.11.1 Devices external to variable frequency drive module, space heater for motor and variable frequency drive panel, auxiliaries for transformers, cubicle CFL lamps, sockets etc. shall be suitable for auxiliary power supply as specified in the data sheet provided by purchaser.

6.11.2 Vendor shall include supply of all control transformers, protective devices, required accessories etc. and any other control supply voltage as required for the system shall be derived from the power supply made available by purchaser.

6.12 Reliability Features

6.12.1 The expected lifetime of the variable frequency drive shall be 35 years. The variable frequency drive including all individual components forming part of the system shall have an availability




of minimum 0.997 and a minimum MTBF of 4 years.

6.12.2 The controller design shall incorporate the following reliability features Pre tested components with power components to be 100% tested under dynamic conditions Printed circuit boards shall be computer tested and adjusted. Printed circuit boards shall be temperature cycled for minimum of 40 hours Printed circuit boards shall be treated for tropical, humid and corrosive environment.

6.13 Maintenance Features

The controller design shall incorporate the following maintenance features: Modular construction Printed circuit boards shall be plug connected All components shall be easily accessible from the front of the panel. Standard diagnostics to aid maintenance personnel. These shall include LED or alphanumeric displays, test or measurement pOints.

7.0 PROTECTION, CONTROL, METERING AND INDICATION REQUIREMENTS

7.1 The vendor shall provide all the necessary system control, protection; alarm equipment and metering for the entire drive system and its auxiliary equipment.

7.2 Automatic sequence control shall include start-up of cooling system, auxiliary system of the motor, interlock checking, automatic start and run-up of drive, planned and emergency shutdown. The same shall be processed through microprocessor-based system.

7.3 Operator Control Panel

a. Each variable frequency drive shall be equipped with a front mounted operator control panel consisting of a backlit alphanumeric display and a keypad with keys for parameterization and adjusting parameter which shall not be limited to start/Stop, Local/Remote, auto/manual, Increase/Decrease, menu navigation and protection and measurement parameter selection, etc.

b. All parameter names, fault messages, warnings and other information shall be displayed in complete English words or standard English abbreviations to allow the user to understand what is being displayed without the use of a manual or cross-reference table. This shall also be used for the modification of all electrical values, configuration parameters, drive menu parameters, application and activity function access, faults, local control, adjustment storage, self test and diagnostics. Keypad shall be operable with password for changing the protection setting, safety interlock etc. However the parameters such as measurements, setting, mode of variable frequency drive etc. shall be allowed to be viewed without any password.

c. Operator console shall have facility / port to connect external hardware such as Lap-Top etc. Console shall have facility for upload and download of all parameter settings from one variable frequency drive to another identical variable frequency drive for start up and operation.

d. User-friendly software for operation and fault diagnostic shall be loaded in the variable




frequency drive before commissioning.

7.4 Protective features

~1

The variable frequency drive offered shall incorporate adequate protective features, properly coordinated for the drive control and for motor but not limited to the following: i. Incoming line surge protection ii. Under / Over voltage protection iii. Phase loss, phase reversal protection. iv. Programmable over current protection. v. Inverter Fault. vi. Over frequency operation. vii. Ventilation loss viii. DC line overvoltage. ix. Over temperature of equipment. x Over speed of motor. xi. Specific motor protection, including motor winding, bearing temperatures, over-current,

overload, negative phase sequence, locked rotor and earth fault protections etc. xii. System earth fault protection.

7.5 Control

The following controls shall be provided as a part of the Operator Control Panel or through separate switches. i. Start/Stop ii. Speed control (Raise/lower) iii. Forward/Reverse(if specified) iv. Auto/Manual/test mode v. Local/rem ote vi. Emergency stop vii. Start/stop for by pass starter (where specified) viii. Trip-Remote Breaker ix. Input / output contactor On / Off (if applicable)

7.6 Indications

Vendor shall provide indications as required for normal operation and for easy maintenance, which shall not be limited to the following indications. 1. Motor running ii. Motor stopped iii. Variable frequency drive Fault iv. Ready to start v. AC mains ON vi. Motor over speed vii. Rectifier output IONI viii. Motor zero speed ix. Remote breaker trip x. Input / output contactor ON (if applicable) xi. Input / output contactor OFF (if applicable) Above indications may be provided as a part of the operator control panel, i.e., door mounted keypad or through hardwired indicating lamps/LEOS. Potential free contacts of items i- iv shall be wired separately for remote indications in DCS system.




7.7 Metering

Digital display of the following parameters shall be as a part of the Operator Control Panel, selectable by the operator. i. Input AC voltage ii. Input AC frequency iii. Input AC Current iv. Output voltage v. Output current VFD / Bypass vi. Output frequency vii. Motor thermal state viii. Variable frequency drive thermal state ix. Motor speed x. Motor energy meter xi DC Link voltage xii. Hour Run

Necessary transducer shall be provided with 4-20mA output for indicating motor speed and motor current in DCS unless otherwise specified for other parameters.

7.8 Alarms and Annunciation

a. The variable frequency drive shall incorporate protection alarms required for various fault conditions, for the motor, supply cables, converter transformer, DC reactor, converter, output transformer etc.

b. Alarms shall also be included for the failure of various auxiliaries together with identification of the failing unit, loss of cooling system, various protection devices provided for converter transformer etc.

c. Potential free contacts shall be provided for following annunciation and shall be wired to terminal block for Purchaser's use for remote monitoring.

i. Rectifier fuse failure ii. Main AC failure iii. Inverter fuse failure iv. Inverter overload v. Inverter high temperature vi. Cooling system failure vii. Motor failed to start viii. Transformer failure ix. Harmonic filters monitoring

8.0 INSPECTION AND TESTING

8.1 During fabrication, MV variable frequency drive shall be subject to inspection by Purchaser or by an agency authorized by the Purchaser. Vendor shall furnish all necessary information concerning the supply to Purchaser. The Purchaser shall have free access to the Vendor's works for the purpose of inspecting the process of manufacture in all its stages and he will have the power to reject any material, which appears to him to be of unsuitable description or of unsatisfactory quality.




8.2 MV variable frequency drive shall be tested in accordance with applicable standards. All acceptance and routine tests as follows shall be carried out on each drive at Vendor's work under his care and expense. Vendor's internal test reports shall be provided for Purchaser's review prior to inspection and testing.

8.2.1 Visual and dimensional check of complete drive assembly and all components

8.2.2 Operational check of all drive components under normal and worst voltage conditions.

8.2.3 Verification of Bill of material

8.2.4 Insulation test.

8.2.5 Light load and functional test.

8.2.6 Verification of auxiliary and control devices

8.2.7 Verification of properties of control equipment

8.2.8 Verification of protective devices

8.2.9 Verification of control and functional requirements

8.2.10 Automatic re-start / re-acceleration

8.3 Type tests as follows shall be performed on one drive of each rating. Type test certificates approved by CPRI or equivalent approved testing agency may be acceptable in lieu of actual type tests on identical MV variable frequency drive subject to Purchaser approval.

8.3.1 Allowable full load current versus speed

8.3.2 Efficiency

8.3.3 Temperature Rise Test

8.3.4 EM immunity

8.3.5 EM em iss ion

8.3.6 Overcurrent capability

8.3.7 Measurement of ripple voltage and current

8.3.8 Power factor

8.3.9 Inherent voltage regulation

8.3.10 Audible noise

8.3.11 Test capability to ride through voltage less than 80% of rated voltage

8.3.12 Test capability to restart the system and resynchronize converter onto running motor after a voltage interruption




8.3.13 Degree of protection

8.4 String Test with driven equipment

If a string test with driven equipment is specified in the data sheet of the driven equipment, it shall be carried out with the job equipment.

8.5 The MV variable frequency drive and associated motor equipment shall have test certificates issued by recognized independent test house (CMRII BASEEFAI LCIElUUFM or equivalent). Motors and variable frequency drive system for hazardous area application as well as safe area shall be type tested as unit.

8.6 Acceptance, routine and type tests shall be witnessed by Purchaser or an agency authorized by the Purchaser. Prior notice of minimum 4 weeks shall be given to the Purchaser for witnessing the tests.

8.7 For equipment bought from other sub-suppliers, certified test reports of tests carried out at the Vendor's works shall be submitted. Normally all routine tests as specified in the relevant standards shall be conducted by the sub-supplier at his works.

9.0 PACKING AND DESPATCH

All the equipment shall be divided into several shipping sections for protection and ease of handling during transportation .The equipment shall be properly packed for selected mode of transportation i.e. by shiplrail or trailer. The panels shall be wrapped in polyethylene sheets before being placed in wooden crates Icases to prevent damage to the finish. Crates Icases shall have skid bottoms for handling. Special precaution notations such as Fragile, This side up, center of gravity, weight, Purchaser's particulars, Purchase number etc. shall be clearly marked on the package together with other details as per purchase order.

The equipment may be stored outdoors for long periods before installation. The packing should be suitable for outdoor storage in areas with heavy rains and high ambient temperature unless otherwise agreed.


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A

DATA SHEET FOR MEDIUM AND HIGH VOLTAGE CABLES

Issued for Customer review Issue Description

resources & energy

~2 DOLV

Originated Checked Approved Client HINDUSTAN PETROLEUM CORPORA TlON LIMITED (HPCL)

EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT Project No: 5131MH2145 SHEET Datasheet No: MH2145-C110-EL-DAS-0006 of 4

Data Sheet for Medium and High Voltage Cables 1 Tag No.: N/A Client: HINDUSTAN PETROLEUM CORPORATION LIMITED (HPC 2 Service: Medium and High Voltage cables Plant Location : REWARI-KANPUR PIPELINE 3 Dwg No.: LATER Manufacturer: LATER 4 Calculation Ref. : LATER Purchase Order No. : LATER 5 No. of Units: N/A 6 Service Description: Medium and High Voltage cables 7 SITE CONDITIONS POWER SYSTEM 8 Location: Indoor - Outdoor - System Voltage: See below 10% 9 Ambient air temp: Min: o C Max: 50C System Frequency: 50 Hz 5%

...............

.... " 10 Min:65% Max.: 90% Altitude: * m Neutral ing: See below 'U""Y"1 11 Ground Temperature: 40C

.

.' 12 PARTICULARS OF EQUIPMENT UNITS PURCHASER'S REQUIREMENTS VENDOR'S RESPONSE 13 GENERAL DATA 14 Applicable Standards As per CI 2.0 of Specification

-.........

15 Manufacturer VTA .....

16 System Voltages: Highest Voltage Grade -

17 415V System V 500 650 11100 -.

18 3.3kV System (E) kV 3.6 1.9/3.3 -

19 3.3kV System (UE) kV 3.6 3.3/3.3 -

20 6.6kV System (E) kV 7.2 3.8 I 6.6 1 .............. ......

21 6.6kV System (UE) kV 7.2 6.6/6.6 1----. . ....

22 11 kV System (E) kV 12 6.35 111 I---- ....... . ....

23 11kV System kV 12 11 I 11 I---- ...... ............................. ...

24 22kV System (E) kV 24 12.7 I 22 I--- 33kVSy~t~~ (E) ..... , ....... . ...... 25 kV 36 19/33

............

26 System Frequency Hz 50 I---- ............ ....... ............... ............... .............. .... ....... ............. , ......

27 Permissible voltage variation % 10% 28 Permissible frequency variation % 5%

I 29 Single Line to Ground (L-G) Fault Currents: -

..... I 30 3.3kV System L-G fault current, duration kA, sec N/A

-

..... I 31 6.6kV System L-G fault current, duration kA, sec N/A

-....... ................ 1 .......

32 11 kV System L-G fault current, duration kA, sec 31.5kA for 1 sec -I' .... 1

33 22kV System L-G fault current, duration kA, sec N/A ...... .......

34 33kV System L-G fault current, duration kA, sec N/A ....

35 Cables to be flame retardunt Yes I No Yes -

36 Cables to be heat resistant Yes I No Yes .... I

37 Armouring Required Yes I No Yes - I' ...... ...

38 Type of Armour Bonding Yes I No Yes -

.......... ........ , ..............

39 Installation under DGMS jurisdiction Yes I No No -

....

40 Cable Type I Code VTA -

41 Number of cores x Size mm2 As per BOM _ ..

42 Conductor: .......

1 43 Material Aluminium and Copper ~ 16mm2 -I ........ .............

44 Shape VTA -

I ....... . ...

45 Maximum temperature under normal operation c 70 (PVC) I 90 (XLPE) -

I 1 ..... 46 Maximum temperature under short circuit c 160 (PVC) I 250 (XLPE) -, ...

1 ..

47 Fault current withstand capacity, duration kA, sec VTA I--- ..... 1 1 .....

48 Conductor semiconducting screen: I--- ......

49 Material VTA 1----, ...... 1 ..... 50 Thickness mm VTA

I

~ ~ )i)\VY I A 11/03/13 Issued for Customer review KULC MAHD Rev . Date Issue Description Originated Checked Approved Client

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL)

1,1 Worley Parsons ~ EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT Project No: 513/MH21451 SHEET resources & energy Datasheet No: MH2145-C110-EL-DAS-0001 2 of 4 WS-DS-EL-006 Print Date 3111/2013

Data Sheet for Medium and High Voltage Cables 1 Tag No.: N/A Client: HINDUST AN PETROLEUM CORPORATION LIMITED (HPCL) 2 Service: Medium and High Voltage cables Plant Location : REWARI-KANPUR PIPELINE 3 Dwg No.: LATER Manufacturer: LATER 4 Calculation Ref. : LATER Purchase Order No. : LATER 5 No. of Units: N/A 6 Service Description: Medium and High Voltage cables 7 PARTICULARS OF EQUIPMENT UNITS PURCHASER'S REQUIREMENTS VENDOR'S RESPONSE 8 GENERAL DATA 9 Insulation: 10 Material PVC (Control) I XLPE (Power) ~--f""""""""""""""""""""""""'"............. ............ ............................................................................. 1+...... . ....................... + .......................................................................... .

11 Thickness 12 Insulation Non-metallic Screen: 13 Material 14 Thickness 15 Insulation Metallic Screen: 16 Material 17 Thickness 18 Size

..............................................................................

...................

19 Fault current withstand capacity, duration 20 Inner Sheath:

.............................

21 Material 22 Thickness

.............................................................

23 Calculated diameter under armour 24 Armour:

25 Material

26 Type ." ................................................................... .

27 Size 28 Fault current withstand capacity, duration 29 Calculated diameter under outer sheath 30 Nominal diameter under outer sheath

mm

mm

mm

mm2

kA, sec

mm

kA, sec mm

mm ................................. 1

31 Outer Sheath: ....................................

32 Material 33 Thickness 34 Nominal outer diameter of cable 35 Tolerance on outer diameter of cable 36 Maximum drum length of cable 37 DC resistance of Conductor at 20C 38 Maximum AC resistance of Conductor at 90C 39 Approximate Cable Reactance 40 Approximate Cable Capacitance

............................

41 Continuous Current Capacities of cable and reference 42 temperatures: 43 In Air 44 In Ground 45 In Duct 46 47 48 49 50

Issued for Customer review Issue Description


WS-DS-EL-006

mm

m

Q/km Q/km Q/km JlF/km

AatOC AatOC AatOC

VTA

Extruded Semi conducting VTA

Copper VTA VTA VTA

Extruded PVC Type ST-2 VTA VTA

Aluminium (1 core) I Galvanised Steel (Multi core)

Flat VTA VTA VTA VTA

..........................

FRLS PVC Type ST-2 VTA

...............................

VTA VTA VTA VTA VTA VTA VTA

VTA VTA VTA

;~ ...... .,.jV )0 -MAHD

Originated Checked Approved Client HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL)

EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT Project No: 513/MH2145 SHEET Datasheet No: MH2145-C11 O-EL -DAS-OOO 3 of 4

Print Date 3111/2013

Data Sheet for Medium and High Voltage Cables Tag No.: N/A Client: HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL)

2 Service: Medium and High Voltage cables Plant Location : REWARI-KANPUR PIPELINE 3 Dwg No.: LATER Manufacturer: LATER 4 Calculation Ref. : LATER Purchase Order No. : LATER 5 No. of Units: N/A 6 Service Description: Medium and High Voltage cables 7 PARTICULARS OF EQUIPMENT UNITS PURCHASER'S REQUIREMENTS VENDOR'S RESPONSE 8 TEST REQUIREMENTS 9 Routine and Acceptance Tests Yes I No Yes

'I~ ......................

Type Tests Yes I No Valid TCs shall be submitted ......................................................................................................................... , II

Tests Yes I No Valid TCs shall be submitted 1'----1 .................. .. . ............................................ 1 .................................... , ..................... .

12 Witnessed Tests Yes I No Yes 13 14 NOTES: 15 1. VTA = Vendor to advise, N/A - Not apIJ/iciablie, TBA - To be advised .

............................................................................................................ , ...........................................................................................

16 2. Vendor shall data I confirmations for all items. 17 3. Vendor shall provide type and special test certificates along with offer. 18 4. Refer to Medium and High Voltage Cables specification MH2145-COOO-EL-SPC-0020 for additional information . 19 20 21

22 23 24 25

26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

42

43 44 45

46 47

48 49 50

A Issued for Customer review Issue Description


WS-DS-EL-006

......................................................................

1J\~ MAHD

Originated Checked Approved Client HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL)

EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT Project No: 513/MH2145 SHEET Datasheet No: MH2145-C110-EL-DAS-000 4 of 4

Print Date 3111/2013

EPMC Services for Rewari-Kanpur Pipeline

LIST OF ATTACHMENTS FOR COMPOSITE TENDER - INSTRUMENTATION

MH2145-C000-IC-LST-0002 Rev 0

05 April 2013

Hydrocarbons WorleyParsons Sea India Private Limited Raheja Plaza, First Floor LBS Marg, Ghatkopar (West) Mumbai - 400086 , India Telephone: +91 22 67818000 Fax: +91 22 67818080 www.worleyparsons.com

EPMC SERVICES FOR REWARI KANPUR PIPELINE LIST OF ATTACHMENT FOR COMPOSITE TENDER INSTRUMENTATION

EPMC SERVICES FOR HPCLS REWARI-KANPUR REV DESCRIPTION ORIG REVIEW WORLEY

PARSONS APPROVAL

DATE CUSTOMER APPROVAL

DATE

0 Issued for Use MARS

MISS

KSHN 5-Apr-13

N:\513-MH-2145-RKPL\11 ENGINEERING\11.5 INSTRUMENTATION AND CONTROL\1.ENGINEERING DELIVERABLES\3.WORKING\COMPOSITE TENDER\1.MH2145-C000-IC-LST-0002.DOC MH2145-C000-IC-LST-0002 Rev.0

Page 2 of 5

SYNOPSIS This document presents the List of attachment for Composite tender for the Rewari Kanpur Pipeline.

Disclaimer

This document has been prepared on behalf of and for the exclusive use of HINDUSTAN PETROLEUM CORPORATION LIMITED, and is subject to and issued in accordance with the agreement between HINDUSTAN PETROLEUM CORPORATION LIMITED and WorleyParsons Sea India Pvt Ltd. WorleyParsons Sea India Pvt Ltd accepts no liability or responsibility whatsoever for it in respect of any use of or reliance upon this document by any third party.

Copying this document without the permission of HINDUSTAN PETROLEUM CORPORATION LIMITED and WorleyParsons Sea India Pvt Ltd is not permitted.



Page 3 of 5

1.0 List of Attachments

S.no. Document Name Document No.

1 List of Attachment MH2145-C000-IC-LST-0002

2 Instrument Scope of Work MH2145-C000-IC-SOW-0002

3 Instrument Scope Matrix MH2145-C000-IC-SCP-0001

4 Specification for Junction Boxes & Glands MH2145-C000-IC-SPC-0007

5 Specification for Fire Alarm System MH2145-C000-IC-SPC-0009

6 Specification for Instrumentation Cables MH2145-C000-IC-SPC-0015

7 General Specification for Instrumentation MH2145-C000-IC-SPC-0016

8 Specification for Instrument fittings MH2145-C000-IC-SPC-0017

9 Instrument Cable tray Specification MH2145-C000-IC-SPC-0020

10 Quality Assurance Plan MH2145-C000-IC-QAP-0001

11 Data Sheet for Pressure Gauges at Rewari MH2145-C060-IC-DAS-0006-B

12 Data Sheet for Pressure Gauges at Bharatpur MH2145-C090-IC-DAS-0005-B

13 Data Sheet for Pressure Gauges at Mathura MH2145-C100-IC-DAS-0005-B

14 Data Sheet for Pressure Gauges at Kanpur MH2145-C120-IC-DAS-0005-B

15 Data Sheet for Pressure Transmitter at Rewari MH2145-C060-IC-DAS-0004-B

16 Data Sheet for Pressure Transmitter at Bharatpur MH2145-C090-IC-DAS-0003-B

17 Data Sheet for Pressure Transmitter at Mathura MH2145-C100-IC-DAS-0003-B

18 Data Sheet for Pressure Transmitter at Kanpur MH2145-C120-IC-DAS-0003-B

19 Data Sheet for Temperature Transmitter with Temperature Element at Rewari MH2145-C060-IC-DAS-0005-B

20 Data Sheet for Temperature Transmitter with Temperature Element at Bharatpur MH2145-C090-IC-DAS-0004-B

21 Data Sheet for Temperature Transmitter with Temperature Element at Mathura MH2145-C100-IC-DAS-0004-B

22 Data Sheet for Temperature Transmitter with MH2145-C120-IC-DAS-0004-B



Page 4 of 5

S.no. Document Name Document No. Temperature Element at Kanpur

23 Data Sheet for Thermal Relief Valve at Rewari MH2145-C060-IC-DAS-0002-B

24 Data Sheet for Thermal Relief Valve at Bharatpur MH2145-C090-IC-DAS-0001-B

25 Data Sheet for Thermal Relief Valve at Mathura MH2145-C100-IC-DAS-0001-B

26 Data Sheet for Thermal Relief Valve at Kanpur MH2145-C120-IC-DAS-0001-B

27 Data Sheet for Differential Pressure Transmitter at Rewari MH2145-C060-IC-DAS-0017-B

28 Data Sheet for Differential Pressure Transmitter at Bharatpur MH2145-C090-IC-DAS-0015-B

29 Data Sheet for Differential Pressure Transmitter at Mathura MH2145-C100-IC-DAS-0015-B

30 Data Sheet for Differential Pressure Transmitter at Kanpur MH2145-C120-IC-DAS-0012-B

31 Data Sheet for Displacer Type Level Transmitter at Bharatpur MH2145-C090-IC-DAS-0016-B

32 Data Sheet for Displacer Type Level Transmitter at Mathura MH2145-C100-IC-DAS-0016-B

33 Data Sheet for Displacer Type Level Transmitter at Kanpur MH2145-C120-IC-DAS-0013-B

34 Data Sheet for Pressure Switch at Rewari MH2145-C060-IC-DAS-0018-B

35 Data Sheet for Pressure Switch at Kanpur MH2145-C120-IC-DAS-0019-B

36 Data Sheet for Flow Element (Orifice) at Kanpur MH2145-C120-IC-DAS-0017-B 37 Data Sheet for Flow Transmitter at Kanpur MH2145-C120-IC-DAS-0018-B

38 Data Sheet for ESD Hand Switch at Rewari MH2145-C060-IC-DAS-0019

39 Data Sheet for ESD Hand Switch at Bharatpur MH2145-C090-IC-DAS-0020

40 Data Sheet for ESD Hand Switch at Mathura MH2145-C100-IC-DAS-0017

41 Data Sheet for ESD Hand Switch at Kanpur MH2145-C120-IC-DAS-0021

42 Data Sheet for Fire and Gas Detector-Rewari (Typical) MH2145-C060-IC-DAS-0010-B



Page 5 of 5

S.no. Document Name Document No.

43 Data Sheet for Fire and Gas Detector-Bharatpur (Typical) MH2145-C090-IC-DAS-0010-B

44 Data Sheet for Fire and Gas Detector-Mathura (Typical) MH2145-C100-IC-DAS-0010-B 45 Data Sheet for Fire and Gas Detector-Kanpur (Typical) MH2145-C120-IC-DAS-0010-B 46 Instrumentation Typical Hook-Ups MH2145-C000-IC-DHU-0001-B

47 Instrument, Fire and Gas, Telecom -Typical Installation Details MH2145-C000-IC-DID-0001-B

48 Instrument Index MH2145-C000-IC-DIO-0001-B

49 Schedule of Rates for Instrumentation Supply-PART A (Rewari) 50 Schedule of Rates for Instrumentation Installation-PART B (Rewari) 51 Schedule of Rates for Instrumentation Supply-PART A (Bharatpur) 52 Schedule of Rates for Instrumentation Installation-PART B (Bharatpur) 53 Schedule of Rates for Instrumentation Supply-PART A (Mathura) 54 Schedule of Rates for Instrumentation Installation-PART B (Mathura) 55 Schedule of Rates for Instrumentation Supply-PART A (Kanpur) 56 Schedule of Rates for Instrumentation Installation-PART B (Kanpur)

EPMC Services for Rewari-Kanpur Pipeline

SCOPE OF WORK FOR COMPOSITE TENDER- INSTRUMENTATION

MH2145-C000-IC-SOW-0002 Rev 0

15 March 2013

Hydrocarbons WorleyParsons Sea India Private Limited Raheja Plaza, First Floor LBS Marg, Ghatkopar (West) Mumbai - 400086 , India Telephone: +91 22 67818000 Fax: +91 22 67818080 www.worleyparsons.com

EPMC SERVICES FOR REWARI KANPUR PIPELINE SCOPE OF WORK FOR COMPOSITE TENDER - INSTRUMENTATION

EPMC SERVICES FOR HPCLS REWARI-KANPUR REV DESCRIPTION ORIG REVIEW WORLEY

PARSONS APPROVAL

DATE CUSTOMER APPROVAL

DATE

0 Issued for Use MARS

MISS

KSHN 15-Mar-13

N:\513-MH-2145-RKPL\11 ENGINEERING\11.5 INSTRUMENTATION AND CONTROL\1.ENGINEERING DELIVERABLES\3.WORKING\COMPOSITE TENDER\2.MH2145-C000-IC-SOW-0002.DOC MH2145-C000-IC-SOW-0002 Rev.0

Page 2 of 18

SYNOPSIS This document presents the Scope of work for Composite tender-Instrumentation for the Rewari Kanpur Pipeline.

Disclaimer

This document has been prepared on behalf of and for the exclusive use of HINDUSTAN PETROLEUM CORPORATION LIMITED, and is subject to and issued in accordance with the agreement between HINDUSTAN PETROLEUM CORPORATION LIMITED and WorleyParsons Sea India Pvt Ltd. WorleyParsons Sea India Pvt Ltd accepts no liability or responsibility whatsoever for it in respect of any use of or reliance upon this document by any third party.

Copying this document without the permission of HINDUSTAN PETROLEUM CORPORATION LIMITED and WorleyParsons Sea India Pvt Ltd is not permitted.



Page 3 of 18

TABLE OF CONTENTS 1. GENERAL ..................................................................................................................................... 4

2. EXCLUSIONS ............................................................................................................................... 5

3. BATTERY LIMIT ........................................................................................................................... 5

4. SCOPE OF WORK ....................................................................................................................... 6

4.1 DESIGN AND ENGINEERING .................................................................................................. 6

4.2 PROCUREMENT AND SUPPLY............................................................................................... 7

4.3 FACTORY TESTING AND ACCEPTANCE .............................................................................. 7

4.4 INSTALLATION, FIELD CALIBRATION/ TESTING AND COMMISSIONING ........................ 7

4.5 SPECIALTY SERVICE .............................................................................................................. 8

5. SCOPE OF SUPPLY .................................................................................................................... 8

6. DESIGN PHILOSOPHY ................................................................................................................ 9

7. TECHNICAL REQUIREMENT .................................................................................................... 10

8. SPARE PHILOSOPHY ............................................................................................................... 13

9. INSPECTION AND TESTING ..................................................................................................... 13

10. VENDOR DATA REQUIREMENT ........................................................................................... 14



Page 4 of 18

1. GENERAL

Hindustan Petroleum Corporation Limited (hereinafter referred to as "HPCL") proposes to lay cross country multiproduct white oil pipeline (440 Km) for distribution of products in Northern India. The pipeline is proposed to be laid to transfer EURO-III MS, EURO-IV MS, EURO-III HSD, EURO-IV HSD and SKO from the existing Tap Off location at Rewari in Mundra Delhi Pipeline (MDPL) in Haryana upto Kanpur in Uttar Pradesh. The pipeline shall be laid from the existing Terminal at Rewari, in Haryana up to Kanpur in Uttar Pradesh. The product shall be made available from the existing Mundra - Delhi Pipeline and newly commissioned Guru Gobind Singh Refinery (GGSR) at Raman Mandi, Punjab thru RamanMandi Bahadurgarh Pipeline. The descriptions and requirements contained in the specifications are concise by necessity and cannot include all details. However it is the responsibility of the contractor to execute the job in accordance with the specifications and internationally recognized good engineering practices for smooth and successful operation of complete package. This scope of work shall be read in conjunction with Job specifications, various Standards and standard specifications attached with the MR documents.

The type of instruments shall be as per requirements of process package, standards, drawings, enclosed with this MR package.

This specification together with Instrument standard specification (Doc no. MH2145-C000-IC-SPC-0016), cover the design, engineering, factory testing, supply, erection, termination till marshalling cabinet, loop checking, preparation for end termination, tagging and ferruling, calibration, site testing & pre-commissioning. The contractor is also expected to provide assistance for commissioning of PLC, CCTV & Video Conferencing, Motorized Operated Valves supplied by other vendors for final commissioning of all instruments and controls with all accessories and materials.

In case of any discrepancy between standards, standard specifications and job specifications, this job specification, shall govern. However contractor shall refer such discrepancies to Purchaser/Consultant for further clarification and only after obtaining the clarification from purchaser/consultant, contractor shall proceed further.

All equipments shall be of field proven quality both with respect to design and materials. Prototype instruments or instruments of an experimental nature shall not be provided.

All instruments provided shall have a well proven performance record of operating satisfactorily in a similar unit or for a minimum of 4000 running hours.

No instrument requiring special maintenance or operating facilities shall be provided as far as possible.

Manufacturer shall be reputed and shall have all the facility to manufacture, integrate and test.



Page 5 of 18

2. EXCLUSIONS

Contractor shall note that following items shall be supplied by Purchaser.

Contractor to note that though the following items are being purchased and supplied by client, the installation, cabling, and preparation for termination, termination, and pre-commissioning shall be in scope of the contractor.

Motorized Valves

Fire Alarm Panel, Telecommunication

Plant PLCs at Rewari, Bharatpur, Mathura & Kanpur

SCADA

Shutdown Valves

Control Valves

Surge relief valves

UPS

Mass Flow Meter & Flow Computer

Ultrasonic Flow Meter

Density Meter

Telecom System

MOV Master Control System

Unit Control Panel for Pumps

3. BATTERY LIMIT

Supply & installation of total field instrumentation, cabling up to control rooms (60-CS-01, 90-CS-01, 100-CS-01 & 120-CS-01, total 4 nos.) and end terminations there-in.



Page 6 of 18

4. SCOPE OF WORK

Contractor shall be responsible for supply & implementation of complete instrumentation and control for the Rewari , Bharatpur, Mathura & Kanpur stations for Rewari-Kanpur pipeline of RKPL Project with scope of work as listed below but not limited to the following:

4.1 Design and Engineering

General

a. The contractor shall be responsible for carrying out the detailed engineering based on the data provided in this MR document and in line with other technical requirements specified elsewhere in this document.

b. Scope shall also include sizing, detailing of system oriented items, preparation of data sheets including residual engineering, coordination drawings, engineering drawings etc. Residual engineering includes instrument sizing, Thermowell Wake frequency calculation, utility consumption, specifying derived data in process data sheets, deriving process data for Instruments where specific data sheet for such instruments are not included in process package, type and material selection of instruments wherever required. Residual engineering shall also include actual transfer/ implementation of the information provided in the form of notes in P&IDs and instrument data sheets/ equipment data sheets and other documents provided in MR specification.

Control Systems & Engineering a. Contractor shall note that SCADA based PLC system and Telecom shall be provided by

Purchaser.

b. Contractor shall be provide assistance to integrate the instrumentation and control systems with the Purchasers Station / Plant PLC and SCADA.

c. Any software required for interfacing the contractor supplied instrumentation and control systems with the Purchaser PLC shall be in contractors scope.

d. Contractor shall carryout construction of control station existing control room for Rewari shall be utilized for installation of new SCADA / PLC / Telecom System (90-CS-01, 100-CS-01 & 120-CS-01, total 3 nos.) required for RKPL Project. The control station shall be constructed by contractor based on guidelines and various requirements given in this documents and attached standard specification, job specifications attached in this MR document. The control station shall house Purchaser supplied PLC cabinets, engineering consoles, telecommunication system, Fire Alarm Panel and other hardwares indicated elsewhere in attached standard/specification.



Page 7 of 18

Engineering Drawings & Documents a. Vendor Data Requirement enclosed indicates the list of drawings and documents required

to be supplied by the contractor, as a minimum. Contractor to note that list specifies only the major deliverables. Documents and drawings not listed but necessary for proper engineering, construction, operation and maintenance of instrumentation and control system shall also be prepared by the contractor.

b. Contractor shall utilize uniform ISA data sheet formats for various instruments, including those which are being prepared by package/ sub package vendors. Use of manufacturer standard formats shall be avoided.

c. The design and engineering work shall also include review of post-order sub-vendor drawings and documents for all instruments and system oriented items for complete package. Vendor shall note that no drawing from sub-vendor shall be forwarded to Client/ EPCM unless the same has been vetted by the vendor.

4.2 Procurement and Supply

Engineering for procurement by contractor shall include preparation of various material requisitions which shall include data sheets for instruments, instrument standard specifications, special requirements etc., evaluation of offers received from various manufacturers/ vendors, preparation of Technical Bid Analysis, preparation of purchase requisition and review / approval of vendor drawings, incorporation of EPCM / owner comments.

All items shall be procured from vendor list attached herewith. In case the item is to be procured and does not exist in list, the vendor shall be get it duly approved by EPCM/ Owner. Contractor shall submit the selected sub-vendor list for EPCM/Owner review for all type of instruments. Contractor shall not procure any items from vendors not approved by EPCM/ Owner.

4.3 Factory testing and Acceptance

Factory Acceptance Test (FAT) and calibration of all instruments shall be carried out/witnessed by the contractor. EPCM/Owner shall witness testing of any or all items at various stages during manufacture and/or at final stage before shipment at the discretion of EPCM/ Owner. No such items shall leave manufacturer works without successful factory acceptance test duly approved by EPCM/Owner. Testing shall be carried out as per approved procedures.

4.4 Installation, Field Calibration/ Testing and Commissioning

Contractor shall be fully responsible for installation, field calibration, testing, loop checking, pre commissioning, commissioning assistance of all instruments for the complete package. In addition contractor shall take care of the following requirements:-



Page 8 of 18

Contractor to note that single feeder of 24V DC shall be provided by the Purchaser at one point in Control stations at 60-CS-01, 90-CS-01, 100-CS-01 & 120-CS-01, total 4 nos. for contractor supplied instrumentation. Contractor shall supply the power distribution cabinets (if required).

Any utility required for instrument operations but not listed in the MR specification shall be arranged by the contractor. Contractor shall furnish consumption of each utility power supply for instruments.

All cables and cable trays meant for the system shall be brought by the contractor from the field / MCC or Substation up to the marshalling cabinets of PLC or other facilities (provided by the Purchaser) in 60-CS-01, 90-CS-01, 100-CS-01 & 120-CS-01, total 4 nos. Termination of cables both at field side and in these marshalling cabinets shall be done by contractor.

Contractor shall leave an extra length of 10m of cable for each multi-pair cable in the control station at 60-CS-01, 90-CS-01, 100-CS-01 & 120-CS-01, total 4 nos. Contractor shall provide 6 pair/12 pair/7 triad/12 Triad cables and corresponding 6 pair/12/7 triad/12 Triad pair junction boxes.

The contractor shall work in co-ordination with the SCADA & Telecom vendor for integration, loop checking, Precommissioning and commissioning of SCADA & Telecom (supplied by Purchaser). The contractor shall provide assistance to implement the same as required.

Insulation and painting of instruments and impulse lines if required in line with insulation and painting specifications attached elsewhere in MR documents.

Any special cable, if required shall be supplied and laid by the contractor.

All testing, calibration and adjustments to instruments shall be included. For all instruments calibration data and test certificates shall be provided.

Any other erection material necessary for installation and commissioning of special instruments, systems or equipment.

4.5 Specialty Service Contractor shall engage specialty services from the suppliers for special instruments and systems. This shall include engagement of qualified engineers and technicians from suppliers for engineering, installation, field testing and commissioning.

5. SCOPE OF SUPPLY Supply of all items related to instrumentation and control system shall be as per the details provided and other technical documents attached with this document. Apart from requirements indicated in this MR document, contractor shall be responsible to supply all instrumentation and control which are necessary for safe and efficient operation of the package. Any additional instrumentation required in



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the opinion of contractor for meeting functional requirements, safe and efficient operation, which is not listed specifically in this document, shall also be supplied by the contractor.

The scope of supply shall include but not limited to the following as a minimum: All instruments as per the approved P&IDs required for complete package for safe and

efficient operation.

All installation and erection materials such as impulse piping, pipe-fittings and valves, tubing, tube fittings, cable tray/duct and supports, cable glands, all type of consumables and accessories for mounting all instruments (pipe stanchions, brackets etc), instrument supports, prefabricated canopies/sunshields for all field mounted instruments & junction boxes. All types of indoor and outdoor cables such as signal, alarm, control, Fire & Gas, RTD, Power, special cables including accessories as necessary.

Main cable duct, trays, structural supports, consumables for cable laying and routing within the package and up to the control stations 60-CS-01, 90-CS-01, 100-CS-01 & 120-CS-01, total 4 nos. Trays for instrument cabling shall be FRP type.

Junction boxes and cable glands for different types of signals such as 4- 20 mA DC, RTD, shutdown, alarm, power etc.

Galvanized iron/ copper earthing strip and earthing cables for earthing of all instrumentation items including junction boxes etc. and their connectivity to instrument earth pits and to electrical earthing strip in the unit. Copper earthing strips shall only be used inside the panels. Insulated multi stranded copper wires of suitable diameter shall be used for earthing inside the control station.

Insulation and paint for instruments, impulse lines, sample lines and for other activities.

Supply of configuration tools like Universal type hand held configurators for smart based instruments such as transmitters, positioners etc.

Any special tools and tackles required for the supplied instrumentation.

Supply of drawings and documents as per vendor data requirement (VDR). Supply of installed engineering spare, commissioning spare for instrumentation as defined

in this MR specification.

6. DESIGN PHILOSOPHY

The design and installation of instruments shall generally be in accordance with ISA/API recommended practices and other applicable standards like BIS. Material specifications and practices shall, in general, conform to appropriate ASTM or equivalent standards. All standards and code of practices referred shall be of the latest edition prior to the date of issue of enquiry.

The design of electronic instruments shall be in compliance with the electromagnetic compatibility requirements as per IEC 60801 'Electromagnetic compatibility for Industrial Process measurement and Control equipment'.



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Field switches/Transmitters shall be used as applicable whose outputs shall be wired directly to PLC for alarm and trip function. For flow, temperature, instruments & pressure, shutdown signals (contacts) shall be generated through analog input card in PLC. However, for pumps and compressors, Pressure Switches may be accepted as per sub-package vendors standard.

All instruments and equipments shall be suitable for use in a hot, humid, dusty and highly caustic atmosphere in which caustic gases, dust and/or chemicals may be present. As a minimum, all instruments, Junction boxes, local control panels and enclosures in field shall be dust proof and weatherproof to NEMA-4X and secure against the ingress of dust, fumes, dampness, insects and vermin. NEMA-4 for transmitters, solenoid valves, junction boxes and field switches (wherever applicable). All external surfaces shall be suitably treated to provide protection against corrosive plant atmosphere.

All instrument connections shall be as per hook-up diagram MH2145-C000-IC-DHU-0001. However, for flanged diaphragm seal type, the connection size shall be 2.

Installation standards of all the instruments shall be followed as enclosed in this document, however standards other than those given in the package, shall be developed by the contactor based on these documents and shall be submitted for owner/consultant review.

All signals shall be provided on terminal strips in the PLC supplied by the purchaser. Cables up to the marshalling cabinets shall be provided by the contractor. Necessary hardware signal multiplication for all instrumentation and their components shall be designed for fail safe operation.

Start/ Stop, Auto/ Manual, Local/ Remote commands for all electrical drives from local control stations in field shall be directly wired to MCC.

7. TECHNICAL REQUIREMENT Power Supplies and their Distribution

a. Power supply at the following voltage levels shall be used :

For Instruments 24V DC 10 %( UPS) All Panel/cabinets (PLC,FAP,CCTV,VHF/GPS/Master Control Stations/ Density etc.) lighting

240 V AC l0% 50 Hz 3%

For CV, SDV, Pump, MOV, Sulphur 415VAC 10% ,3Ph, 50Hz For Telecom System - 48 V DC

Any other voltage levels required shall be generated by the contractor.



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b. For bulk power supply, enough redundant power supplies/battery banks shall be provided which shall take over automatically in case of main common power source failure. All bulk power supplies shall have one to one redundancy and shall be sized for 1.5 times the full load.

c. Voltages higher than 240VAC shall not enter instrumentation panels.

Cabling philosophy

Junction box

All signals from field to control stations in 60-CS-01, 90-CS-01, 100-CS-01 & 120-CS-01 shall be terminated in the Junction Boxes.

Separate junction boxes shall be used for the following type of signals:

-Contact Inputs for alarm -Contact Input/Output for shutdown -Analog Inputs/Outputs (4-20mA) -RTD Separate JBs shall be used for signals connected to PLC.

All cables and junction boxes shall be sized to keep at least 20% of spare cables and terminals in each. Cables for field instruments shall be single pair/triad up to junction boxes. The junction box shall be suitable for 6 pair/12 pair/7 triad/12 triad signal multipair cables PLC. All junction boxes shall have terminals for termination of cable shields/ drain wires. All spare entries in the junction boxes shall be suitably plugged.

Control and Signal cables used