T000001839_FileName2_Euro-IV analyser MR - Final
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TENDER NO. BPCL(R) / P&CS /OT/10
FOR ONLINE ANALYSERS FOR EURO - IV MS AND HSD
BPCL MUMBAI REFINERY
BHARAT PETROLEUM ONLINE ANALYSERS FOR EURO-IV MS 01.07.09
CORPORATION LTD. AND HSD PR SPEC
MUMBAI REFINERY
PR/PO - 12205099 Pages- 52
CONTENTS
1. 0 Notice Inviting Tender
BHARAT PETROLEUM
1.1 Intruduction
1.2 Bid Process
2.0 Instructions to Vendor
2.1 General
2.2 Area Classification
2.3 Warranty
2.4 Guarranted Performance
2.5 Inspection
2.5.1 FAT
2.5.2 SAT
2.6 AMC
2.7 Spares
2.8 Training
2.9 Delivery
2.10 Payment Schedule
2.11 Shipment
3.0 Design Basis-MS-Introduction
3.1 Blend composistion
3.2 Euro-IV MS Component Stream Properties
3.3 Blend Automation scheme-MS
3.4 Required Product Specification
3.5 Site conditions
4.0 Design Basis-HSD- Introduction
4.1 Blend composistion
4.2 Euro-IV MS Component Stream Properties
BHARAT PETROLEUM
4.3 Blend Automation scheme-HSD
4.4 Required Product Specification
CONTENTS
4.5 Site conditions
5.0 Scope of work - MS& HSD
6.0 Responsibility Chart
7.0 Logistic Support
8.0 Analyser Specification-MS & HSD
8.1 Introduction
8.2 General Requirements
8.3 List of analysers
8.4 Interfacing with DCS
8.5 NIR Analyser
8.5.1 General Specification
8.5.2 Hardware requirements
8.5.3 Software requirements
8.5.4 Sample conditioning system
8.5.5 LAB NIR Analyser
8.5.6 Model Development
8.6 Sulphur Analyser
8.7 Sp. Gravity Analyser
8.8 Analyser Calibration
8.9 PC for the analysers
8.10 Utilities for the analysers
8.A Sulphur and Sp.Gravity Spec sheet-MS
8.B Sulphur and Sp.Gravity Spec sheet-HSD
9.0 Analyser Shelter
9.1 General Requirements
9.2 Design & Construction
9.3 Safety Measures
9.4 Tubing/Wiring & Chemical Filters
CONTENTS
9.5 HVAC System
9.6 Power Supply
9.7 Earthing
9.8 Utilities
9.9 Lighting
9.10 Foundation
9.11 Painting
9.12 Name Plate
9.13 Inspection and testing
10.0 Vendor Data Requirements
11.A Price Schedule-MS
11.B Price Schedule-HSD
12.0 Vendor List
13.0 Tender Terms and Conditions /Attachments
Page 5 of 59
ON-LINE ANALYSERS FOR BLENDING OF EURO-IV MS AND HSD
1.0 Notice Inviting Bids
1.1 Introduction
BPCL Mumbai Refinery has taken up various projects to produce Euro IV grade MS and
HSD. As per the GOI policy on Auto fuel, Euro III/IV grade transport fuel shall be mandatory
in the market from April 2010.
In order to verify Euro-IV product specifications of the blended MS & HSD, it is envisaged to
install NIR and ASTM analysers in the offsite area near to the respective headers.
This tender describes the complete scope of work for the analyser vendor.
1.2 Bid Process
1.2.1 Sealed bid invited for design, engineering, inspection,supply,integration,testing,
installation,pre-commissioning,commissioning,GTR, warranty, training and maintenance
service of blending analyser system from competent agencies from India and abroad with
sound technical and commercial capabilities.
1.2.2 The bid shall be single stage three envelope type, Part-I:Pre-Qualification bid, Part-II:
Unpriced Techno-commercial bid & Part-III: Priced bid. The bidders shall be fulfilling the
qualification criteria stated under Sr. no. 1.2.3 below. The envelopes are to be superscribed
as PART-I: PRE-QUALIFICATION BID & EMD, PART-II:TECHNICAL & UNPRICED
COMMERCIAL BID, PART - III:PRICED BID. All the above three envelopes shall be
sealed and together they shall be kept in a bigger 4th envelope. The 4th envelope shall bear
the title " ONLINE ANALYSERS FOR MS & HSD BLENDING"
1.2.3 Qualification Criteria for Bidders:
1.2.3.1 Bidder shall be either,
Manufacturer of NIR or sulphur analyser
OR
Authorized Indian representative of NIR or sulphur analysers
OR
Designer and supplier of sample handling system (SHS) with adequate experience of
analyser system integration as mentioned in 1.2.3.2.
Vendor to produce relevant documentary proof for the above.
1.2.3.2 Further to satisfying above criteria specified in sl. no. 1.2.3.1, bidder should have executed
at least two analyser system order in last five years for similar application. Similar
application means the analysers should have been utilized for measurement of physical
properties of MS/HSD.Vendor need to submit order copy & execution proof like SAT /MOM /
Invoice etc. having reference of the order.
1.0 NIB
Page 6 of 59
Bidder shall submit a list of past installations performed in past five years with user name,
contact no., year of installation and whether presently in use or not status. In addition,
bidder may submit the performance certificate from the user ,if available.
The system supplied should have completed a minimum of 4000 hours of successful
operation as on bid due date of this tender.
The make and model number of individual analysers as offered should be identical to at
least two unit which has been supplied by the analyzer vendor and has been operating
satisfactorily for minimum 8000 hours in the similar application at the time of bid due date of
this tender.
1.2.3.3 Bidder must have executed in the immediate preceding five financial years, at least one
single order for blend analyser system of value not less than Rs. 7 Crores or two blend
analyser system orders of each value not less than Rs. 3 Crores, for supply of the
analyser(s) in similar application. However, the annual turnover of the bidder shall not be
lower than Rs. 20 Crores, in each of the three financial years (2008-09,2007-08, 2006-07).
1.2.3.4 Bidder shall have fully operational directly owned service back up or of strategic tie-up with
recognised vendor in India for past three years. Bidder shall be able to provide ON-CALL
service facilities as and when required by the purchaser and shall have the capability to
provide AMC service.
Bidder shall submit the details of local representative's maintenance experience record with
proof like purchase order etc along with list of engineers having experience in maintaining
such analysers and developing chemometric models. A letter of
certification/recommendation from the original manufacturer as regards to capability of the
persons in maintenance of the analysers & model developement is a must.
1.2.3.5 Bidder shall submit details of concurrent commitment
1.2.3.6 Net worth of the bidder during financial year 2008-09 shall be positive.
1.2.3.7 Bidder should not be under liquidation, court receivership or similar proceedings.
1.2.3.8 Bidder shall furnish documentary evidence by way of copies of the work orders, completion
certificates and balance sheets including profit and loss accounts, certificate from bank etc.
along with the bid to establish bidder's conformance to qualification criteria.
Any bid not meeting the above qualification criteria shall be rejected without any further
communication. Hence, bidder shall take due care in submitting the complete documentary
evidence 'at the first instance itself', in support of their fulfilling the qualification criteria as
given above.
1.2.4 Bidding documents:
1.0 NIB
Page 7 of 59
1.2.4.1 A set of bidding document (non-transferable) may be purchased on any working day
(Monday to Friday) between 1100 Hrs. and 1500 Hrs. during the sale period from BPCL
Refinery, P&CS department, Mahul, Chembur,Mumbai-400074 on payment of non-
refundable fee of Rs. 1000/- by demand draft, in favour of BPCL payable at Mumbai. Tender
fee in any other form shall not be accepted.
1.2.4.2 The bidding document may be downloaded from website (www.bharatpetroleum.in/tender).
1.2.4.3 EMD shall be paid in favour of BPCL-Mumbai in the form of demand draft payable at
Mumbai or Bank guarantee in the prescribed proforma issued by a scheduled bank in India
(except for co-operative banks) and valid for 6 months from the due date of submission of
bids.
1.2.4.4 PSU/NSIC units are exempted from payment of EMD as per Government guidelines on
production of valid supporting documents.
1.2.4.5 Sealed bids shall be received at BPCL Refinery, P&CS department, Mahul,
Chembur,Mumbai 400074. Bids not received by the due date and time shall be rejected and
representatives of such bidders shall not be allowed to attend the bid opening process.
1.2.4.6 BPCL reserves the right to reject any or all bids without assigning any reason, whatsoever.
1.2.4.7 Bids by telefax/fax/email etc shall not be accepted at any circumstances.
1.2.5 In general deviation list is not acceptable, however in case vendor has any valid and
important technical reason, a deviation list may be submitted along with proper technical
explanation.
1.0 NIB
Page 8 of 59
2.0 Instructions to Vendor
2.1 General
2.1.1 Online analysers for blending headers are being procured to analyse the physical
properties of the Euro-IV quality MS & HSD. The analysers are part of the blending scheme
in which blending ratio controller sets the ratio of the component streams to get the desired
quality of blended MS or HSD.
The selected system integrator or vendor should carry out:-
- Application Engineering,
- Selection of most suited process analyzers,
- Design and fabrication of sample conditioning, sample transport and sample disposal
systems,
- Design & Fabrication of Analyzer shelters, accessories like explosion proof HVAC, gas
warning system, electrical utilities,
- Installation of the same in shelters,
- Factory acceptance test,
- Site installation
- Start-up and commissioning services,
- Training of customer personnel and
- Annual Maintenance Contracts
2.1.2 Proper material selection for analyser probes and other wetted parts shall be vendor's
responsibility. However vendor shall follow material specification given in datasheets as
minimum requirement.
2.1.3 Bidder shall complete the pricing schedule as per attached format. Price schedule shall
indicate clearly the model offer and shall be inclusive of charges for inspection, testing and
applicable statutory requirements.
2.1.4 The offered model shall be selected as per the specification in this MR. It shall be bidders
responsibility to understand the technical requirements stated in this MR and select the
applicable analyser model number. At any stage, if it is observed that the analyser system
including the shelter and the HVAC is not as per the MR requirement, the bidder shall
replace the same with no cost to the purchaser.
2.1.5 Where there are any conflicts between Purchaser’s specifications, data sheets and the
applicable codes and standards, such conflicts shall be promptly referred to Purchaser.
2.1.6 Un-priced bid shall contain all the relevent back up literature and technical catalogues.
2.1.7 Bidder shall furnish with the offer required wiring schematic for analyser system.
2.1.8 Bidder shall furnish general arrangement drawings.
2.1.9 The main functioning of any of the analysers shall not be affected due to the possible
upsets in the blending streams.SHS shall be designed to take care of such upsets.
2.1.10 SHS sytem may be vendor's own design or bought out item. However, the design shall be
certified by a reputed third party (M/s Horbe or equivalent).
2.0 Instructions
Page 9 of 59
2.1.11 The Analyzer systems for blending project are special and hence need expertise and
knowledge for correct selection, design and engineering, supply and maintenance
capability. Vendor shall have adequate experienced manpower to complete the project and
provide after sales service.
2.1.12 Analyser dynamics – A complete dynamics model of the analyzer performance including
analyzer dead time, filter time constant etc. shall be provided to allow the blend software to
run at a frequency faster than the analyzer feedback.
2.1.13 Bidder shall prepare detailed work schedule for engineering, manufacturing, testing and
site activities.
2.1.14 Bidder to facilitate documentation, training,performance guarantee,and warranty of the
complete system.
2.1.15 Any special tools and tackles required for maintenance work shall be included in the
supply. The price of all the special tools and tackles shall be included in the cost of the
respective items.If at any stage it is observed that special tools & tackles are required, the
same shall be provided by the vendor without any cost and time implication.
2.1.16 Vendor shall submit the bill of materials with make/model/part no. details along with the
offer. However it is the responsibility of the vendor to include all the necessary
items/equipments to meet the functional requirement as specified in the MR. BOM
submitted with the offer shall be for information only. The same shall be finalized after
placement of offer during detail engineering.
Sample handling system shall be able to take care of trace water(500-2000 ppm) or caustic
(2500 ppm) which may be present in the header.
As per present practice, Dye (Liquid red 8R-Xylene) is added in the blended header.
Vendor shall ensure that addition of dye shall not affect the performance of the analyser.
Vendor may consider special sampling system, if necessary.
2.1.17 Power points for 110VAC UPS and 415 VAC shall be available in control room and near by
substation. Further distribution of power to analyser shelter shall be under vendor's scope.
2.2 Area Classification
2.2.1 All equipments installed inside or outside the analyser shelter for which the supply is in
bidder scope shall be certified for Zone 1, Gr. IIA/IIB as minimum.
2.2.2 Field mounted analyzers with electrical components, which are to be located in hazardous
area, shall be approved for use in the specified areas by an authorized testing agency.
Vendor shall submit certificate from relevant authority for ex. CMRS, CENELEC, FM,
BASEEFA etc. In addition to the above, certification of CCOE Nagpur, India shall be
obtained as a mandatory requirement.
2.2.3 For all flameproof /intrinsically safe equipment manufactured locally in India, the testing
shall be carried out by any of the approved testing house namely CIMFR, ERTL etc. The
item shall also have valid certification of CCE and manufacturer BIS licence.
2.0 Instructions
Page 10 of 59
2.2.4 As a minimum all the instruments and enclosures in field shall be dust proof and
whetherproof to IP 65 as per IEC 60529/IS-2147
2.3 Warranty
2.3.1 i. Vendor shall be fully responsible for the manufacture in respect of proper design, quality
workmanship and operation of all the equipment, accessories etc. supplied by them for the
complete analyser system.
2.3.2 ii. It shall be obligatory on the part of the vendor to modify and /or replace any hardware
and modify the operating application and diagnostic software free of cost, in case any
malfunction is revealed even during online operation after taking over by owner within the
warranty period. During the warranty period vendor shall visit the site once in quarter and
ensure the calibration/proper functioning of the analyser.
2.3.3 iii. In the event of any malfunction of the analyser system hardware/system software during
warranty period, experienced service engineer shall be made available at site along with
the necessary spares within 48 hours of the receipt of such information from the owner.
2.3.4 iv) Vendor shall provide min. one year of warranty on complete analyser system from the
date of commissioning of the system excluding the consumable items.
2.4 Guaranteed Performance
Vendor to provide guarantee that the analyser result shall be consistent with refinery
laboratory methods used.
Performance Criteria - MS
Analysis Required
Componet Unit Accuracy Euro-IV spec Range
Benzene Vol% ± ½% 1 0-5
Aromatics Vol% ± ½% 35 0-85
Olefins Vol% ± ½% 18-21 0-50
RON Oct No. ± 0.2% 91-95 85-105
MON Oct No. ± 0.3% 81-85 75-100
RVP Kpa ± ½% 60 30-150
E70 Vol% ± 1% 10-45 0-100
E100 Vol% ± 1% 40-70 0-100
E150 Vol% ± 1% 75 0-100
FBP Deg C ± 1% 210 150-270
Sp.Gravity ±1% 0.72-0.775 0.65-0.85
2.0 Instructions
Page 11 of 59
Performance Criteria - HSD
Analysis Required
Componet Unit Accuracy Euro-IV spec Range
Cetane No. ± 0.2% 51 0-65
Cetane ± 0.2% 48 0-65
Index
VOL % 360 Vol% ± 0.5% 95 0-100
DEG
VOL % 370 Vol% ± 0.5% 95 0-100
DEG
Flash Point Deg C ± ½% 35 25-50
Pour Point Deg C ±1% 15 -Summer 0-25
3 - Winter
CFPP * Deg C ±1% 18 -Summer 0-25
6 - Winter
Polycyclic Mass % ± 0.5% 11 5-20
Aromatic
Hydrocarbon
(PAH), max
SP.GRAVIT ±1% 0.820-0.845 0.7-0.85
Y
Kinematic CST ±1% 2-4.5 0.5-6
Viscosity @
40 degC
* CFPP stands for COLD FILTER PLUGGING POINT
2.5 Inspection
2.5.1 FAT
NIR analyser and sulphur analyser being supplied by the vendor shall be subject to
inspection by the purchaser at country of origin. The inspection shall include
calibration,testing of repeatability, training and performance verification.
The QA plan and inspection test plan shall be developed by the vendor and shall be
forwarded to purchaser for approval.
Calibration and performance checking of integrated factory acceptance test of the analyser
system along with analyser shelter shall be witnessed/inspected by the purchaser at the
place of integration.
The system shall only be dispatched after integrated testing is completed to the
satisfaction of the purchaser.
2.5.2 SAT
Vendor shall depute competent and experienced chemometric experts to develop the NIR
model and commission the analyser system.
Vendor shall develop detail SAT procedure for purchaser approval.
2.6 AMC
2.6.1 Vendor shall be capable of providing post warranty comprehensive maintenance service of
the total system i.e. analysers,HVAC and other sub-systems like sample handling system.
2.0 Instructions
Page 12 of 59
2.6.2 Scope shall include supply of maintenance spares,tools & tackles,travel, boarding and
lodging of service engineer.
2.6.3 In the event of any malfunction of the system hardware/ system software, experienced
service engineer shall be made available at site within 8 hours on receipt of such
information from the owner. Owner responsibility is to report the problem with diagnostic
message,if available. However vendor shall be fully responsible to attend rectify the root
cause and the failure withing shortest time. Vendor shall submit field report on attending
any call.
2.6.4 The quotation shall be year-wise for 4 years after warranty period. The price shall remain
firm for 4 years which shall be extendable to another 3 years with reasonable price
negotiation. AMC shall be renewable every year with the above price validity.
2.6.5 A monthly report shall be prepared and submitted regarding the status of the analyser
system.The analyser system availability shall be more than 90%.
2.6.6 Vendor may store the required spares,subject to prior permission, in owner wearhouse at
vendor risk.
2.6.7 Vendor shall quote for remote maintenance facility with modem/router as optional item.
2.6.8 The services under post warranty maintenance agreement, including supply of spare parts
and services shall broadly comprises of
i) Preventive Maintenance during Shutdown
ii) Periodic Maintenance
iii) Emergency Service
iv) Software support
v) Modelling support
2.6.8.1 Preventive Maintenance during Shutdown:
Once in a year during shutdown or planned outage. Owner shall inform vendor one month
in advance. This will involve complete overhaul of the system, inspection of hardware &
software, power supply, sample handling system, cleaning of filters, checking the sample
pumps, cleaning of analyser electronics,PC,calibration etc.
2.6.8.2 Periodic Maintenance:
Site visit of six(6) times in a year (expected total days 24). Schedule of visit to be decided
latter after diccussion between owner and the vendor.It shall involve inspection of general
healthiness of the system,study & advise on daily maintenance. Inspection of all
hardware,software, checking the dignostic messages and resolving problems reported.
2.6.8.3 Software support
Vendor shall upgrade the analyser system software as and when new upgradation is
available with no extra cost.
2.6.8.4 Modelling support
2.0 Instructions
Page 13 of 59
Owner's enginner shall carry out the modelling of the analyser during normal operation of
the system. However ,if required, vendor shall be able to provide necessay support in this
regard.
Owner enginner shall be associated with the vendor during any maintenance work carried
out on the analyser system. Vendor shall provide on the job training to these engineers.
2.7 Spares
2.7.1 Quote consumable spares like fuses, printer cartridges for 6 months for each analyser
system including the analyser shelter.
2.7.2 Supply start up and commissioning spare parts for each analyser system as per vendor
recommendations, as commissioning is vendor responsibility.Additional spare parts, if
required,during start up and commissioning, even though not in listed , shall be supplied by
the vendor without any price implications.
2.7.3 Any special tool required,if any, shall be supplied along with the analyser system.
2.7.4 Quote two years O&M spare part list for analysers and its accessories as per vendor
recommendation. These spares shall be supplied as loose items.
2.8 Training
2.8.1 Vendor shall provide on-site training for the operation and maintenance personnel in two
batches for five days each during and after commissioning of the analyser system.
2.8.2 Vendor shall also arrange training at original manufaturer works during inspection of the
individual analysers.Duration of training shall be min. three days for three persons.
2.8.3 Vendor to quote a lumsum training cost which shall include vendor's travel,
boarding,lodging,telephone etc during on-site training but shall exclude travelling etc cost of
the owner representatives during inspection cum training.
2.9 Delivery
Delivery period shall not exceed 8 months from date of LOI. Part delivery is not acceptable.
However separate delivery of complete MS or complete HSD anlyser system is acceptable.
In case of part delivery of either of MS or HSD system, the site work shall be started
immediately without delay.
2.10 Payment Schedule
10% - After system definition meeting & submission of drg
70% - Delivery of Analyser Sytem at site
10% - Complete system Installation
10% - Commissioning,SAT & System Handing over
2.11 Shipment
Analysers and sample conditioning unit shall be fully assembled, firmly mounted,
completely wired and fully tested before shipment.
2.0 Instructions
Page 14 of 59
All threaded and flanged openings shall be suitably covered to prevent entry of foreign
material.
Glass windows shall be covered with thermo-coal sheet of appropriate thickness to avoid
damage during transport.
Shipping breaks shall be provided in all equipment, which are supplied in installed
conditioninside the analyser shelter. Equipment, which is likely to damage during shipment,
shall be packed separately for shipment.
One copy of the following documents shall be shipped with the Instruments.
1) Installation, operation and maintenance manual, including detailed information.
2) Packing list of all instruments and accessories.
2.0 Instructions
Page 15 of 59
3.0 Introduction
BPCL Mumbai Refinery has taken up various projects to produce Euro IV grade MS and
HSD. As per the GOI policy, Euro III/IV grade transport fuel shall be mandatory in the market
from April 2010
In order to verify the product specifications of the blended MS & HSD in the header, it is
envisaged to install NIR and ASTM analysers in the offsite area near to the respective
headers.
The analyser system shall be a part of the blending automation system (supplied by others)
consisting of blend streams,field instruments,DCS and blend ratio controller(BRC).
This tender describes the complete scope of work for the analyser vendor.
Presently MS blending is carried out in 12" header in PH5 area. The header consists of eight
component streams, a static mixer and a run down line to tank. Analyser sample tapping and
return line shall be made available after the staic mixer. Liquid dye injection is carried out
before the static mixer.
Header pressure is 0.5 to 2.0 Kg/cm2 and temperature 30 to 40 deg C
On-line analysers are required to continuously track the quality of blended product so that
corrective action is taken at the earliest to change the blend ratios to obtain on spec. product.
3.1 Blend composistion for MS
For MS, there are eight streams coming from CCU(2),FCCU,CRU,Naphtha rundown ex plant,
Naptha ex TK403/404, Reformate ex TK 524/529, MTBE ex TK 358.
The anticipated production of total Euro-IV MS shall be 500 TMT/A.
MS Properties to be measured
Analyser Properties
NIR RON,MON,RVP,Aromatic,Olefins,
Benzene, E70,E100,E150,FBP
Sulphur Sulphur
Sp.Gravity Density
3.2 Euro IV MS Component Stream Properties
Parameter CCG Naptha Raffinate HR MTBE
Density, 0.69 0.690-0.740 0.68 0.85 0.7463
gm/cc
Sulphur 110-160 10-50 10 10 100-300
RON 90 70 70 105 105
MON 80 60 60 90 90
Olefins, 45-70 1 0 0.1 1
%vol
Aromatics,% 18 12 3 95 0
vol
Benzene, 0.66-0.84 0.33-0.96 0 0.1 0
%vol
RVP.psi 10 10 6 5 8
REC 70 20 30 30 0 100
3.0 Design Basis-MS
Page 16 of 59
3.3 Blend Automation scheme - MS
Blending of MS component streams shall be carried out in PH/5 area under PH/5 control
room.The existing blend ratio controller (BRC) for MS is in Ph/5 control room installed in the
DCS supplied by M/s Yokogawa.Blending analysers (NIR & ASTM) shall measure the
physical properties of the blend header and provide required data to the BRC to acheive the
optimum control of the blend ratios of various components. Reconfiguration of BRC is not
part of the scope of this tender which is separately being executed.
The blend analyser system shall consists of NIR analyser, ASTM analyser, sulphur analyser
and analyser shelter. Analyser shelter shall be installed near to the header. Sample handling
system shall be installed near to the shelter.The sample intake line to the analyser is taken
from downstream of the static mixer and returns back to the same header.
3.4 Required Product Specification
The supplied system shall not deviate from the specified acceptable limits given in design
basis table below for MS for minimum 90% of the total number of individual batches made for
the period of two months or 6 batches as per BPCL MR's QC laboratory results. The
performance testing of the sample shall be carried out in BPCL Lab as per approved
procedure.
Euro - IV equivalent emmission norms - MS
Sr. No. Property Unit Requirements
Unleaded Unleaded
Regular Premium
1 Colour,Visual Orange Red
2 Density @ 15 degC Kg/m3 720-775 720-775
3 Distillation
a) Recovery upto 70 degC (E70) % vol 10-45 10-45
b) Recovery upto 100 degC (E100) % vol 40-70 40-70
c) Recovery upto 150 degC (E150),min % vol 75 min 75 min
d) Final boiling point (FBP), max degC 210 210
e) Residue, max. volume % vol 2 2
4 Research Octane Number (RON), min Oct No. 91 95
5 Motor Octane Number (MON), min Oct No. 81 85
6 Potential Gum(solvent washed),max mg/100ml 5 5
7 Oxidation stability,min minutes 360 360
8 Sulphur, total,max ppm 50 50
9 Lead content (as Pb),max g/l 0.005 0.005
10 Reid vapour Pressure (RVP),max kPa 60 60
11 Vapur lock index(VLI = 10RVP + 7E70)
(Calculated)
a) Summer,max 750 750
b) Other months,max 950 950
12 Benzene content,max % vol 1 1
13 Copper strip corrosion for 3 hrs@ 50 degC Rating Class 1 Class 1
rating,max
14 Olefin content,max % vol 21 18
15 Aromatic content,max % vol 35 35
3.0 Design Basis-MS
Page 17 of 59
16 Water tolerance of gasoline alcohol blends,
Temp for phase separation,max
Summer degC 10
Winter degC 0
17 Oxygen content,max % mass 2.7 2.7
18 Oxygenates content:
a) Methanol,max % vol 3 3
b) Ethanol,max % vol 5 5
c) iso-propyl alcohol, max % vol 10 10
d) iso-butyl alcohol,max % vol 10 10
e) tertiary-butyl alcohol, max % vol 7 7
f) ethers containing 5 or more carbon atoms % vol 15 15
per molecule, max
g) other oxygenates, max % vol 8 8
3.5 Site Conditions
Ambient temperature (Max/Min): 42 deg C / 12 deg C
Relative Humidity: 100% at 32 deg C(max)
Maximum recorded rainfall : 102 mm in 1 hour
3.0 Design Basis-MS
Page 18 of 59
4.0 Introduction
BPCL Mumbai Refinery has taken up various projects to produce Euro IV grade MS and
HSD. As per the GOI policy, Euro III/IV grade transport fuel shall be mandatory in the market
from April 2010
In order to verify the product specifications of the blended MS & HSD in the header, it is
envisaged to install NIR and ASTM analysers in the offsite area near to the respective
headers.
The analyser system shall be a part of the blending automation system (supplied by others)
consisting of blend streams,field instruments,DCS and blend ratio controller(BRC).
This tender describes the complete scope of work for the analyser vendor.
Presently HSD blending is carried out in 18" header in the offsite area. The header consists
of ten component streams, a static mixer and a run down line to tank. Analyser sample
tapping and return line shall be made available after the staic mixer.
Header pressure is 3.0 to 5.0 Kg/cm2 and temperature 35 to 50 deg C
On-line analysers are required to continuously track the quality of blended product so that
corrective action is taken at the earliest to change the blend ratios to obtain on spec.
product.
4.1 Blend composistion
For HSD, there are ten streams coming from CCU,CDU1,CDU2,CDU3,DHDS,HN,LD,
HD,HK & UCO
The anticipated production of total Euro-IV HSD shall be 700 TMT/A.
HSD Properties to be measured
Analyser Properties
HSD NIR Flash Point,Pour Point,Cold Filter
plugging point (CFPP), Cetane
number, Cetane Index, Distillation -
Rec@360 & 370 degC, Polycyclic
Aromatic HC
Sulphur Sulphur
Sp.Gravity Density
4.0 Design Basis-HSD
Page 19 of 59
4.2 Euro IV HSD Component Stream Properties
Streams Sulfur Density Flash CI Recovery
@ 360
ppmw gmm/cc degC Vol %
GO-1 1150 0.8476 85 51.5 95.0
GO-3 1150 0.8520 105 55.2 100.0
GO-4 1800 0.8566 150 70.0 70.0
LK1 100 0.8000 38 36.0 100.0
HK 560 0.8260 60 44.1 100.0
LGO-2 1100 0.8520 65 51.9 100.0
DHDS 50 0.8350 70.6 51.5 93.0
product
HCU HN 5 0.7400 5 30.0 100.0
LD 10 0.8208 85 54.0 100.0
HD 10 0.8342 85 58.0 98.0
HCU 5 0.7930 50 35.0 100.0
Kero
UCO 25 0.8470 80 65.0 1.8
Splitter 515 0.7578 10 10.0 100.0
Bot
HN-1 18 0.7780 22 25.5 100.0
4.3 Blend Automation scheme-HSD
Blending of HSD component streams shall be carried out in offsite area on Road no. 7
pipetrack under RMP control room. Blending analysers (NIR & ASTM) shall measure the
physical properties of the blend header and provide required data to the BRC (Blend ratio
controller) in RMP control room to acheive the optimum control of the blend ratios of various
components. The blend ratio controller (BRC) for HSD is being procured separately and
shall be installed in RMP control room DCS supplied by M/s Honeywell.
The blend analyser system shall consists of NIR analyser, ASTM analyser, sulphur analyser
and analyser shelter. Analyser shelter shall be installed near to the header. Sample handling
system shall be installed near to the shelter.The sample intake line to the analyser is taken
from downstream of the static mixer and returns back to the same header.
4.4 Required Product Specification
The supplied system shall not deviate from the specified acceptable limits given in design
basis table below for HSD for minimum 90% of the total number of individual batches made
for the period of two months or 6 batches as per BPCL MR's QC laboratory results. The
performance testing of the sample shall be carried out in BPCL Lab as per approved
procedure.
4.0 Design Basis-HSD
Page 20 of 59
Euro - IV equivalent emmission norms - HSD
Sr. No. Property Unit Requirements
1 Ash, max % mass Unleaded Regular
0.001
2 Carbon Residue (Ramsbottom) on 10%
% mass 0.3
residue, max
3 Cetane Number (CN), min 51
4 Cetane Index (CI), min 48
5 Distillation - 95% vol. recovery at degC,
degC 360
max
6 Flash Point- Abel, min degC 35
7 Kinematic Viscosity @40 degC cst 20-45
8 Density @15 degC kg/m3 820-845
9 Total Sulphur, max mg/kg 50
10 Water Content, max mg/kg 200
11 Cold Filter Plugging Point (CFPP)
Summer, max degC 18
Winter, max degC 6
12 Pour Point
Summer, max degC 15
Winter, max degC 3
13 Total Contaminants, max mg/kg 24
14 Oxidation Stability, max g/m3 25
15 Polycyclic Aromatic Hydrocarbon (PAH),
% mass 11
max
16 Lubricity, corrected wear scar diameter
microns 460
(wsd 1,4) @60 degC, max
17 Copper Strip Corrosion for 3 hours @50
rating class-1
degC, max
4.5 Site Conditions
Ambient temperature (Max/Min): 42 deg C / 12 deg C
Relative Humidity: 100% at 32 deg C(max)
Maximum recorded rainfall : 102 mm in 1 hour
4.0 Design Basis-HSD
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5.0 Scope -MS & HSD
5.1 Design,engineering,testing,inspection,supply,integration,installation, pre-
commissioning,commissioning, GTR, warranty,training and maintenance service of analyser
system consisting of NIR analyser and ASTM analysers (Sp.Gravity & Sulphur) along with
sample handling system. The analyzer systems shall be supplied in fully assembled condition
in analyzer shelters with HVAC and other associated accesories. Also one number Lab NIR
analyser shall be supplied along with analyser system for modelling.
5.2 Following facilities are required for the Euro-IV headers,
For MS Header :
1) NIR analyser - one number
2) Sulphur analyser - one number
3) Sp.Gravity analyser - one number
4) Analyser shelter with HVAC - one number
5) Sample handling system and other accessories - lumsum
For HSD header :
1) NIR analyser - one number
2) Sulphur analyser - one number
3) Sp.Gravity analyser - one number
4) Analyser shelter with HVAC - one number
5) Sample handling system and other accessories - lumsum
5.3 Vendor shall carry out the application engineering based on the data supplied by the
purchaser. Purchaser reserves the right to involve their representative, as deemed
necessary by them, in any or all phases of job execution by the vendor.Vendor shall supply
the analyser application software along with driver softwares.
5.4 The analyser shelter along with HVAC shall be installed by the vendor as per the location
drawing to be furnished to the successful bidder.All the associated civil & mechanical jobs
including transportation of shelters,analysers, other materials from wearhouse to respective
site shall be under vendors scope.
5.5 Vendor to design, supply and install the Sample handling system (SHS) along with sample
take-off,transport,return and disposal for the analyser system. Common SHS shall be used
for all the analysers which shall be vendor's responsibility to design. Related civil &
mechanical work for the transportation of sample from take-off point to analyser, installation
of sample pump,filters etc shall be under vendor scope of work including supply of all
tubes,pipes & fittings..
5.6 For MS, one common SHS for NIR,Sulphur and Sp. Gravity shall be considered. For HSD,
sulphur analyser sample handling system shall be designed in such a way that, it can
measure two streams namely DHDS & main HSD header. Vendor shall design the system
such a way that continuous indication is available for both the measurements.
5.0 SOW-MS&HSD
Page 22 of 59
5.7 It shall be bidder's responsibility to connect the analyser vent/drain to safe location.
5.8 Site sample collection,chemometrics model development and tuning of NIR analyser is in
vendor scope.Vendor to build the calibration model for the supplied NIR analyser for a period
of 6 months with the help of Lab NIR analyser, transfer the model to NIR anlyser and make
the analysed data available in DCS.
5.9 Power supply for the HVAC,lighting and analyser shall be provided by the purchaser at
source point. Bidder shall lay cables with cable tray including supply of cables from source
point to analyser shelter. Supply of suitable junction boxes,glands, at both ends shall be
vendors scope of supply. All internal cabling inside the shelter shall be under vendors scope.
Cabling from shelter to DCS panel for the analyser indications including serial communication
shall be under bidder scope.
5.10 Cable entry to shelter shall be through MCT frame complete with blocks.
5.11 All the interconnecting cables, junction box,isolation switch, cable glands etc shall be
supplied by the vendor. All the power supply line shall have isolation switch outside the
analyser shelter which shall be easily accessable.
5.12 Analyser shelter earthing including supply of cables.
5.13 All the piping/tubing including supply, required for the utility connection in analyser shelter
shall be bidder's responsibility. Nearest utility source available in the plant area shall be used
for this purpose.
5.14 Stability and long term validation of the prediction to be carried out with the help of samples
taken from SHS. Bidder shall submit detail methodology for such checking of stability and
performance monitoring.
5.15 Where special test equipment is specified to facilitate calibration, testing and checking of the
analyser, such test equipment shall be made part of the offer. Calibration gas cylinders as
applicable with dual manifold and equipments such as pressure regulators,sensor head
connections, fittings, etc. should be part of the main offer. Cylinder connections shall be
compatible with the local standards. A certificate shall be supplied with every cylinder, stating
composition of the gas contained,the date of filling and the expiry date.
5.16 Analyser system shall be connected with engineering PC installed inside the shelter for data
wearhousing/management,trending,configuration,report generation,tuning,validation etc.
Latest PC along with furniture and operating software shall be part of the supply.
5.17 Shelter shall be fitted with becon light and hooter suitable for area classification which shall
be activated during emergency conditions.
5.18 Vendor shall depute experienced representative well in advance prior to installation of
analyser along with calibration kit and the lab analyser. This is required to collect the blending
sample from site and tune the analyser model.
5.19 Vendor shall have single point responsibility for the site installation,integration,testing,
interconnection, calibration, pre-commissioning and commissioning of complete analyser
system.
5.0 SOW-MS&HSD
Page 23 of 59
5.20 Vendor shall attend the pre-commisioning and commissioning checklist jobs as and when
informed by the purchaser.
5.21 Vendor shall co-ordinate with purchaser for gathering information necessary for generation of
database for building the analyser model and related application.
5.22 Purchaser shall provide aasistance to get any information required from existing system for
the purpose of integrating the analyser system with others.However it shall be vendors
responsibility to co-ordinate the activities.
5.23 Preparation of FAT document and conducting integrated FAT at vendor's works.
5.24 Vendors shall co-ordinate with purchaser during comssioning and SAT activities.
5.25 Packing, forwarding, and transportation of complete system including analysers and analyser
shelter shall be vendors responsibility.
5.26 Purchaser's approval for all drawings and documents is must. However such approval shall
not relieve vendor of his responsibility to meet all requirements of the purchase order,
applicable codes and standards.
5.27 Bidder shall provide necessary certificate for support in prescribed format attached with the
tender.
5.28 Bidder shall provide proposal for post warranty comprehensive AMC facilities for all
analysers, HVAC and other sub-systems.
5.29 Any other job, which is not mentioned/listed here, but required to be carried out for the
satisfactory functioning of the supplied analyzer systems shall be under bidder's
responsibility.
5.0 SOW-MS&HSD
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5.0 SOW-MS&HSD
Page 25 of 59
5.0 SOW-MS&HSD
Page 26 of 59
5.0 SOW-MS&HSD
Page 27 of 59
5.0 SOW-MS&HSD
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Responsibility Chart
Sl.No. Description Vendor BPCL Third Party
1 Design, engineering, manufacturing, factory testing,
integration, calibration, Factory Acceptance Test, supply of √
complete analyser system as per MR including:
i) All Analysers complete with all its accessories √
ii) Sample handling system including sample probe √
iii) Analyser Shelter complete with HVAC, air intake duct,
warning /safety devices like LEL detector, smoke detector,
√
warning panel, annunciator panel, and other accessories/
items / instruments.
iV) Packing, forwarding, transportation, custom clearance,
insurance, storage at site including unloading of all hardware
√
supplied by vendor, keeping under safe custody and shifting
of hardware to control room for complete system.
2 Complete installation material including
i) Sample tubes as applicable between sample take off to
analyser shelter including tube fittings as necessary, sample
√
tube between the analyzer shelter & sample return line
including tube fittings as necessary
ii) Pipe and pipe fittings necessary for sample take-off and
√
return connectivity to purchaser’s system.
(iii) Cables, cable glands and accessories for interconnection
√
of equipments supplied by vendor.
iv) Power distribution boxes, signal junction boxes, serial
√
communication junction boxes as necessary.
(v) Pipes/ tube and pipe/ tube fittings necessary for utility
√
distribution for vendor supplied equipment.
(vi) Galvanised cable trays for cable/ tube routing within
analyzer shelter for the vendor supplied equipment/ items (as √
applicable).
(vii) Galvanised cable trays/trench opening for cable routing
√
from analyzer shelter to control room
(viii All necessary supports for installation of items supplied by
√
vendor including cable trays
(ix) Serial link cable RS 422/ 485 from analyzer shelter to
√
DCS/Blending system
6.0 Resp chart
Page 29 of 59
(x) MCT frame complete with blocks for the cable entry to the
√
analyzer shelter
(xi) Signal cable (4-20 mA signal from analog JB, contacts
signal from the gas detector JB ) √
(Xii) Power cable (415 VAC, 110V AC UPS) between analyzer
√
shelter and control room.
3 Calibration bottles, Combustion gas/ carrier gas cylinders as
√
applicable along with dual manifold and accessories
4 Packing, forwarding and transportation of complete system
√
including analysers and Analyser Shelter
5 Installation of complete system at site including: √
Installation of Analyser Shelter, with HVAC unit, air intake duct
and Analyser’s hook ups with analyzer shelter and
accessories including tubing piping, cabling for cables/ trays √
pipe entry, safety system, junction boxes, power supply
distribution etc.
Modelling for NIR Analyser for 6 months √
Commissioning of analyser system & Documentation √
Training √
6.0 Resp chart
Page 30 of 59
CERTIFICATE FOR LOGISTIC SUPPORT
(TO BE SIGNED BY VENDOR'S PRINCIPAL CORPORATE LEVEL SIGNATORY ON
COMPANY LETTERHEAD)
I, ON BEHALF OF M/s ___________________ CONFIRM THAT THE ONLINE BLENDING
AUTOMATION SYSTEM QUOTED BY M/s ___________________________FOR BPCL
REFINERY BLENDING ANALYSER PROJECT,MUMBAI AGAINST RFQ/PO
________________ SHALL CONTINUE TO BE SUPPORTED BY US AND QUOTED
SYSTEM SHALL NOT BE WITHDRAWN FROM “INDIAN” MARKET AS A MATTER OF
CORPORATE POLICY.
I, FURTHER CONFIRM THAT IN CASE OF PLACEMENT OF ORDER BY M/S BPCL MR
ON M/s ___________________, M/S BPCL MR SHALL BE SUPPORTED IN PROVIDING
BACK-UP ENGINEERING, MAINTENANCE SUPPORT, AND SPARE PART SUPPORT
FOR A PERIOD OF NOT LESS THAN TEN (10) YEARS FROM THE DATE OF
PLACEMENT OF ORDER.
(SIGNATURE WITH SEAL)
7.0 Logistic Support
Page 31 of 59
CERTIFICATE FOR LOGISTIC SUPPORT
(TO BE SIGNED BY VENDOR’S CORPORATE LEVEL SIGNATORY ON COMPANY
LETTERHEAD)
I, ON BEHALF OF M/s._______________________ CONFIRM THAT THE ONLINE
BLENDING AUTOMATION SYSTEM QUOTED BY US FOR BPCL MUMBAI REFINERY
,BLENDING ANALYSER PROJECT,MUMBAI, AGAINST RFQ/PO ________________
SHALL CONTINUE TO BE
SUPPORTED BY US AND OUR PRINCIPAL M/S__________________.
I, FURTHER CONFIRM THAT IN CASE OF PLACEMENT OF ORDER BY M/S BPCL
MR ON US WE SHALL CONTINUE TO SUPPORT M/S BPCL MR IN PROVIDING
BACK-UP ENGINEERING, MAINTENANCE SUPPORT, AND SPARE PART
SUPPORT TO BPCL MR FOR A PERIOD OF NOT LESS THAN TEN (10) YEARS
FROM THE DATE OF PLACEMENT OF ORDER.
(SIGNATURE WITH SEAL)
7.0 Logistic Support
Page 32 of 59
CERTIFICATE FOR LOGISTIC SUPPORT
(TO BE SIGNED BY VENDOR’S CORPORATE LEVEL SIGNATORY ON COMPANY
LETTERHEAD)
Applicable for all major sub-systems bought-out by the vendor
I, ON BEHALF OF M/s CONFIRM THAT THE_______________________QUOTED BY US
THROUGH M/S
____________________FOR BPCL MUMBAI REFINERY BLENDING ANALYSER PROJECT
AGAINST
RFQ/PO ________________ SHALL CONTINUE TO BE SUPPORTED BY US AND OUR
PRINCIPAL M/S__________________.
I, FURTHER CONFIRM THAT IN CASE OF PLACEMENT OF ORDER BY M/S BPCL MR
ON M/S_______________________ WE SHALL CONTINUE TO SUPPORT BPCL MR IN
PROVIDING BACK-UP ENGINEERING, MAINTENANCE SUPPORT, AND SPARE PART
SUPPORT FOR A PERIOD OF NOT LESS THAN TEN (10) YEARS FROM THE DATE OF
PLACEMENT OF ORDER.
(SIGNATURE WITH SEAL)
Note:This form has to be filled separately by each sub vendor for major boughtout items like
analysers and analyzer shelter etc .
7.0 Logistic Support
Page 33 of 59
8. 0 Analyser Specification
8.1 Introduction
8.1.1 This section defines the requirements of online analyser for MS and HSD blending
operation.This specification is the guideline for the selection of suitable analyser
system, however selection and designing of suitable analyser for the process
condition indicated in the specification sheet shall be solely vendor's responsibility.
Any modification required to satisfy the process condition requirements shall be
carried out by the vendor without any price implication.
8.2 General Requirements
8.2.1 Unless otherwise specified in this specification, all equipment, components and
devices shall comply with the latest edition of the following applicable codes and
standards,
1. API 555 Process Analyser
2. AGA 3 American Gas association, Gas measurement committee.
3. ANSI/ASME B16.5 Steel Pipe Flanges and Flanged Fittings.
4. ANSI/ASME B1.20.1 Pipe Threads-General purpose (Inch)
5. ANSI/ASME B16.20 Metallic Gaskets for pipe flanges, ring joint, spiral wound &
Jacketed
6. IEC 60529 Classifications of Degrees of Protection Provided by Enclosures
7. API-MPMS Manual of Petroleum Measurement Standards
8. IEC-801 Electromagnetic compatibility for Industrial process measurement and
control equipment . 9.
IEC-60079 Electrical Apparatus for explosive Gas Atmospheres.
10. IEC-60332-1 Cable Flame Retardancy
11. API-550 Manual of installation of refinery instruments & control systems.
12. BS5308 (Part II) Specification for PVC insulated cables.
13. NFPA National Fire Protection Association
14. NFPA-496(1998) Purged and pressurized enclosures for electrical equipment.
15. ANSI Cl.12.12 Color Coding of Instrument Cables
16. IS-1239 Mild Steel Tubes, Tubular and other wrought steel fittings
17. NEC National Electrical Code
18. NEMA ICS.6 Enclosures for Industrial Controls and Systems
19. BS EN-50054 Electrical Apparatus for the Detection and Measurement of
8.2.2 In general, analyzer and sampling system shall be designed and constructed in
accordance with API-MPMS (relevant portions) or equivalent.
8.2.3 The analysers shall provide continuous, accurate and real time on-line blend
analysis data to host control system to allow the precise control/blend of the
stream components.
8.0 Analyser SpecMS&HSD
Page 34 of 59
8.2.4 The anlyser system shall be reliable and have proven design. Any prototype
design or experimental design shall not be offered.
8.2.5 The analysers shall be microprocessor based.
8.2.6 The analysers shall provide detailed system dignostics, system alarms and SHS
related alarms.All the diagnostics and alarms shall be available through serial link
in the host control system as well as local PC.
8.2.7 Analysers and SHS shall be immune to EM and RF interferences as per IEC
60801 as a minimum.
8.2.8 Analyser electronic memory shall be preferably non volatile. If RAM memory is
offered, then it shall have battery back up and provide additional batteries for each
electronics.
8.2.9 Vendor to ensure that offered analysers work satisfactorily at the ambient site
conditions specified in this MR.In case of ambient site conditions exceeds the
limit,due to failure of HVAC or otherwise,the system shall provide alarms to the
DCS based on which operator may decide to swith-off the analyser.
8.2.10 During abnormal conditions like LEL high and /or oxygen low and/or temperature
high inside the shelter,all the analyser shall automatically shit off.
8.2.11 All the eletrical and electronic enclosures like junction boxes,power distribution
boxes, cable glands,safety devices like LEL/Smoke/Hydrogen detectors, lighting
fixtures,annunciator panels etc whether they are installed inside an analyser
shelter or in any area of the process plot, shall be suitable for installation in Zone 1
hazardous areas, irrespective of the area classification.
8.2.12 During the time when HVAC is working normal and alalyser purge fails, the vendor
shall provide purge failure alarm, When HVAC and purging both fails at the same
time, the power supply to the analyser shall be put-off.
8.2.13 Separate step-down transformers shall not be used to supply power to any of the
apparatus inside the analyser shelter.
8.3 List of analysers
Analyser Properties Qty
MS NIR RON,MON,RVP,Aromatic,Olefins,Be 1
nzene, E70,E150,FBP,VLI,MTBE
MS Sulphur Sulphur 1
MS Sp.Gravity Density 1
HSD NIR Flash Point,Cetane,Distillation, 1
Polycyclic Aromatic HC
HSD Sulphur Sulphur 1
HSD Sp.Gravity Sp.Gravity 1
LAB NIR Spectrum 1
8.0 Analyser SpecMS&HSD
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8.4 Interfacing with DCS
Each analyser communication module shall have following connectivity as min.
a) Modbus link via RS 422/485 with host DCS serial card.
b) OPC
c) Ethernet connectivity with PC
Analyser connection to DCS shall be via MODBUS. All the analysis data along
with diagnostics shall be available via MODBUS.
8.5 NIR Analyser
8.5.1 General Specification
8.5.1.1 The NIR analysers shall be used to measure the poperties in the blended header
for MS & HSD.
8.5.1.2 The analyser shall be microprocessor based,latest and well proven. The
manufacturer/integrator shall be experienced manufacturer of analysers/ supplier.
Analyser spectrometer accuracy shall be min ±0.2 nm, repeatability ±0.01 nm,
-1.
resolution 2.0 nm and reproducibility of 0.007 cm Vendor to provide details on
analyser response/cycle time.
8.5.1.3 NIR analyser shall have min two channels, out of which one shall be used in this
project and the other to be used in future. Analyser performance shall have no
impact with multiple channels. Provision shall be available to switchover to any
other channel in case of such requirement arises.
8.5.1.4 Sample handling system shall be able to take care of any water which may be
present in the stream.Maximum water content in the blended sample lines shall be
maximum 500 ppm. Vendor to design the system in such a way that readings are
not affected by water content. The requirement of sample handling system shall be
decided accordingly.
8.5.1.5 As per present practice Dye is added in the blended header. Vendor shall ensure
that addition of dye shall not affect the performance of the analyser. Vendor may
consider special sampling system, if necessary. Toxicological Information
of the dye used, Xylene
TVL (twa) mg/m3 100
LD50 g/kg
Rat Oral 4.3
Rabbit Dermal 3.16
LC50 (ppm)
(Rat)
Inhalation 5000
8.0 Analyser SpecMS&HSD
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8.5.1.6 The sampling system shall provide facility for for automatic calibration. The
switching system shall initialize double block and bleed valves for system integrity.
8.5.1.7 Provision of automatic collection of sample shall be provided in the sample
handling system.
8.5.1.8 Analyser shall generate alarm whenever the detected sample parameter is
'outside' the measuring range available in the analyser spectra model.
8.5.1.9 Analyser shall generate end of cycle alarm.
8.5.1.10 Fibre optic cable between spectrometer and sample cell shall be redundant. All
the flexible cables shall be protected by the SS flexible conduit.
8.5.1.11 The analyser reading, diagnostics,alarms,error codes and historical data shall be
viewable in this PC. It shall be possible to send historical data to other PC via
existing LAN network.
8.5.1.12 Provide power consumption for each analyser and its accessories.
8.5.2 Hardware requirements
The NIR analyser shall be supplied with all its components, accessories and
software to make the system complete. The system in general shall consist of,
a) NIR Spectrometer
b) Signal conditioning hardware
c) Sample conditioning system
d) Sample probe
e) Analyser sample analysis software
f) Communication module
g) Analyser PC
h) System maintenance tools
8.5.3 Software requirements
a) Vendor shall supply the latest version application software to be installed in the
analyser which shall meet the requirement specified in ASTM D6122.
b) The application software shall save the mesured spectra,generate calibration
model, display trends,alarms,mode, set parameters,data storage and report
generation.
c) Vendor shall also supply chemomatric software for developing or tuning
correlations for specified properties. It shall be possible to add more properties
without any change in the software.
d) Operating system software for PC.
8.5.4 Sample conditioning system
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8.5.4.1 Sample probe is used to extract sample from the line. Its design shall allow
representative sample extraction from the line It shall be possible to remove the
sample probe on-line for cleaning and maintenance.
8.5.4.2 Since the sample is returning to the same temp/pressure vendor shall consider
sample pump while designing the sample conditioning system. Then the pump
shall be located near to the shelter and not close to the take-off point.
8.5.4.3 Sample handling system shall be capable of providing clean and bubble
free.Sample property shall not change during transportation of sample from take-
off point to spectrometer.
8.5.4.4 The sample shall be filtered, pressure and temperature conditioned,degassed and
prepared so as to provide the analyser a uniform sample which is the true
representative of the header liquid.
8.5.4.5 To minimise potential leakages and to keep the fast loop flow as high as possible,
the number of joints shall be minimised, i.e. bends in pipes instead of elbows. The
number of joints in sample transport lines shall be kept to a minimum.
8.5.4.6 The process conditions and the nature of fluid shall be taken into consideration
when selecting materials.AISI 316 stainless steel should be used for all wetted
parts of the sampling system. Sample lines in piping shall adhere to the piping
class.
8.5.4.7 Process shut-off valves for sample line shall be in accordance with the piping
class and should be ball valves.
8.5.4.8 The mechanical design, engineering and construction criteria for sample take-off
connections shall be in accordance with the specified piping class.
8.5.4.9 The sample line shall be such that minimum time-lag is obtained with the sample
transport flow.Vendor to provide calculation of lag time.
8.5.4.10 Waste samples and/or by-products from the process of analysis shall either be
returned to a suitable point in the process or to a suitable utility system.
8.5.4.11 Vendor shall provide suitable arrangement for emergency isolation and shutdown
of the sample line. Necessary alarm shall also be generated in DCS.
8.5.4.12 A detailed drawing shall be prepared showing various components of sample
conditioning system and their piping/tubing hook up arrangement including the
sample return,vent,utilities connection and requirement of heat tracing (i.e steam
tracing) as necessary.
8.5.4.13 Sample transportation time calculations from sample point to analyser.
8.5.5 LAB NIR Analyser
This analyser shall be used for generating the spectrum of the sample and to
develop the model for the field NIR analyser based on the actual sample analysis
at BPCL Lab.
8.0 Analyser SpecMS&HSD
Page 38 of 59
It shall be possible to transfer data from LAB analyser to field NIR analyser.
8.5.6 Model Development
Vendor shall develop the model based on the data collected from the Refinery.
In order to collect data, vendor shall depute their trained person along with a lab
NIR analyzer to site in advance(6 months). Suitable data shall be collected during
this period for various plant operating conditions so that models are developed
and fine tuned to be as good as the near operating conditions.
Calibration model shall be transferred from Lab analyser to NIR analyser without
any modification.
8.6 Sulphur Analyser
8.6.1 The Suplhur analysers shall be used to measure the sulphur content in the
blended header for MS & HSD.
8.6.2 Material of construction of the components in contact with the sample stream shall
be SS 316 except where the stream composition requires other material.
8.6.3 Vendor shall submit a G.A drawing with dimensions for the analyzer cabinet. All
interconnecting wiring shall be colour / number/Ferrule coded and terminal blocks
clearly identified.
8.6.4 In general, analyzer and sampling systems shall be designed and constructed in
inline with API-555 (Relevant portions) and shall correlate to relevant ASTM
methods. The sample handling system shall consist of necessary fast loop to
improve the response time.
8.6.5 Sampling system design shall be such that the sample drawn for analysis is a true
representative of the process stream. Extra care shall be exercised in the selection
of the various components forming the sampling system.
8.6.6 Vendor to furnish the details of the Sample tubing, (The design /sizing, selection of
materials & supply of the entire system is in vendor’s scope.
8.6.7 Consumption figures of electrical power, and other utilities for analyzer system
shall be provided along with quotation.
8.6.8 It is proposed to use separate cables for power supply, 4 - 20 mA DC analog
signal, digital alarm outputs and serial communication. The analyser shall have
sufficient cable entries and unused ones plugged with plugs suitable for the area
classification, for their terminations. In addition, 'IS' and 'non IS' circuits if used
shall be segregated and an 'IS' ground provided inside the Analyser, where
applicable.
8.6.9 Utility other than Instrument air if required is not available at site and should be
taken care by vendor.such as Zero grade air (99.99 % pure)and nitrogen are to be
considered for MS and HSD respectively.
8.0 Analyser SpecMS&HSD
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8.6.10 The analyzer shall provide sulfur measurement corrected for density variations.
The calibration of the analyzer shall include the use of standards covering the
expected variations.
8.6.11 The control unit shall be solid-state programmable type and shall provide the
following, which shall be used to connect to a DCS (YOKOGAWA), which is at a
distance of about 500 mtrs from the analyser shelter.
(a) Isolated analog current output signal (4-20 mA).
(b) A built in high alarm and system fault alarm with SPDT contacts rated 5 AMP at
110 V DC. Necessary electronics shall be provided to give high level dc output
signals for remote transmission over relatively long distances.
(c) RS 485 Modbus.
8.6.12 Calibration gases are required for six months. These calibration gas cylinders shall
be supplied in two sets. One set of these cylinders shall be connected to the
analyser and the other set of cylinder shall be kept in store. Calibration gas
accuracy shall be adequate to demonstrate the repeatibility of the analyser.
8.6.13 Any special instrument/tools needed for maintenance work on the analysers shall
also be included in the scope of supply.
8.6.14 filters shall always be provided in dual configuration . It shall be possible to replace
the filter without up setting the operation of the analyser
8.6.15 sampling system shall include provision for connecting calibration sammple /gases
in AUTO or MANUAL configuration mode.
8.6.16 the maximum height of the analyser cabinet shall be 2100mm.cabinet shall be
suitable for side and bottom entry.
8.6.17 Special filters shall be offered to minimise the interfarenece of background
components which are of least interest in process stream.
8.6.18 The analyser cell and window material shall be suitable for the mentioned process
condition, the cell length shall be selected as per the specified component range.
8.6.19 Vendor to consider proper means to remove the moisture content from the
sample.
8.7 Sp.Gravity Analyser
8.7.1 Sp.Gravity analyzer shall be continuous online density measurement based on
vibrating cylinder principle.
8.7.2 The analyzer-wetted parts shall be selected by the vendor though the approval for
the same is to be taken from BPCL.
8.7.3 The density analyzer shall be provided with a remote display unit & this shall be
located in the analyzer shelter.
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8.7.4 Sample handling system shall be common for all the three analysers(NIR,Sulphur
& Sp. Gravity) .
8.7.5 Out put of the analyser shall be one 4-20 mA and one RS-485 signal serial output.
8.7.6 Respons time shall be 10 seconds to 1minutes depending upon the flow rate and
control pressure.
8.7.7 Configured parameters shall be stored within non-volatile memory which is
retrivible.
8.7.8 Sample input flow , pressure and temperature shall be decided by the vendor.
8.7.9 If the sulphur analyser calls for density input the same to be given as 4-20 mA
signal. In that case one more 4-20 mA out put from the density analyser is
required.
8.8 Calibration
The sampling system shall have automatic calibration facility.
Vendor shall depute its expert engineer to site to collect and analyse the data of
the existing blend properties under different crude scenarios to fine tune the basic
calibration module.
The analyser shall have online calibration/validation facility.
All the necessary calibration kit shall be supplied along with the analyser system.
8.9 PC for the analysers
Latest configuration PC shall be supplied at the time of delivery with following
minimum specifications,
Dual Core Technology with Core 2 Duo Processor
2 GB DDR2 RAM with at least 60% spare memory capacity at full loading
320 GB Hard Disk, 19" High quality TFT Monitor
R/W DVD drive , Front Usb,Lan connectivity, PC Lock
The PC shall be installed inside the analyser shelter with furniture and chair. The
analyser reading, diagnostics,alarms,error codes and historical data shall be
viewable in this PC. It shall be possible to send historical data to other PC via
existing LAN network.
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8.10 Utilities for the analysers
Electric power : For Analyzer : 110 V, AC 50 Hz, Single phase, UPS
For HVAC : 415 V, AC 50 Hz, 3 Phase
For lighting / heaters : 240 V, AC 50 Hz to be distributed from 415 VAC feeder
near shelter
Instrument air : Pressure : 2.0-3.0 kg/cm2g
Temperature : Ambient (Normal)
Vendor shall inform the utility consumption and requirements to the Purchaser at
the time of quotation.
Instrument air shall be available at one point in the plant area. Further distribution
shall be in vendor's scope.
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SULPHUR ANALYSER - EURO - IV MS
GENERAL 1 Tag No. Quantity
2 Service
ANALYSER 3 Type Pulsed UV Fluorescence Detection
4 Test Procedure ASTM D-5453/ISO20846
5 Measuring Range 0-100 ppm
6 Accuracy +/- 1/2%
7 Repeatability As per ASTM D-5453
8 Cycle time As per ASTM D-5454
9 Response Time *
10 Measuring Element Xenon lamp with life two years or more
11 Material of Element SS316 SS316
12 construction-body
Output 4-20 mA and seial communication.
13 Power supply 110 VAC,50 Hz
14 Cable Entry-Output Power Supply 1/2" NPT(F) 1/2" NPT(F)
15 Location Analyser shelter
16 Area Classification *
17 Compliance Requirement As per ASTM D-5454
ACCESSORIES 18 Sample Probe Req. (common for all analysers)
19 Sample Handling Req. (common for all analysers)
20 Fluid State Euro-IV MS Liquid
21 Sample Take off From blend header
22 Pressure-Normal Max. 0.5-2.0 Kg/cm2
23 Temp.-Normal Max. 30-40 deg C
24 Sample return To return header
25 Viscosity @ 40 Sp.Gravity - 720-775 kg/m3
degC - cst
Inst Air Pres-Norm Max. 1.5 kg/cm2 2.5 kg/cm2
Sulphur wt% -
Make Model * *
26 Flash Point Pour Point - -
Note: * = Vendor to specify
8.A Sulphur&Sp.Gravity spec-MS
Page 43 of 59
DENSITY ANALYSER - EURO - IV MS
GENERAL 1 Tag No. Quantity
2 Service
ANALYSER 3 Type Density
4 Test Procedure ASTM
5 Measuring Range 0-1000 Kg/m3
6 Accuracy +/- 0.1% of span
7 Repeatability +/- 0.1% of span
8 Cycle time continuous
9 Response Time *
10 Measuring Element Vibrating cylinder/tube
11 Material of Element Ni-SPAN-C Ni-SPAN-C
12 construction-body
Output 4-20 mA and seial RS485
13 Power supply communication.
110 VAC,50 Hz
14 Cable Entry-Output Power Supply 1/2" NPT(F) 1/2" NPT(F)
15 Location Analyser shelter
16 Area Classification *
17 Compliance Requirement As per ASTM method
ACCESSORIES 18 Sample Probe Req. (common for all analysers)
19 Sample Handling Req. (common for all analysers)
20 Fluid State Euro-IV MS Liquid
21 Sample Take off From blend header
22 Pressure-Normal Max. 0.5-2.0 Kg/cm2
23 Temp.-Normal Max. 30-40 deg C
24 Sample return To return header
25 Viscosity @ 40 Sp.Gravity - 720-775 kg/m3
degC - cst
Inst Air Pres-Norm Max. 1.5 kg/cm2 2.5 kg/cm2
Sulphur wt% -
Make Model * *
26 Flash Point Pour Point - -
Note: * = Vendor to specify
8.A Sulphur&Sp.Gravity spec-MS
Page 44 of 59
SULPHUR ANALYSER - EURO - IV HSD
GENERAL 1 Tag No. Quantity
2 Service
ANALYSER 3 Type Pulsed UV Fluorescence Detection
4 Test Procedure ASTM D-5453/ISO20846
5 Measuring Range 0-100 ppm
6 Accuracy +/- 1/2%
7 Repeatability As per ASTM D-5453
8 Cycle time As per ASTM D-5454
9 Response Time *
10 Measuring Element Xenon lamp with life two years or more
11 Material of Element SS316 SS316
12 construction-body
Output 4-20 mA and seial communication.
13 Power supply 110 VAC,50 Hz
14 Cable Entry-Output Power Supply 1/2" NPT(F) 1/2" NPT(F)
15 Location Analyser shelter
16 Area Classification *
17 Compliance Requirement As per ASTM D-5454
ACCESSORIES 18 Sample Probe Req. (common for all analysers)
19 Sample Handling Req. (common for all analysers)
20 Fluid State Euro-IV HSD Liquid
21 Sample Take off From blend header
22 Pressure-Normal Max. 3.0-5.0 Kg/cm2
23 Temp.-Normal Max. 35-50 deg C
24 Sample return To return header
25 Viscosity @ 40 Sp.Gravity 2-4.5 cst 820-845 kg/m3
26 degC - cst
Flash Point Pour Point - -
Inst Air Pres-Norm Max. 3.0 kg/cm2 4.5 kg/cm2
Sulphur wt% 50 ppm
Make Model * *
NOTE: * = Vendor to prodide the data.
8.B Sulphur&Sp.Gravity spec-HSD
Page 45 of 59
DENSITY ANALYSER - EURO - IV HSD
GENERAL 1 Tag No. Quantity
2 Service
ANALYSER 3 Type Density
4 Test Procedure ASTM
5 Measuring Range 0-1000 Kg/m3
6 Accuracy +/- 0.1% of span
7 Repeatability +/- 0.1% of span
8 Cycle time continuous
9 Response Time *
10 Measuring Element Vibrating cylinder/tube
11 Material of Element Ni-SPAN-C Ni-SPAN-C
12 construction-body
Output 4-20 mA and seial RS485 communication.
13 Power supply 110 VAC,50 Hz
14 Cable Entry-Output Power Supply 1/2" NPT(F) 1/2" NPT(F)
15 Location Analyser shelter
16 Area Classification *
17 Compliance Requirement As per ASTM method
ACCESSORIES 18 Sample Probe Req. (common for all analysers)
19 Sample Handling Req. (common for all analysers)
20 Fluid State Euro-IV MS Liquid
21 Sample Take off From blend header
22 Pressure-Normal Max. 3.0-5.0 Kg/cm2
23 Temp.-Normal Max. 35-50 deg C
24 Sample return To return header
25 Viscosity @ 40 Sp.Gravity 2-4.5 cst 820-845 kg/m3
degC - cst
Inst Air Pres-Norm Max. 3.0 kg/cm2 4.5 kg/cm2
Sulphur wt% -
Make Model * *
26 Flash Point Pour Point 25-125 deg C -
Note: * = Vendor to specify
8.B Sulphur&Sp.Gravity spec-HSD
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9.0 Analyser Shelter Specification
9.1 General Requirements
9.1.1 The main purpose of an analyser house is to ensure continuity of operation of
analyser systems at a specified rate of reliability by providing a suitable operating
environment for analysers which cannot otherwise operate properly, i.e. if exposed
to outdoor, ambient conditions.
9.1.2 An analyser house typically comprises:
• the analyser room, which shall have forced ventilation to make it by design a
normally non-hazardous area, and
• sample handling area(s) on the outside of the longest walls. These areas shall be
designed so that the area classification shall not become more hazardous.
9.1.3 Vendor is required to design, selection of material,painting,testing,inspection and
shipping of analyser shelter with HVAC system complete with accessories, which
are required for housing industrial process analysers and their associated
piping,wiring and auxiliary instruments.
9.1.4 Unless otherwise mentioned vendor shall follow the latest edition of the following
standards,
9.1.5 ANSI/ASME B16.5 Steel Pipe Flanges and Flanged Fittings.
ANSI/ASME B1.20.1 Pipe Threads-General purpose (Inch)
ANSI/ASME B16.20 Metallic Gaskets for pipe flanges, ring joint, spiral wound &
Jacketed
9.1.6 IEC 60529 Classifications of Degrees of Protection Provided by Enclosures
EN 10204 Inspection of documents for metallic products
IEC-61000-4-X Electromagnetic compatibility for Industrial process measurement
and control equipment
IEC/TR 60079-16 for the procedures to achieve a safe area inside the analyser
house that satisfies IP 15;
9.1.7 IEC-60332-1 Cable Flame Retardancy
IEC 61285 Industrial Process control - Safety of analyser houses.
IS - 13947 Specification for low voltage switch gears and control gears
IS-2148 Electrical apparatus for Explosive gas atmospheres-Flame proof
9.1.8 enclosures.
ANSI Cl.12.12 Color Coding of Instrument Cables
IS-1239 Mild Steel Tubes, Tubular and other wrought steel fittings
NEMA ICS.6 Enclosures for Industrial Controls and Systems
BS EN-50054 Electrical Apparatus for the Detection and Measurement of
Combustible Gases – General Requirements and Test Methods.
9.1.9 The analyzer shelter shall be fully prefabricated, assembled, tested and shall be
supplied as ready-to-install at project site with all items including analyzers and their
accessories duly mounted, wired, tube and tested before shipment.
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9.1.10 The arrangement of equipments shall be such that it provides enough access to
front/back/sides of the equipments as necessary during normal operation as well as
during startup and maintenance. Sufficient space shall be provided for work bench,
signal and power cables entries and routing, power sockets utility, supplies,
auxiliary and control equipments. Suitable arrangements shall also be made for
locating devices like recorder, portable printers etc, near each equipment.
9.1.11 The housing shall be provided with fluorescent lamps to provide an illumination of
300 or more at the floor level, convenient for reading and carrying out maintenance
and adjustments on the instruments / equipments. Fluorescent lamps shall also be
provided outside of the analyzer shelter for carrying out the repair / adjustments on
the equipments mounted on outside of the analyzer shelters e.g. sample
conditioning systems etc.
9.1.12 Shelters shall be equipped with all safety measures like panic bar at the doors.
Emergency alarm push buttons. LEL gas (hydrocarbon) detectors, Fire detection
system, warning panels,Fire extinguishers, wash basin etc. LEL detectors shall be
installed inside and outside/around shelter with interconnection to DCS. The control
and safe guarding system shall be stand alone mounted inside the shelter. The LEL
detector shall be IR type, H2 shall be catalytic type and electrochemical for H2S
detector shall be used.
9.1.13 Shelter shall be provided with ventilation and air conditioning to maintain the
temperature and humidity suitable for the analyzers stable performance and human
comfort.
9.1.14 All electrical equipments, fittings, fixtures shall be Flame proof suitable for
hazardous area
9.1.15 classification. cables shall be flame retardant low smoke cables as minimum.
All instruments
9.1.16 Analyzer shelter / room shall be sized considering 25% additional spare space for
future Vendor to consider all other factors within the Analyzer / Room like A.C.
System load, power load etc considering for analyzer to be installed.
9.1.17 All furniture required for installation of vendor supplied equipment shall be supplied
by vendor.
9.2 Design & Construction
9.2.1 The shelter shall be constructed using materials capable of satisfying all the
functional requirements and shall not be cause of any safety hazards at any point of
time.
9.2.2 Design and construction of the shelter shall be self supporting type and shall be
sized to house required analyzers sample conditioning system and other
accessories. Shelters shall also be provided with suitable transportation
arrangement.
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9.2.3 The base structure of the shelter shall be constructed using suitable size ‘I’ beams,
channels, angles, welded properly and adequately. All structural members shall be
sized to ensure structural rigidity and to prevent deformation during dragging, lifting,
loading and unloading operation of the shelter.
9.2.4 The floor shall be fabricated from anti-slip and non-corrosive Aluminum plates as a
minimum,strong enough to withstand load of all equipments and atleast 10
maintenance personal also unaffected during transportation and various other
obvious forces and shall be sealed to prevent any loss of ventilation pressure.
9.2.5 External sidewalls shall be ribbed interlocking Stainless Steel sheet of thickness
2mm and internal walls shall be Stainless Steel sheet of thickness 2 mm. The walls
of the shelter shall be strong enough to take load of the rack mounted analyzers,
related sample conditioning system and associated accessories.
9.2.6 The shelter roof shall be capable of supporting the combined weight of atleast 4
men without permanent deformation and shall be sealed properly to prevent loss of
ventilation pressure and entry of rain and jet water.
9.2.7 Lifting of the complete shelter along with all analyzers, sample conditioning systems
and associated accessories mounted in it shall be assured by means of suitably
designed lifting lugs.
9.2.8 The walls and roof shall be insulated by using rock wool of high density and low
thermal coefficient, thickness approximately 100 mm commensurate with the HVAC
design. Higher insulation thickness, if necessary shall be provided by vendor.
9.2.9 Door dimensions shall allow free access for analysers and analyser racks and shall
be
9.2.10 Door sills shall be flush with the floor to prevent tripping hazards, and to allow
hydrocarbon spills, if any, to be flushed to the drain pit outside.
9.2.11 The shelter shall be provided with a main door and an emergency door opposite to
main door. Both the doors shall be opening outwards, provided with wire reinforced
safety glass window, automatic spring door closer opening by simple push, fitted
with panic hardware for use incase of emergency. The main door shall be provided
with outside pad lock holes. Warning light shall be provided at both the Main door
and the emergency door indicating the Hydro Carbon presence within the shelter.
9.2.12 Extension roof (overhang) made of stainless steel sheet shall be provided along all
the wall of the shelter over the sampling system for protection of the sampling
system and maintenance personal from the direct weather conditions. The
extension roof shall be over hanged atleast 1.5 mtr outside the analyzer shelter.
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9.2.13 A name plate of SS 316 with the analyzer shelter number shall be fixed near the
main floor and emergency door. Tag numbers of the analyzers shall be fixed near
the main door. Tag numbers of each analyzers and all sampling system shall be
fixed near the respective items. All inlet and outlet tubes / pipes shall be provided
with tag number & proper identification numbers engraved in the stainless steel
plate. All shall be wires / leads shall be identified inside distribution devices
9.2.14 Provisionelectrical made for keeping all fast loop devices,the junction box /
outside the shelter. A suitable restriction orifice shall be provided in each sample
line to limit the sample flow not exceeding thrice the normal flow in the event of tube
rupture / opening of the tube down the line.
9.2.15 The equipments which are not suitable for inside shelter area in case of ventillation
failure and gas detection shall be de-energised.
9.3 Safety Measures
9.3.1 Gas detection,fire detection and oxygen deficiency detection shall be provided. A
PLC shall be provided to execute safety logics. PLC shall have redundant CPU.
PLC shall be mounted in Ex-proof enclosure. PLC fault shall be annunciated.
9.3.2 The following safety related local alarms/indicators shall be generated and
displayed:
9.3.3 a) Ventillation failure
b) Flammable Gas detected(>20%)
c) Fire detected
d) Oxygen Deficiency
e) Gas detection instrument fault
f) Manual Emergency (Panic)
9.3.4 These alarms shall be provided at the location,
9.3.5 a) inside shelter annunciator panel
b) Near shelter doors on warning panel
c) Potential free contact to control room DCS.
9.4 Tubing/Wiring & Chemical Filters
9.4.1 All safety valve outlets shall be terminated in a common header of 2” NB schedule
80 SS304 pipe and single outlet shall be provided outside the shelter with one non-
return and lock open type 2” ball valve, Similarly all vents to atmosphere shall be
terminated in a similar 2” NB Sch 80 SS 304 pipe and single outlet shall be
provided with non-reurn valve (if required) and Lock open type 2” ball valve.
9.4.2 All atmospheric gas outlet line shall be equipped with protection from climatic
condition
9.4.3 All tubing work shall be done by using ¼” OD SS tube and Swagelok/Parker
flareless, double compression type fittings.
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9.4.4 All wiring / tubing and all other erection work shall be done in accordance to API RP
551-5
9.4.5 All cable entries / outlets in the junction boxes / distribution boxes etc and to the
analyzer shall be provided with double compression type certified flame proof
cables glands suitable for the indicated hazardous area. The material of the same
shall be Nickel plated brass. The junction box shall be of die cast aluminum &
suitable for Zone 1 IIC.
9.4.6 All cabling wiring works inside the shelter shall be in accordance with the
international standard / practice being practiced in industry for similar application,
however the cables shall be armored as minimum.
9.4.7 Dimensions and layout of each shelter offered shall be provided by vendor for
Owner review before taking up for fabrication.
9.4.8 The design, selection, manufacture and supply of chemical air filters for the duty
specified shall be in vendor’s scope
9.4.9 Chemical air filters are required to be installed in fresh air circuit. The following
conditions shall be considered as a minimum for outside ambient air:
GAS OUTSIDE (g/m3) INSIDE
Yearly Average Max.(8hr.average) (PPM by Vol.)
SO2 / SO3 100 13000 < 0.010
Nox 100 9500 <0.05
H2S Traces 13900 <0.003
Cl2* Traces 2900 <0.001
NH3* Traces Traces <0.5
SPM 400 15000 <200 g/m3
RSPM 250 - <100 g/m3
* Normally not present in Refinery emmissions.
9.4.10 Chemical filters shall be selected on the basis of Refinery environment as given in
Max.(8 hrs average) column. Chemocal filters shall have a min. life of 2 years. The
supplier shall furnish the calculations and nomographs etc in support of the
chemical media life.
9.4.11 Chemical filters shall be flanged at inlet & outlet with inspection cover having easy
access for maintenance.
9.4.12 Chemical filters shall be three stages having one/two modules of Puracarb or
equivalent media and other metal modules containing chemisorbant or equivalent
media.Unit shall be suitable for outdoor installation & continuous operation. Unit
shall be provided with indication of differential pressure across the filters.
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9.4.13 The pre-filters at inlet & fine filters at outlet shall be capable of removing dust
particles of 10 microns with 90% efficiency & of 1+ microns with minimum 90%
efficiency respectively.
9.5 HVAC System
9.5.1 The purpose of ventilation and air conditioning is to provide:
• a safe operating environment for equipment and personnel;
• the required climatic conditions for optimal equipment performance;
• a sustainable climate for the comfort of personnel in line with local regulations
and/or practice.
9.5.2 To meet the above objective, vendor shall
design,engineer,procure,manufacture,shop-paint, inspect & test at works,transport
and commission the HVAC system for analyser shelter complete with all
accessories as required.
9.5.3 Two HVAC on time sharing basis should be provided, both the HVAC should be
independent with individual compressor and blower system. HVAC shall be
interlocked to start automatically incase of failure of another.
9.5.4 As far as practicable, the flow through the analyser house should be uniform and
shall not leave any stagnant pocket of air where flammable mixtures may develop.
9.5.5 Fresh air shall be taken from a safe area. The air intake system shall typically
consists of air blower with drive,back draft dampers, cleanable chemical filters
(95%, 5 micron),bird screen etc.The size of the filter shall be sufficient to require
cleaning not more than once per fortnight under the maximum dust conditions
expected.
9.5.6 Analyzer shelter shall be designed as per NFPA 496 standards. Pressurisation and
Ventilation blowers / ducts shall be capable of maintaining a positive constant
pressure of not less than 5 mm water column in spite a frequent door opening
closing so that hazardous gas from outside entry is prevented. Provision shall be
made for positive sealing of cable and sample entry points and maintaining air flow
sufficiently large to carry away hazardous gases from leakages.Loss of
pressurisation shall initiate an audio-visual alarm.
9.5.7 The ducting shall be completely leak proof while passing through hazardous area.
The ducting material shall be corrosion resistant, e.g. hot-dip galvanized steel.
9.5.8 The ventilation air shall escape from the analyser house through vertical ducts at
two opposite corners of the analyser house, via louvres with adjustable openings.
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9.5.9 The blower fans blade shall be made of no sparking material and motors used shall
be certified from statutory body as suitable for the hazardous area classification.
9.5.10 Fresh air makeup requirements shall be calculated by the vendor based on the
requirements as specified in NFPA 496(latest edition). During release of flammable
gas or vapour either in normal operation or under abnormal condition, protection
shall be provided to dilute the flammable mixture less than 25% of its lower
flammable limit of any individual gas or vapour. However, min 5 air changes shall
be provided as per IEC 61285 for ventilation purpose.
9.5.11 Analyzer shelter shall be equipped with heating and air conditioning system to keep
the inside atmosphere of the shelter at a comparatively constant temperature of
24ºC ± 3ºC with humidity 35-70 % to obtain repeatability and reliability of the
analysers and also a comfortable working environment for workman.
9.5.12 Inside temperature rise shall be limited to 5 deg C above ambient, by fresh air from
pressurisation system, in case of failure of AC. Vendor shall confirm that all
analysers installed inside the shelter are suitable for continuous operation in this
temperature (Max. ambient + 5 deg C.)
9.5.13 Vendor shall provide high temperature alarm inside the shelter and in the control
room. The power to analyser shall be cut-off in case of high temperature.
9.5.14 Vendor shall provide heat load calculation for owner's review. Heat load on account
of fresh iar shall be considered while deciding the capacity of the air conditioner.
9.5.15 The analyzer shelter manufacturer shall submit a certificate from the statutory
authority stating that the housing design and construction meet in general the
requirement of NFPA 496.
9.5.16 The shelter manufacturer shall ensure that all electrical items used for shelter are
suitable for electrical area classification. Certificate from statutory authority shall be
furnished showing the suitability of every electrical items used. HVAC shall be
certified for Zone 1 IIC T3.
9.6 Power Supply
9.6.1 Electrical facilities inside the building should have a type of protection suitable for a
Zone 1 hazardous area unless an alternative is specified by the owner.
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9.6.2 Following power supply shall be made available at the source point. Vendor shall
arrange to lay cable from source point to analyser shelter.
Item Voltage Location
For Analysers - 110 VAC 50 Hz Single phase UPS - Control room
For HVAC - 415 VAC 50 Hz Three phase with - Switch house
For lighting / heaters - 240 VAC 50 Hz Single Phase - At Shelter by
vendor
9.6.3 Supply voltage fluctuation of +/- 10% and supply frequency fluctuation of +/- 3 Hz
from the specified value, shall not affect the system performance.
9.6.4 The size of the cable shall be decided by the vendor based on the load and the
distance. Laying of cable and supply of cable glands on both end shall be under
vendor scope.
9.6.5 Main switches all three power supplies shall be mounted outside the analyser
shelter which shall be weather proof to IP66 and explosion proof suitable for the
specific hazardous area classification.Individual switches shall be provided for each
instrument for independent de-energisation of the items.
9.6.6 The three power supply cables will be terminated after the main switches inside the
shelter in different junction boxes with terminals and switch fuse units for power
distribution to the relevant equipments / items. Individual switches shall be provided
for each instrument for independent designation of the items. “Power supply on”
indication shall be provided on the main power supply line to each analyzer on
PDB. All cables to/from the shelter shall be through Multi cable transit (MCT) blocks
to ensure gas tightness of the shelter.
Unused entries in the MCT shall be closed with dummy blocks. Vendor shall be
responsible for sizing the MCT. Vendor to note that only 50% of MCT block capacity
shall be utilized while sizing. A minimum size of RGB 6+6 X 6 shall be considered
by the vendor.
9.6.7 Two power sockets of 110 VAC 50 Hz and 230 VAC 50 Hz supply for electrical
tools or test equipments shall be provided at two opposite corners of each shelter.
9.7 Earthing
9.7.1 For analyser shelters, earth pit, interconnecting grounding cables, and other related
accessories required for barrier earth and system earth shall be in vendor’s scope
of supply and installation. Vendor shall size the earth cables based on fault levels
and maximum allowable resistance.
9.7.2 An earth-loop of 70 mm2 earthing conductors shall be installed inside the analyser
house and shall be connected to the plant earth ring.
9.7.3 The earth-bar of the switchboard, unless it is installed elsewhere (e.g. in the
nearest substation/CCR), shall be bonded to the earth-loop and the earth bar of the
supply substation.
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9.8 Utilities
9.8.1 Available Instrument air at site:
Pressure : 2.0 ~ 3.0 Kg/cm2g
Temperature : Ambient (Normal)
Dew point : -40 degC at atmospheric pressure
9.8.2 Vendor shall inform any other utilities required with required Pressure & temp.
9.9 Lighting
9.9.1 Power supply for lighting insider and outside the shelter shall be 240 V 50 Hz.
9.9.2 Internal lighting shall be provided by fluorescent tube lamps to provide in
illumination of 300 to 400 lux minimum at all places on the floor.
9.9.3 External lighting shall be under overhands to provide illumination sufficient for
maintenance / repair work.
9.9.4 Lighting fixtures inside and outside the shelter shall be suitable to the electrical area
classification given above.
9.9.5 Lighting switch shall be provided outside the shelter near to the main door.
9.10 Foundation
All the civil work releted to installation of shelter & HVAC shall be carried out by the
vendor as per best practices in the industry. All the installation drwg shall require
owner approvals.
9.11 Painting
Non SS parts of the analyzer shelter shall be treated and painted as follows:
a) All surfaces including structures shall be sand blasted and grinded smooth and
free
of scale, rust etc.
b) Chemical treatment shall be done to remove rust, oil, entrapped impurities and
other foreign materials.
9.12 Name Plate
9.12.1 Each analyser shelter shall have a stainless steel nameplate attached firmly to it at
a visible
place near the main and Emergency doors, furnishing the following information:
a) Tag number as per purchaser's data sheet.
b) Manufacturer’s serial number (If any).
c) Manufacturer's name/trade mark.
d) Area classification in which the shelter can be used.
e) Size of shelter.
9.0 Shelter&HVAC
Page 55 of 59
9.12.2 Accessory equipment such as probes, sample conditioning elements, and other
items which cannot be mounted on the Analyzer but are furnished separately shall
be tagged with a 25mm (1 in.) diameter stainless steel tag on which is stenciled the
instrument tag number. The tag shall be attached with stainless steel wire. Only one
tag is required for each individual assembly.
9.13 Inspection & Testing
Vendor shall submit the following test certificates and test reports for owner's
review:
a) Material test certificate as per clause 3.1B of EN 10204 for flanges, fittings and
sheet steel.
b) Certificate of radiography/ X-ray for header welded joints. Dye penetration test
certificate shall be provided for joints where radiography/ X-ray is not possible.
c) Dimensional verification certificate as per clause 4.3 of this specification.
d) Hydrostatic testing of all headers.
e) Leakage and continuity testing.
f) Power Distribution and wiring check
g) Functional check for HVAC
h) Type test certificates
9.0 Shelter&HVAC
Page 56 of 59
Vendor Data Requirement
Sl No Name of Drg/Doc With the For As-Built
offer Approval
1 Bill of materials with make/model/part no. √ √ √
2 Analyser shelter Layout √ √ √
3 Sampling system general arrangement drawing √ √
4 Analyser/Rack general arrangement Drawing √ √
5 Detailed Specification for: √ √ √
-NIR Analyser
- Sulphur Analyser
-Density Analyser
6 Tubing/Piping detail for each analyser √ √
7 Transportation time calculations for each √ √
8 analyser
Overall configuration Diagram √ √
9 Utility Consumption Details √ √ √
10 Power Supply Distribution √ √
11 Interconnecting Cable Details √ √
12 System Grounding Details √ √
13 Factory Testing and Acceptance procedure √
14 (FAT) and Site Acceptance Test (SAT)
Wiring Diagram √ √
15 Special Software Details Including NIR Analyser √
16 Programming
Details of interface with DCS √ √
17 Complete catalogues with part list for all √
18 contractor supplied instruments, control etc.
Installation, operation and maintenance √
manuals
19 Spares summary √ √
- Commissioning
- 2 years Spares
20 Special test equipment required for calibration, √ √
maintenance etc.
21 Sub Vendor List √ √ √
22 Calibration Cylinder Details √
23 Statutory Body Certification for Hazardous Area √
Note:Any drawing/document not indicated in the list above but required during
erection, commissioning or for reconfiguration of the system shall also be
supplied by the vendor
10.0 Vendor data req
Page 57 of 59
BOM/Price Schedule for Blending analyser - MS
Items Qty Unit Price in Rs. Total (Rs.)
NIR Analyser-MS 1 No
Sulphur Analyser 1 No
Sp.Gravity Analyser 1 No
Sample handling system 1 Set
Analyser Shelter with HVAC 1 Set
Lab Analyser 1 No
Software 1 Set
PC with furniture 1 Set
Calibration Kit 1 Set
start up & commissioning spares 1 Set
2 yrs O&M spares,
NIR Analyser-MS 1 Set
Sp.Gravity Analyser 1 Set
Sulphur Analyser 1 Set
Analyser Shelter with HVAC 1 Set
Installation Charges Lumsum
Commissioning Charges Lumsum
Training Lumsum
Modelling Service (6 Months) Lumsum
AMC - 1 st Year Lumsum
AMC - 2 nd Year Lumsum
AMC - 3 rd Year Lumsum
AMC - 4 th Year Lumsum
Total
Note: In addition to the above mentioned BOM, if any other hardware/
software/ services are required to fulfill the system specification as per this
tender, it is vendor responsibility to include the same.
11.A Price schedule-MS
Page 58 of 59
Price Schedule for Blending analyser - HSD
Items Qty Unit Price in Rs. Total (Rs.)
NIR Analyser-HSD 1 No
Sulphur Analyser 1 No
Sp.Gravity Analyser 1 No
Sample handling system 1 Set
Analyser Shelter with HVAC 1 Set
Lab Analyser 1 No
Software 1 Set
PC with furniture 1 Set
Calibration Kit 1 Set
start up & commissioning spares 1 Set
2 yrs O&M spares,
NIR Analyser-MS 1 Set
Sp.Gravity Analyser 1 Set
Sulphur Analyser 1 Set
Analyser Shelter with HVAC 1 Set
Installation Charges Lumsum
Commissioning Charges Lumsum
Training Lumsum
Modelling Service (6 Months) Lumsum
AMC - 1 st Year Lumsum
AMC - 2 nd Year Lumsum
AMC - 3 rd Year Lumsum
AMC - 4 th Year Lumsum
Total
Note: In addition to the above mentioned BOM, if any other hardware/
software/ services are required to fulfill the system specification as per this
tender, it is vendor responsibility to include the same.
11.B Price schedule-HSD
Page 59 of 59
Euro-IV Vendor List for Blending Analyser System
A. NIR Analyser E HVAC
1 Guided Wave 1 Chemtrol
2 Yokogawa 2 Stolway Pvt. Ltd., Australia
3 ABB 3 Marc Climatic Control,USA
4 Hamilton sunstrand 4 Scientific Systems,USA
B Sulphur Analyser 5 Kelvin Trust Ltd,USA
1 Thermo Fisher Scientific 6 Shultz,Australia
2 Asoma F Sample Handling
3 Meterex 1 Hobre
4 Antak 2 Chemtrol
C Sp. Gravity Analyser G Chemical Filters
1 Sarasota 1 Puroletor,UK
2 Solatron 2 Circulae Air,Canada
3 Thermo Fisher Scientific H MCT Block
D Analyser Shelter 1 Bratterberg
1 Chemtrols 2 Roxtex
2 ABB I Tube fitting
3 Any Other vendor with requisite 1 Swagelock
PTR for similar system
2 Parker
12 vendor list
