PLC based Process Automation Systems at Second Launch Pad … · 2018. 2. 27. · Automation System - 2: ... 11.11 Control Network, Operator Network and SCADA Network .. 84 11.12

Satish Dhawan Space Center – SDSC SHAR

Indian Space Research Organization (ISRO)

Tender Specification PLC based Process Automation Systems at Second Launch Pad

Indent Ref Number: SHAR/LS/2018007697

SSaattiisshh DDhhaawwaann SSppaaccee CCeenntteerr –– SSDDSSCC SSHHAARR,, IInnddiiaann SSppaaccee RReesseeaarrcchh OOrrggaanniizzaattiioonn ((IISSRROO))

TTeennddeerr SSppeecciiffiiccaattiioonn ffoorr PPLLCC bbaasseedd PPrroocceessss AAuuttoommaattiioonn SSyysstteemmss aatt SSeeccoonndd LLaauunncchh PPaadd



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1 Introduction ........................................................................... 1

1.1 List of Abbreviations: ........................................................... 1

1.2 Terms and Conditions .......................................................... 3

2 Spares ................................................................................ 23

3 SDSC SHAR deliverables at Site ................................................... 23

4 Scope of work ....................................................................... 24

5 Detailed engineering ............................................................... 26

6 Non-Comprehensive AMC for the systems ...................................... 27

6.1 Terms & Conditions ........................................................... 27

6.2 Frequency of visits ............................................................ 29

6.3 Payment Conditions .......................................................... 29

6.4 Scope of Work for AMC ....................................................... 29

6.5 Breakdown maintenance ..................................................... 32

7 Overview of the Proposed System Requirements .............................. 33

7.2 List of major items / sub systems in Automation System -1 and Automation System - 2: ...................................................... 38

8 Overall Configuration of the Automation systems ............................. 42

8.1 Geographical Distribution of Automation System: ....................... 42

8.2 Proposed Configurations & Connectivity Diagram: ....................... 45

8.3 Overall System Specification of Automation System – 1 and Automation System – 2 and Automation System- 3 ..................................... 46



9 Controllers and I/O card specifications ......................................... 49

9.1 Main Controller specifications .............................................. 49

9.2 IO Card Specifications ........................................................ 51

9.3 PLC CPU to IO Connectivity .................................................. 55

9.4 SCADA System Connectivity ................................................. 55

9.5 Performance Characteristics ................................................ 55

9.6 IO Interfaces configuration .................................................. 56

10 Data Concentrator.................................................................. 59

10.7 Serial data Interface – RS422 ................................................ 59

10.8 Serial data Interface – Ethernet ............................................ 60

11 SCADA System ....................................................................... 60

11.1 Servers .......................................................................... 60

11.2 Development Capabilities ................................................... 63

11.3 Runtime System Capabilities ................................................ 65

11.4 Performance Capabilities .................................................... 66

11.5 SCADA Historian ............................................................... 67

11.6 Storage Server for Data backup ............................................. 70

11.7 Network Management, Monitoring and Security Tools................... 71

11.8 SCADA System Enclosures .................................................... 72

11.9 Operator Stations ............................................................. 80

11.10 SCADA Software licenses ......................................... 83

11.11 Control Network, Operator Network and SCADA Network .. 84

11.12 Printers ............................................................. 86



12 CCTV Monitors ...................................................................... 87

13 Application Software Component Development ............................... 87

14 Housing Racks ....................................................................... 88

15 Remote Power ON/OFF Requirements and Panel Environment Monitoring System .............................................................................. 90

16 Fiber Optic Interface Requirements ............................................. 91

17 General Requirements ............................................................. 92

17.1 Detailed Response time calculation study to be provided (Network, PLC, SCADA) ......................................................................... 92

17.2 Test Modules for system validation ........................................ 92

17.3 Environmental Conditions ................................................... 93

18 Existing System Configuration .................................................... 94

18.1 SCADA System ................................................................. 95

18.2 PLC System ..................................................................... 96

18.3 Data Concentrator ............................................................ 96

18.4 Network ........................................................................ 96

18.5 Interface with field I/Os ..................................................... 96

19 Existing Rack Configuration: ..................................................... 112

19.1 CPU Rack: ..................................................................... 112

19.2 IO Racks: ...................................................................... 112

19.3 MIL connectors ............................................................... 113

19.4 IO module distribution in the existing system ........................... 115

19.5 Tentative Bill of Materials of automation systems based on existing system configuration ................................................................. 120





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Figure 1 PLC Based Automation System -1 Tentative Configuration diagram ........ 35

Figure 2 PLC Based Automation System -2 Tentative Configuration diagram ........ 37

Figure 3 Geographical distribution of Automation System-1 ........................... 43

Figure 4 Geographical distribution of Automation System-2 ........................... 44

Figure 5 Configuration of Automation System-1 ......................................... 94

Figure 6 Configuration of Automation System 2 .......................................... 95

Figure 7 Typical TMR digital input cards with interface board for a single field input with triplication in IO Panel .................................................... 98

Figure 8 Typical TMR Digital Output interface board for a single channel .......... 102

Figure 9 Typical TMR pulse input interface board for a single channel .............. 105

Figure 10 Typical TMR Analog input interface board for a single channel .......... 107

Figure 11 Typical TMR Analog Output interface board for a single channel ........ 109



SSaattiisshh DDhhaawwaann SSppaaccee CCeenntteerr -- SSDDSSCC SSHHAARR,, IInnddiiaann SSppaaccee RReesseeaarrcchh OOrrggaanniizzaattiioonn ((IISSRROO))



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TTeennddeerr DDooccuummeenntt ffoorr PPLLCC bbaasseedd PPrroocceessss AAuuttoommaatt iioonn SSyysstteemmss aatt SSeeccoonndd LLaauunncchh PPaadd

1 Introduction

SDSC SHAR is planning to replace the existing two numbers of PLC based Process Automation Systems at Second Launch Pad with new systems of state of the art technology. The envisaged system must provide trouble free operation of the process, meeting the operational, functional and performance requirements with high degree of safety, availability, maintainability and reliability.

The scope of tender deals with removal of existing automation systems, detailed engineering, supply, Erection and Commissioning of PLC based Automation Systems while maintaining the interfaces with existing Instrumentation System.

1.1 List of Abbreviations:

Acronym Description PLC – Programmable Logic Controller

SCADA - Supervisory Control and Data Acquisition

TMR – Triple Modular Redundant

I/O - Input/output

OT - Operator terminal

IJB - Instrumentation Junction Box

IDE - Integrated Development Environment

UPS - Uninterruptible Power supply

SMPS - Switched Mode Power Supply

MCB - Miniature Circuit Breaker

LAN - Local Area Network

NAS - Network attached storage

OPC - OLE for Process Communication

OLE - Object Linking and Embedding

SDSC – Satish Dhawan Space Centre

SHAR – Sriharikota High Altitude Range

SLP - Second Launch Pad

FCC - Filling Control Centre

RL - Remote Location

GPS - Global Positioning System




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Acronym Description NTP - Network Time Protocol

FO - Fiber Optic

TCP - Transmission Control Protocol

UDP - User Datagram Protocol

ISA - International Society of Automation

IEC - International Electro technical Commission

TUV - Technical Inspection Association

CE - European Conformity

ISO - International Organization for Standardization

UL - Underwriters Laboratories




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1.2 Terms and Conditions

1.2.1 Instruction to bidders

1.2.1.1 Bidder must quote for all the items specified in the tender enquiry. Values quoted in the price bid only will be considered and any other price information in any part of the document will not be considered.

1.2.1.2 Original PLC manufacturers with the experience of executing similar projects in India and in operation for the last five years from the date of tender enquiry shall participate in the bidding process. Necessary documentary proof for the same shall be provided along with bid.

1.2.1.3 Authorized system integrators of PLC manufacturers with the experience of executing similar projects in India and in operation for the last five years from the date of tender enquiry shall also participate in the bidding process. Necessary documentary proof for the same shall be provided along with bid.

1.2.1.4 Bidder should have executed at least one purchase order value of Rs 18 crores or two purchase order of Rs 11 crores or three purchase order of Rs 9 crores of similar automation project in any PSU's/Central Govt establishment/reputed private firms in the last seven years(before 31/12/2017). Documentary proof such as purchase order and completion certificate for the same shall be provided along with bid.

1.2.1.5 As a pre qualification criteria, offered system (same make and similar configuration) must be commissioned in India in the last three years. Documentary proof of project completion certificate must be provided.

1.2.1.6 Bidder shall have at least 5 years’ experience as on 31/12/2017 in the field of Design, Supply of Hardware & Software, Erection & Commissioning of Process Automation Systems using PLCs (10,000 I/Os) & SCADA systems (20,000 tags) and associated related Instrumentation interfaces. Documentary proof for the same shall be provided along with bid.

1.2.1.7 The Bidder should have annual turnover of minimum Rs.27 crores per year for last 3 financial years ending with March 2017. Documentary proof for the same shall be provided along with bid.




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1.2.1.8 Bidder in case of system integrators must have executed projects with reputed PLC makes and should be part of PLC OEM of same make for minimum of five years continuously and necessary document shall be provided.

1.2.1.9 Based on the criticality of the system under realisation, for MSME bidders, relaxation to the extent of 20% will be allowed in terms of turnover and values of previous purchase orders executed under clause 1.2.1.4 and 1.2.1.7 as part of pre qualification criteria

1.2.1.10 For System integrators, the proposed system configuration / architecture must be approved by OEM of PLC the same shall be submitted along with the bid.

1.2.1.11 The bidder should have an establishment in India in providing services and maintenance support along with all type of spares for the offered PLC system. Documentary proof of the establishment, service setup and other resources required for prompt service to be furnished by the bidder along with the offer. Bidder has to submit the copy of purchase order or work order of AMC for a period 2 years (as minimum) and completion certificate.

1.2.1.12 The offered PLC Controller and IO family should have a proven performance track record of continuous trouble free operation at least for the last 1 year preceding from the date of technical bid opening. Bidder shall furnish the following details along with bid.

a) Name of the organization & Purchase order details

b) Make, model of the PLC system & End application use of the system

c) Date of project completion (Site Acceptance certificate and performancece report by the end user)

d) Name, contact details of the end user along with e-mail id




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1.2.1.13 Details of technical specifications & commercial terms are enclosed in this document. Bidder shall sign and stamp each page of the document as a token of their acceptance & submit along with their offer. Document shall be scanned and uploaded in e-procurement portal. In case it is not possible to upload due to higher file size, hard copy of the documents (without any price figures) shall be submitted before due date to the PSO,SCF Tender Cell, SDSC SHAR Sriharikota by indicating Tender number, Due Date and Time.

1.2.1.14 The proposal shall be completely filled in all respects and shall be submitted together with requisite information. Any offer incomplete in any particulars is liable for rejection.

1.2.1.15 Site visits are permitted for understanding the geographical conditions and the existing system to be replaced. Bidder clarifications (if any) sought in writing will be replied within 10 days.

1.2.1.16 Non comprehensive AMC charges, after warranty, for period of 5 years must be quoted as per the bid and the same will be considered in evaluation and finalizing the bid.

1.2.1.16.1 For the cash flows pertaining to Annual Maintenance Contract (AMC) charges for FIVE years, Net Present Value (NPV) method will be adopted for normalizing the different quotes from vendors to bring all the vendors at par for the purpose of evaluation.

1.2.1.16.2 For arriving L1, NPV of AMC charges quoted by the tenderers will be added to the Equipment Cost. To calculate NPV, the interest rate shall be as per prime lending rate of Reserve Bank of India (RBI) as on date of opening of the tender.




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1.2.1.17 Commencement of Non comprehensive AMC will be after successful commissioning of the system and completion of warranty period.

1.2.1.18 Bidder must provide assurance for NON-comprehensive AMC of the offered system for a period of 15 years after warranty period with mutually agreed terms & conditions The bidder must support the offered system for a period of minimum 15 years for spares(hardware and software) from the date of commissioning. If the bidder is not OEM, then he must submit a copy of agreement with the OEM of the offered system to meet the above criteria.

1.2.1.19 Bidder must provide detailed BOM as part of technical bid. Offer will not be considered if price of BOM is included in technical bid.

1.2.1.20 Successful Bidder shall submit project execution plan and work break down chart, detailing the methodology of execution (process plan) within 15 days from the date of issue of purchase order.

1.2.1.21 Details of IO channel requirement is provided in this document. The tentative BOM based on existing system configuration is provided for your reference. However if any item which is not mentioned explicitly but essentially required to meet the functional and performance requirements of system is in the scope of the Bidder.

1.2.1.22 Department reserves the right to remove some of the items / services in the tender from the scope of supply if found necessary

1.2.2 Technical Terms

1.2.2.1 The configuration of major bought out items like PLC, SCADA, CCTV and Fiber Optic cable etc., shall be reviewed and vetted by original equipment manufacturer (OEM). If any of the item supplied as part of this contract is not meeting the system requirement or any compatibility/ interface issues with other systems are found at any stage of the project, same shall be replaced by the bidder with suitable items without any additional cost.

1.2.2.2 Bidder shall arrange technical training on the offered System to the department engineers at site by OEM trainers for PLC & SCADA system including programming for a period of at least 10 days.

1.2.2.3 Factory Acceptance Test (FAT) procedures (verification of BOM, functional checks, compliance to specifications, load test, burn-in test, environment software testing, diagnostics data, alarms and report generation




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check etc.,) and Site Acceptance Test (SAT) procedures shall be submitted to department for approval.

1.2.2.4 During Factory Acceptance Test (FAT), system shall be demonstrated for a period of 100 hrs continuous burn-in test in an integrated mode to meet the functional, performance and redundancy requirements specified in this document.

1.2.2.5 All the supply items specified in tender will be inspected by department Central Level Inspection Panel engineers at factory before dispatch (FAT), necessary test set up and test equipment shall be arranged by supplier.

1.2.2.6 After delivery of items to site, the Erection works shall be taken up after obtaining necessary clearance from the department.

1.2.2.7 System must tolerate any single point failure of dissimilar elements in the chain.

1.2.2.8 Bidder will be responsible for meeting the Reliability, Availability, Maintainability and Safety (RAMS) requirements as per standards. Safety, Reliability and Quality Assurance (SR & QA) shall encompass all activities of design, procurement, manufacturing and site works.

1.2.2.9 During the warranty period, the bidder has to perform periodical maintenance once in every three months and unlimited breakdown calls by employing a trained resident engineer and shall replace the failed/ malfunctioning components without any additional cost.

1.2.3 General Terms

1.2.3.1 Cost quoted shall be firm and fixed.

1.2.3.2 Bidder can award any part of the work under the scope of this tender to any sub vendor only after obtaining necessary approval from the department. Bidder shall submit relevant information as required by the department to evaluate the capabilities of sub vendor. Department has every right to accept or reject the proposal submitted. Approval of the sub vendor by the department is no way relieves the bidder from his responsibility and the bidder is wholly responsible for execution of work as per the specifications, terms and conditions mentioned in this document.




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1.2.3.3 All items in the bid are technically interrelated and hence overall L1 will be considered for placing the purchase order. Split up of the bid is not technically acceptable.

1.2.3.4 Bidder must supply the details of international standard third party certifications of the items supplied.

1.2.3.5 Language of correspondence must be in English for all forms of communication.

1.2.3.6 Any charges towards documentation shall be borne by the bidder

1.2.3.7 Before starting the site work (at SDSC SHAR), the party shall provide insurance as per workman compensation act to all his personnel working at site in Sriharikota against accidents. Till commissioning of equipment, the safe storing and handling of all equipment is in the scope of supplier.

1.2.3.8 The transfer of title of PLC based automations systems to the Purchaser (SDSC SHAR) will take place only after satisfactory erection, testing and commissioning of the all equipments by the supplier and full acceptance by the Purchaser (SDSC SHAR).

1.2.3.9 Quote shall be based on F.O.R. Sriharikota.

1.2.3.10 As per Notification No.47/2017-Integrated Tax (Rate) Dt.14.11.2017, SDSC SHAR is eligible to pay a reduced rate of IGST @ 5% for supply items. SDSC SHAR will issue IGST Exemption Certificate. Same is not applicable for erection & Commissioning and any other service related items.

1.2.3.11 Customs Duty: Customs Duty Exemption Certificate (CDEC) will be provided by SDSC SHAR as per Notification No.58/2018 dated 25.01.2018 to avail reduced rate of custom duty for the imported components. This may be taken into account while quoting for imported items. The list of imported items for which CD exemption is required shall be provided as part of technical bid. The FE component considered should be included in the price bid.

1.2.3.12 Necessary care shall be taken during erection and commissioning of equipment at our site. Any damage to the property of Department shall be adequately compensated by the Party.

1.2.4 Publicity Related To Tenders




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1.2.4.1 Advertisements, press release or other specialized publicity documents, which are related to or reveal the existence of a tender and are intended by the Bidder for public distribution and/or the press, broadcasting, or television, shall be cleared/approved by the Department.

1.2.4.2 The Department may direct the Bidder to withhold such publicity or to require modifications to the publicity material. The Bidder shall comply with such direction.

1.2.5 Site Visit

1.2.5.1 Bidders can visit and examine the site and its surrounding to familiarize themselves of the existing system, facilities and environment and may collect all other information which may help in preparing and submitting the Bid.

1.2.5.2 Claims and objections due to ignorance of existing conditions or inadequacy of information will not be considered after submission of the Bid and during implementation.

1.2.6 Location Conditions

1.2.6.1 During the erection, testing and commissioning of equipment at site in Sriharikota, the supplier has to make his own arrangements for boarding, lodging and transportation of his men and materials. However, subjected to availability, hostel accommodation may be provided by the Purchaser (SDSC SHAR) on chargeable basis.

1.2.6.2 Party (successful bidder) shall adhere to good daily housekeeping practices during erection of the system. During erection, the party shall keep all work and storage areas used by them free from accumulation of waste materials. Scrap shall be removed from the site to the satisfaction of the purchaser.

1.2.6.3 Free electricity and water will be provided by the Purchaser (SDSC SHAR) for the erection, testing and commissioning works at the site.

1.2.6.4 Satish Dhawan Space Centre – SHAR (SDSC-SHAR) Sriharikota is declared as prohibited place under Official Secrets Act 1923. Necessary security requirements enforced by the department from time to time shall be followed strictly during the execution of site works.




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1.2.7 Validity of Offer

1.2.7.1 Bid shall remain valid for acceptance for a period of six months from the due date of opening of the Bid.

1.2.7.2 The Bidder shall not be entitled during the above said period to revoke or cancel his Bid or to vary the Bid except and to the extent required by Department in writing.

1.2.8 Cost of Bidding

1.2.8.1 All direct and indirect costs associated with the preparation and submission of Bid (including clarification meetings and site visit, if any), shall be in the scope of Bidder's account and Department will not be responsible or liable for those costs, regardless of the conduct or outcome of the Bid process.

1.2.9 Project Monitoring

1.2.9.1 Bidder shall provide details of project team with their bio-data.

1.2.9.2 Party shall submit the project status report for every 15 days mentioning the status of various activities w.r.t. planned schedule for realization.

1.2.9.3 Party shall depute their Project team/ engineers for Monthly meeting to review the status and discuss/ resolve minor issues related to project execution at SDSC SHAR/ party’s site based on mutual agreement on mutually agreeable dates.

1.2.10 Arbitration

1.2.10.1 In the event of any question, dispute of difference arising under these conditions or any conditions contained in the Purchase Order, (except as to any matters the decision of which is specially provided for by these conditions) the same shall be referred to the sole arbitration of the Director SDSC SHAR Office or some other person appointed by him, it will be no objection that the arbitrator is a Government Servant that he had to deal with matter to which the contract relates or that in the course of his duties as Government Servant he had expressed views on all or any of the matters in disputes or difference.




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The award of the arbitrator shall be final and binding on the parties of this contract.

1.2.10.2 If the arbitrator be the head of the purchase office.

(a) In the event of his being transferred or vacating his office by resignation or otherwise, it shall be lawful for his successor-in office either to proceed with the reference himself, or to appoint another person as arbitrator, or.

(b) In the event of his being unwilling or unable to act for any reason, it shall be lawful for the Head of the Purchase Office to appoint another person as arbitrator: or

1.2.10.3 If the arbitrator be a person appointed by the Head of the Purchase Office in the event of his dying, neglecting or refusing to act, or resigning or being unable to act, for any reason, it shall be lawful for the Head of the Purchase Office either to proceed with the reference himself or to appoint another personas arbitrator in place of the outgoing arbitrator.

1.2.10.4 Subject as aforesaid, the Indian Arbitration and Conciliation Act, 1996 and the rules there under and any statutory modifications thereof for the time being in force shall be deemed to apply to the arbitration proceedings under this Clause. The arbitrator shall have the power to the extent with the consent of the Purchaser and the Contractor the time making and publishing the award.

1.2.10.5 The venue of arbitration shall be place as the purchaser in his absolute discretion may determine. Work under the purchase order shall, if reasonably possible, continue during arbitration Proceedings.

1.2.10.6 In case order is concluded on the public Sector Undertakings, the following Arbitration Clause will be applicable.

(a) In the event of any dispute or differences relating to the interpretation and application of the provisions of contracts, such dispute or difference shall be referred by either party to the Arbitration of one of the Arbitrator in the Department of Public Enterprises to be nominated by the Secretary to the Government of India in-charge of the Bureau of Public Enterprises.

(b) The Indian Arbitration and Conciliation Act, 1996 shall not be applicable to the Arbitration under this clause.




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(c) The award of the arbitrator shall be binding upon the parties to the dispute provided; however, any party aggrieved by such award may make a further reference for setting aside or revision of the award to the Law Secretary, Department of Legal Affairs, Ministry of Law & Justice, Government of India. Upon such Additional Secretary when so authorized by the Law Secretary whose decision shall bind the parties finally and conclusively.

(d) The parties to the dispute will share equally the cost of arbitration as intimated by the arbitrator.




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1.2.11 Performance bank guarantee

1.2.11.1 PBG for 10% of the value of the Purchase Order shall be submitted during the warranty period in the form of bank guarantee from any of the Scheduled / Nationalized Banks on non-judicial stamp paper of appropriate value as per the format given by Department or by DD drawn in favour of AO SDSC,SHAR, and shall be valid for a period of sixty days beyond the date for completion of warranty period. The PBG shall be submitted along with final bill after commission of the system.

1.2.12 Liquidated damage

1.2.12.1 Time is the essence of this order. If the supplier's defined scope of work is not completed by the end of delivery period, liquidated damage will be levied @ 0.5 % per week or part thereof subject to a maximum of 10% of the order value.

1.2.13 Security deposit

1.2.13.1 Party shall submit security deposit, within 15 days of Order Acknowledgement, for 10% of the total order value. Security Deposit shall be obtained through Bank Guarantee from any of the Scheduled / Nationalized Banks executed on non-judicial stamp paper of appropriate value or by Fixed deposit receipt (FDR) or by Demand Draft, and shall be valid for a period of sixty days beyond the date for completion of the Purchase Order.

1.2.13.2 In case the bidder fails to furnish the security deposit within the specified date or extended due date, the Purchase Order/Contract shall be cancelled, and the EMD (Earnest Money Deposit) , if any, made earlier shall be forfeited, and, in addition, appropriate penal action will be taken.

1.2.13.3 Central PSUs/PSEs/Autonomous Bodies shall be exempted from the payment of Security Deposit, and instead, an Indemnity Bond shall be submitted by them in lieu of the Security Deposit.

1.2.14 Earnest Money Deposit (EMD)

1.2.14.1 The tenderer has to submit an Earnest Money Deposit (EMD) for Rs.5,00,000(Rs. Five Lakhs only) in a single installment through Demand Draft (DD)/Banker’s Cheque/ Fixed Deposit Receipts or Bank Guarantee from any of the Scheduled Banks executed on non-judicial stamp paper of appropriate value. In case of Bank Guarantee, it shall be valid for a period of 120 days




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beyond the final tender validity date. It shall be taken in favour of Sr. Accounts Officer, SDSC SHAR payable at State Bank of India, Sriharikota branch. Any tender not accompanied with EMD shall be treated as invalid tender and rejected.

1.2.14.2 Foreign vendors, registered vendors or vendors who have already applied for renewal of registration, Central PSUs/PSEs/Autonomous Bodies, Micro and Small Enterprises, KVIC, National Small Industries Corporation, etc., shall be exempt from the payment of EMD. Vendors seeking exemption from payment of EMD shall submit necessary documentary proof.

1.2.14.3 EMD of a bidder shall be forfeited if the bidder /Contractor withdraws or amends his tender or deviates from the tender in any respect within the period of validity of the tender.

1.2.14.4 Failure to furnish security deposit by a successful bidder within the specified period shall also result in forfeiture of EMD.

1.2.14.5 EMD shall be refunded to all the unsuccessful bidders within thirty days after placement of the Purchase Order.

1.2.14.6 EMD shall be refunded to the successful bidder/Contractor after payment of the Security Deposit or may be adjusted against the Security Deposit.

1.2.14.7 EMD shall be refunded to all the participants in cases where the tender is cancelled or withdrawn by the Centre/Unit, within thirty days from the date of such cancellation or withdrawal.

1.2.15 Force majeure

1.2.15.1 Should a part or whole work covered under this agreement be delayed due to reasons of Force Majeure which shall include legal lockouts, strikes, riots, civil commotion, fire accident, quarantines, epidemic, acts of God and Government, fright embargoes, the completion period for work, plant or equipment referred to in this agreement be extended by a period not in excess of the duration of such Force Majeure. The occurrence shall be notified by either party within reasonable time.




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1.2.16 Warranty /Guarantee

1.2.16.1 The PLC based automations system and related accessories shall be guaranteed against any manufacturing defects for a period of 24 months from the date of supply or 12 months from date of commissioning whichever is earlier. For defects noticed during the guarantee period, replacement rectification should be arranged at free of cost within a reasonable period of such notification. Software updates or services shall be carried out during this period at free of cost. During the warranty period, the bidder has to perform periodical maintenance once in every three months and unlimited breakdown calls. One trained resident engineer must be positioned at SDSC SHAR for post commissioning support and performing maintenance activities as per schedule during warranty period.

1.2.17 Payment Terms

1.2.17.1 Not exceeding 30% advance on supply portion against submission of advance bank guarantee from Nationalized/scheduled bank on Rs. 100/- stamp paper valid till completion of scope of work.

1.2.17.2 60% on supply portion along with taxes on pro rata basis for each item after FAT by our department Center Level Inspection Panel (CLIP) and receipt of items at SDSC SHAR.

1.2.17.3 10% on supply portion along with erection and commissioning charges after successful commissioning of the respective system/item and acceptance by our Centre Level Inspection Panel (CLIP) on pro rata basis and submission of Performance Bank Guarantee (PBG).

1.2.17.4 Man day charges will be paid on pro rata basis as when utilized for the support during application software development.

1.2.17.5 Wherever advance payment is requested, Bank Guarantee from any Nationalized Bank/Scheduled Bank should be furnished.




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1.2.18 Delivery

1.2.18.1 Delivery schedule is essence for this contract. Vendor shall adhere to the delivery date as per the following schedule.

S.No Description Schedule

1. Purchase Order release T0

2. Detailed Engineering Drawings T0 + 6 Weeks (T1)

3. Approval of Detailed Engineering drawings by department

T1 + 2 weeks

4. PLC based Process Automation System -3 (Trainer / Development system)

S.No:3 of Purchase Order

T0 + 6 weeks

5. Supply of other items in Purchase Order

S. No: 1,2,4,5,6 and 7 T0 + 48 weeks

6. Erection and Commissioning of PLC based Process Automation System -1


Site Clearance by Department + 12 weeks

7. Erection and Commissioning of PLC based Process Automation System -2


Site Clearance by Department + 12 weeks




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Note: - LD is applicable for only for total supply items (all supply items must be delivered at our site within 48 weeks from the date of purchase order) and it is not applicable for intermediate delivery schedules.

1.2.19 Packing & Forwarding

1.2.19.1 The bidder will be held responsible for the stores being sufficiently and properly packed for transport by rail, road, sea or air, to withstand transit hazards and ensure safe arrival at the destination. The expenses for the packing & Marking of packages and transportation to site shall be completely borne by the bidder and must be quoted in the bid.

1.2.20 Exclusion of Tenders

The following tenders shall be summarily rejected from the procurement process

1.2.20.1 Tenders of bidders who have been removed from the vendor list or banned/debarred from having business dealings.

1.2.20.2 The tenders which materially depart from the requirements specified in the tender document or which contain false information.

1.2.21 Drawings

1.2.21.1 Each drawing submitted by the Bidder shall be clearly marked with the following details.

a) Name of the Owner: Satish Dhawan Space Centre - SDSC SHAR, ISRO

b) Project Title : Process Automation System at Second Launch Pad

c) Purchase Order No :

d) Title of the Drawing clearly identifying the system, equipment or part.

e) Drawing, Revision Number and Date.

f) Name of the Bidder:

In case of Sub-Vendor or Manufacturer's drawing, name of the Bidder and Sub-Vendor or Manufacturer shall be incorporated.

g) Drawings duly signed in "checked" and “approved" columns.

h) Scale to which the drawing is drawn.

i) Cross references to all relevant drawings.




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1.2.21.2 The drawings shall indicate all dimensions and details of equipment, materials of construction etc.

1.2.21.3 For all revisions of the drawing, Bidder shall ensure that all revisions are clearly encircled with revision numbers marked on the drawing.

1.2.21.4 Bidder shall also ensure that general details of revisions are indicated for each revision in the revision block of the drawing along with the date and signed by the approving authority.

1.2.22 Documents Comprising the Bid

1.2.22.1 Being an e-procurement tender, all the necessary documents need to be scanned and attached to the bid under “documents solicited from Vendor” form. In case it is not possible to upload due to higher file size, hard copy of the documents (without any price figures) shall be submitted physically before due date.

1.2.22.2 Offers shall be sent online only using standard digital signature certificate of class III with encryption / decryption. The tenders authorized online on or before the open authorization date and time only will be considered as valid tenders even though the bids are submitted online.

1.2.22.3 The bidder must authorize bid opening within the time stipulated in the schedule by SDSC SHAR. Otherwise the online bid submitted will not be considered for evaluation.

1.2.22.4 The Tender shall be submitted in “two bid system” in two parts viz. PART-1 (Technical and un-priced commercial Bid) and PART-2 (Priced Commercial Bid) as detailed below through online mode only.




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On-line bids shall consist of the following:-

Part – 1 Technical & un-priced commercial Bid :Technical & commercial aspects

of the offer with NO PRICE indicated

Part – 2 Price Bid: It shall be noted that this part shall contain only PRICES and no

conditions whatsoever. Any condition mentioned in Part-2 of the tender shall not be considered at the time of evaluation of the tender and may make the offer liable for rejection.

1.2.23 Part – I: Technical and Un-priced Commercial Part

Technical and un-priced commercial part shall comprise the following documents/information. All the documents shall be scanned and uploaded in the SDSC SHAR e-procurement portal.

1.2.23.1 Submission of bid letter along with one set of proposal document shall duly signed and stamped as a token of acceptance. Scanned copy shall be uploaded in the ISRO e-procurement portal.

1.2.23.2 Power of attorney in favour of authorized signatory of the bid/ proposal documents.

1.2.23.3 Latest income tax clearance certificate for the last 3 years.

1.2.23.4 Latest solvency certificate from a scheduled bank as detailed in bid qualification criteria.

1.2.23.5 List of projects in hand & completed during last five financial year indicating the name of client with contact details.

1.2.23.6 Any other relevant document, bidder desires to submit.

1.2.23.7 Confirmation w.r.t bid qualification criteria as per Annexure -1.

1.2.23.8 Compliance statement as per Annexure -2 and Annexure -3.

1.2.23.9 Deviations, if any, w.r.t technical and commercial terms & conditions shall be clearly brought out under deviation list Annexure-4. If deviations are




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not listed separately, it will be presumed that party is adhering to all the specification and terms & conditions given in this document.

1.2.23.10 Technical literature/ catalogue, information of materials is under Contractor’s scope of supply.

1.2.23.11 Submission of the information and details shall be done strictly in the manner described. PRICE SHALL NOT APPEAR ANYWHERE IN PART – 1 OF THE TENDER.

Note: All the above documents shall be uploaded in the ISRO e-procurement portal.

1.2.24 Part – II Price Bid

1.2.24.1 Priced commercial bid shall contain schedule of prices and shall be filled in ISRO e-procurement portal. No deviations, terms and conditions, assumptions, discounts etc. shall be stipulated in price bid. Department will not take cognizance of any such statement and may at their discretion reject such bids. The price offered by the bidder shall not appear anywhere in any manner in the Technical Bid.

1.2.25 Bid Submission

Bid shall be submitted in two parts

1. Part-1 Techno Un-priced Commercial Part of the Bid

2. Part-2 Price Part of the Bid

1.2.24.1. Offers should be submitted On-line using standard digital signature of class -3 with encryption/decryption options.

1.2.24.2. The tenders authorized online on or before the open authorization date and time will only be considered as valid tenders.

1.2.24.3. Prices shall be mentioned in the space/column provided in the ISRO e-procurement portal only for such purpose.

1.2.24.4. Physical copy of the bid will be accepted only in case if the file size is bigger and not possible to upload the same. In such case, the hard copy shall be submitted within due date. Documents received after due date will not be considered.




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1.2.24.5. Prices quoted should be on the basis of F.O.R. Sriharikota.

1.2.24.6. Bids duly filled in by the Bidder should invariably be submitted as stipulated in the e-procurement portal.

1.2.24.7. Department may open Part–1 of the bid on the due date of opening at convenience. Part-2 of the bid (technically and commercially acceptable bids) shall be opened at a later date.

1.2.24.8. Department reserves the right to reject any or all the Bids without assigning any reasons thereof.




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1.2.26 Bid Evaluation

1.2.26.1 The bidder shall provide all the relevant data/information/details required for evaluating the bid technically and commercially in the specific formats enclosed with the tender. Apart from this, bidder is free to add any other relevant information.

1.2.26.2 During the evaluation, department may request Bidder for any clarification on the bid/ additional documents/ information required. Bidder shall submit all clarifications/ additional documents/ information requested in original. If not submitted within the stipulated time department has right to reject such bids.

1.2.26.3 Techno-commercial discussion shall be arranged with Bidder, if needed. Bidder shall depute his authorized representatives for attending discussions.

1.2.26.4 The complete scope of work is defined in the Proposal document. Those Bidders who undertake total responsibility for the complete scope of work as defined in the Proposal document will only be considered.

1.2.26.5 In case bid does not fully comply with the requirement of Proposal document and the bidder stipulates deviations to the clauses of the proposal, which are unacceptable to the Department, the bid will be rejected.

1.2.26.6 Performance of Bidder on similar nature of works executed/ under execution shall be taken into consideration before selecting the bidder for opening his price bid.

1.2.26.7 The time schedule for completion of the project is given in the Proposal document. Bidder is required to confirm the completion period unconditionally.

1.2.26.8 Department shall not be obliged to furnish any information / clarification to unsuccessful bidder as regard non acceptance of their Bids.

Bid qualification criteria as per Annexure - 1 will be considered for evaluating the technical bids.




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1.2.27 List of Annexure

Sl. No. Description

Annexure-1 Bid qualification criteria

Annexure-2 General Compliance Statement

Annexure-3 Technical Compliance Statement

Annexure-4 Deviations if any

Annexure-5 BOM of automation systems

Annexure-6 BOM of spares

Annexure-7 Bidder’s Checklist

2 Spares

5% or minimum of 2 numbers whichever is higher of all major items of PLC System (PLC Modules, necessary interface boards,24V DC power supplies , PLC & SCADA network switches, FO accessories, Panel accessories, pre-fab cables etc.) in bill of materials of PLC based process Automation Systems must be supplied as spare. Tentative BOM of spares to be supplied are provided in Annexure-6 as reference. However actual BOM & BOQ shall be finalized based on BOM of AS1, AS2 and AS3 and details shall be provided as per Annexure-6.

3 SDSC SHAR deliverables at Site

The following items will be provided by the department at site free of cost during Erection.

3.1. Leech make Group authorization relays used in DO interface chain.

3.2. Field cables with MIL Connector’s mating part to interface the existing

instrumentation system to the PLC IO panels.

3.3. Redundant UPS incoming power to the panel.




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4 Scope of work

The Scope of work is broadly classified as given below:

4.1. Removal of existing old Process Automation Systems at Control Centre and Remote Locations by retaining the existing instrumentation interfaces.

4.2. All Hardware and Software shall be STATE-OF-THE-ART at the time of delivery.

4.3. Supply of hardware related to Controllers with necessary accessories (interfacing circuitry, prefab cables with necessary mating connectors, fiber optic devices, relays etc.,) built-in at factory in fully pre-wired and tested cabinets as per specifications, maintenance spares and associated systems and sub-systems etc provided in the tender document.

4.4. Supply, Erection and Commissioning of SCADA components such as Servers, network components, operator stations, control desks and server housing racks as required.

4.5. Supply of the necessary Operating system, Application software development tools / environments, standard libraries for process control applications, software packages and supporting tools for the Controller, SCADA and interface components.

4.6. Communication between the SCADA system and the PLC based control system shall be through local dual redundant Ethernet LAN. Required interfaces in the dual redundant Ethernet LAN is to be considered for such communication.

4.7. Supply of receptacle part of MIL connectors within the PLC panel as per the details provided in the document.

4.8. Supply of necessary interface boards including relays for interfacing the IO Modules to the existing Instrumentation system.

4.9. Erection of the system at site and integration with existing instrumentation system (including MIL connector terminations etc.,), testing and commissioning of the system as per approved test procedures.

4.10. Laying and termination of power / control and data cables as per the requirement.

4.11. All the miscellaneous items like cable glands, lugs, terminal blocks & internal wirings required for realizing the above scope of works are in the scope of Party. Party shall obtain approval prior to procurement of the above items for its make & model.

4.12. Supply of installation material required for system commissioning.




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4.13. Factory Acceptance Tests (FAT) and Site Acceptance Tests (SAT) to be conducted to demonstrate the functional specifications of each of the items being purchased and overall performance specification demonstration.

4.14. FAT & SAT documents shall be generated by the supplier as per mutually agreed test procedures.

4.15. Necessary test jigs / PLC based simulators for sub system level testing of pre wired PLC panel during FAT and SAT for all the types of IO channels must be provided by the supplier and same shall be handed over to the department after SAT.

4.16. Provide Training on the system to the SDSC SHAR engineers. The training will include the following

a) Erection and configuration of control systems hardware b) Configuration and usage of the system software c) Application software development at controller, server and client. d) Hardware and software fault diagnostics and necessary maintenance

4.17. Technical support during Application Software development activities and System maintenance activities.

4.18. Erection of control desk at Control center as per approved layout.

4.19. Laying, Splicing and termination of Fiber optic cable as per configuration finalized during detailed engineering and generation of test reports.

4.20. Field Instrumentation cables entering into PLC Panels available in the existing system for mating with PLC Mil connectors. These cables if disturbed during commissioning for any reason shall be normalized (re-routing / re-connectorisation/ glanding ) by the bidder as per the requirements.

4.21. Preparation of detailed reports for each system and presentation of the same to ISRO design review committee whenever required.

4.22. Non-Comprehensive Annual maintenance contract of the system for a period of 5 years from the date of completion of warranty / guarantee period.

4.23. List of documents to be submitted in English (3 sets of soft & 2 set of printed copy)




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a) Full set of as built drawings (system configuration, GA, as built wiring, cable layout etc.,).

b) Final BOM with make & model number. c) All technical catalogues and datasheets of all items. d) All test results (Internal tests by bidder, FAT, software test results, SAT

etc.,). e) Warranty certificates. f) Passwords/ Licenses/ Operating keys etc, g) Any other relevant document not listed above.

4.24. Some of the essential documents which will be supplied in advance are as

follows

a) Programming and user manuals for system as well as application software at controller, server and client.

b) System operation and user documents c) Procedure for hardware Erection and commissioning document.

5 Detailed engineering 5.1. Preliminary design of the proposed system architecture with associated

interfaces must be provided prior to detailed design.

5.2. Bidder shall obtain clearance for panel engineering drawings, I/O wiring schemes and Technical specifications of all the items from Department prior to the commencement of supply, erection and commissioning activities.

5.3. Detailed design of system architecture, power supply distribution, panel internal general arrangements, IO Module allocation, IO module wiring from module interface boards and from interface boards to field MIL connectors.

5.4. Detailed engineering of the control system HW & SW and interfacing schemes system shall be supplied along with necessary documents based on inputs given by the department.

5.5. The PLC racks will have provision for cable entry through metallic glands through false floor. All the cables entering or leaving the control systems racks should be through double compression type metallic cable glands and terminated in plug-in-type MIL standard circular multi- pin male connector. The termination to the connectors will be of crimp type with suitable ferruling. The control DC wiring will be completely isolated from the AC wiring with in racks or consoles.

5.6. Detailed specifications and makes of all components used for the system.




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5.7. All the cables, terminal blocks, screws etc. shall be as per IS standard. All cables will have overall shield and FO cables will be armored.

5.8. Preparation of electrical interconnection loop drawings.

5.9. Plan for equipment layout in the proposed buildings depicting all interconnections including the power distribution.

5.10. Preparation of all drawings in EPLAN or equivalent . Drawings to be provided in both HARD and SOFT copies. 2 no. of EPLAN or equivalent license to be included in your tender quotation to enable the user to modify the wiring drawings in case of requirements.

5.11. Drawings/Specifications/catalogues and other documents for submission in multiple copies for approval and further revisions.

5.12. Layout plan as per requirement.

5.13. Point to point connection details for prefab cables used between modules to interface boards and from interface boards to connectors.

5.14. Fibre optic system engineering includes termination details for the LIU and the overall Fibre optic connectivity diagrams.

5.15. Gland plate and MIL connector fixing bracket details.

5.16. Preparing detailed functional design specifications, FAT and SAT documents.

5.17. Preparation of channel wise IO schedule having details from the module side till the MIL connector end.

5.18. System software configuration for the PLC and SCADA.

5.19. Providing all relevant test reports of major items used in the system.

6 Non-Comprehensive AMC for the systems

6.1 Terms & Conditions 6.1.1. Non comprehensive AMC of the offered system must include preventive maintenance and breakdown maintenance.

6.1.2. AMC shall include all the items in Automation System-1, Automation System-2 and Automation System-3 except third party IT hardware like Servers and Client Stations.




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6.1.3. Bidder representatives will not be paid any transport fare to reach SDSC SHAR. Bidder representatives can make their own arrangements for boarding and lodging in case it is not available in SDSC SHAR.

6.1.4. A week prior intimation will be given to the bidder regarding date and time of quarterly maintenance activity.

6.1.5. Bidder is solely responsible for coverage of their work force under different statutory regulations including workmen’s compensation act, factory act, labor act, minimum wages act and other relevant statutory regulations.

6.1.6. Bidder shall ensure that all safety precautions are invariably taken to safeguard accidents and injuries to their own workmen.

6.1.7. Down-Time Compensation will be levied @ 0.5% of each maintenance charge per day subjected to maximum of 5% of total AMC value, in case the bidder fails to report the preventive or break down maintenance call within the allotted intimation period (one week of preventive maintenance and 48 hrs for break down maintenance) from the date of receipt of information from SDSC SHAR (including Sunday and Holidays).

6.1.8. The bidder shall pay all the relevant taxes as per rules and regulations prevailing at the time of payment and department shall not entertain any claim whatsoever in this respect.

6.1.9. The bidder should make necessary arrangement for reception of maintenance calls during working hours. Maintaining a Call register is mandatory.

6.1.10. The maintenance Agency should observe the security procedures applicable at SDSC SHAR. SDSC SHAR, Sriharikota is declared as Prohibited Place under Official Secrets Act, 1923 and infiltrators in to the Premises of SDSC SHAR are liable for prosecution. The bidder should ensure that persons of trustworthy bearing good Character, discipline and Antecedents are only posted/employed to carry out works related to contract awarded and take the responsibility for their proper conduct during the period of employment.

6.1.11. Customer will not be responsible for any injury to your personnel, damage to your property, caused at site.

6.1.12. The security regulations of the centre should be faithfully observed and any loss or damage incurred by us on account of your failure of any nature to follow such security regulations will be to your account.

6.1.13. Customer will identify one/two Contract coordinator/s and he/she will

a) Supervise/Follow up the maintenance activity.




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b) Recommend the quarterly payments. c) Evaluate the spares being replaced, if needed.

The bidder shall carry out the instructions of Contract Coordinator / authorized representative in all technical aspects. Bidder should provide detailed report about maintenance status and Preventive maintenance activities whenever the Coordinator requests the same.

6.2 Frequency of visits 6.2.1 Preventive Maintenance visits: 4 Normal visits in a year.

6.2.2 Breakdown Maintenance: As and when required during AMC period.

6.2.3 In case of breakdown maintenance Bidder should attend the problem within 48 hours from the date of receipt of information (including Sunday and Holiday).The department will provide the necessary spares for rectification.

6.3 Payment Conditions 6.3.1 Invoice along with the detailed report of the maintenance should

be sent to the customer by the end of every quarter. Payment will be approved within one month after submission of the invoice and maintenance report.

6.3.2 No payment will be made in advance by the customer.

6.3.3 No payment will be made for break down maintenance separately during the AMC period.

6.3.4 In case the bidder knowingly or unknowingly found causing any damage to systems in SDSC SHAR, suitable cost as worked out by SDSC SHAR will be recovered.

6.4 Scope of Work for AMC 6.4.1 Test and verify the functionality PLC hardware modules in the

system to ensure satisfactory performance of the same.

a) Redundancy checks of PLC CPU b) Testing of all the PLC modules for proper functioning c) Diagnostics check of the PLC CPU module and error identification d) Testing of the PLC communication modules and communication errors

identifying using Diagnostics in Status Words




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e) Diagnostics testing of all the PLC DI, DO, AI, AO & PI modules status and fault identification

f) Checking of PLC module errors and using status words & bits. g) Testing of rack Power supply modules & Bulk power supply modules. h) Checking the healthiness of the batteries & EPROM/Flash PROMs and

battery back-up RAM modules i) Reloading of system software into PLC modules in case of any

need/corruption

6.4.2 PLC firmware up gradation shall be provided.

6.4.3 Ensure Firmware compatibility of old and new modules including spares.

6.4.4 Logging/recording, of maintenance activities done, problems faced, report generation on tests carried out.

6.4.5 Attending to all the system related problems reported by the customer.

6.4.6 Checking of software program through diagnostic routines and status bits.

6.4.7 Check the SCADA system health

a) Redundancy checks of SCADA Servers b) Communication & Network Healthiness checks of PLC & SCADA systems c) Checking of Software program for diagnostics and communication status. d) Checking the healthiness of network components, servers, operator stations and dongles e) Checking the overall network connectivity at all levels and integrity




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6.4.8 Checking the functionality of interface modules and other third party items configured in the system.

6.4.9 Verifying the health of the total system as per the configuration and ensure its normalcy.

6.4.10 Fault finding, troubleshooting and rectification of problems in PLC & SCADA system and Engineering / operator stations, Report generation in case of break down maintenance

6.4.11 Overall checking of the system performance and taking complete backup of PLC & SCADA Software / system files periodically.

6.4.12 In the event, any module(s), software is/are obsolete, the same to be communicated to SDSC at least 6 months in advance.

6.4.13 In any case maintenance/repair activities to be carried out should be briefed to the focal point identified (customer Representative) and it should be carried out with consent of the representative.

6.4.14 Recovery of license if it gets corrupted or damaged.

6.4.15 Checking healthiness of PLC memory modules and SCADA dongles.

6.4.16 Sample checking of the inputs and outputs (Random Checking).

6.4.17 Voltage & Grounding checks on the PLC Panels.

6.4.18 Supervisory category: Following activities shall be supervised by your Service engineer with the support of customer

a) Cleaning of all panels & checking of Air circulation, Panel temperature, humidity and corrections as applicable.

b) Cleaning of hardware modules, backplanes and contact points and module guide connectors in case needed




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6.5 Breakdown maintenance 6.5.1 Identification of fault in the system.

6.5.2 Rectification of fault by changing the hardware modules with spare unit or by rectifying the software etc.

6.5.3 Checking the entire system after rectification of the fault and ensuring the normalcy of system performance (On Load).

6.5.4 Analyzing the cause of failure and recommending preventive maintenance.




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7 Overview of the Proposed System Requirements

The proposed system consists of three independent automation systems described in detail in this document.

S.No System Requirement

1. PLC based Process Automation System – 1 Replacement

2. PLC based Process Automation System – 2 Replacement

3. PLC based Process Automation System – 3 New System

7.1.1 PLC based Process Automation System – 1

PLC based Automation system-1 consists of a set of 4 PLC Controllers with associated IO distributed across 4 remote locations and redundant SCADA system. Additional PLC based data acquisition system with Serial and Ethernet interfaces must be available to acquire data from external system and provide to other automation systems. Details of PLC systems with associated IO channels requirement for the PLC based Automation system-1 is provided in Table-1. The proposed configuration diagram of system-1 is provided in figure-1.




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CARD

PLC-1

Total

PLC-2

Total

PLC-3

Total

PLC-4

System Total

RL1 RL2 RL1 RL3 RL1 RL4 RL1

DO 768 576 1344 768 576 1344 1440 384 1824 1248 5760

DI 2304 1824 4128 2304 1824 4128 5088 1632 6720 2976 17952

AI 336 432 768 336 432 768 432 144 576 496 2608

PI 36 24 60 36 24 60 48 0 48 60 228

AO 24 24 48 24 24 48 24 0 24 48 168

Table 1List of I/Os Channels for Automation System1




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Figure 1 PLC Based Automation System -1 Tentative Configuration diagram

7.1.2 PLC based Process Automation System – 2

PLC based Automation system consists of a set of 4 PLC Controllers with associated IO distributed across 5 remote locations and redundant SCADA system. Additional PLC based data acquisition system with Serial and Ethernet interfaces must be available to acquire data from external system and provide to other automation systems. Details of PLC systems with associated IO channels requirement for the PLC based Automation system-2 is provided in Table-2. The proposed configuration diagram of system-2 is provided in figure-2.




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CARD

PLC-1

Total

PLC-2

Total

PLC-3

Total

PLC-4

Total Total RL1 RL6 RL1 RL7 RL1 RL8 RL1 RL9

DO 1344 768 2112 1056 384 1440 864 480 1344 384 384 768 5664

DI 4512 2592 7104 4128 1728 5856 3168 1632 4800 1152 1536 2688 20448

AI 432 240 672 240 192 432 240 288 528 288 192 480 2112

PI 60 0 60 0 24 24 48 12 60 0 0 0 144

AO 48 24 72 0 0 0 48 24 72 24 24 48 192

Table 2 List of I/Os Channels for Automation System-2




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Figure 2 PLC Based Automation System -2 Tentative Configuration diagram

7.1.3 PLC based Process Automation System - 3 (Developer / Trainer System)

A trainer system with Two Dual redundant/Hot standby controller (same make and model of Main System), one set of TMR IOs (DI, AI, PI, DO, AO), Serial/Ethernet communication modules, backplanes and power supplies mounted in an trainer cum demo stand must be delivered at our site before the main systems are supplied. This system must have similar configuration as main system with redundant servers and four numbers of Client stations. Necessary licenses for the controller programming IDE and SCADA software must also be provided. This




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system will be used to develop the application software and evaluate the system features before the actual system is delivered. The actual configuration of the proposed system shall be finalized during detailed engineering.

Static PLC program Analysis tool(PLC Checker or equivalent) for testing the PLC application software developed must be provided and details of the tool are given below

• Automatic static analysis tool for PLC programs for verification of coding rules and computation of metrics as per ISO/IEC25010:2011 standard and configurable rule sets

• The tool should allow analyses on an unlimited number of PLC programs for unlimited period for the offered PLC make

• Rule set like PLC Open is to be provided for software tool against which to analyse the code should be done.

• Software tool should generate documentation automatically

7.2 List of major items / sub systems in Automation Sys tem -1 and Automation System - 2:

The list of items / sub systems in Automation System-1 and Automation System-2 are technically same with difference only in the quantity of items. The detailed list of the number of IO channels are provided in chapter 6.1.1 for Automation System-1 and 6.1.2 for Automation System-2.

7.2.1 PLC Based Controllers with IO’s configured in Tripl e Modular Redundant (TMR) mode:

The proposed control system, based on latest state-of-the-art technology, will be a Dual redundant/Hot standby PLC based system, with IOs configured in TMR mode. The system shall have fault tolerance and self-diagnostic features. The Input/output modules reside in the remote I/O units connected to their respective main controllers. The remote I/O units will be configured based on the functional requirements. The Controllers along with the associated remote I/O units are to be realized for each system and the I/O modules must be interfaced to the existing instrumentation system through interface modules. All the PLCs in a system should be interconnected on a Network (Say Control Network) with dual redundancy. The PLC systems are henceforth referred to as 'Controllers' as part of this document.




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7.2.2 Data Concentrators: The function of the data concentrator is to acquire data from third party communication devices and provide these data to the PLC based controllers. The Data concentrator need to interface to RS422 and Ethernet data interfaces. The Data Concentrator should co-exist along with the controllers on the Control Network and provide data to the PLCs at the scan cycle rate. The Data Concentrator System should have Hot-Standby redundancy with fault tolerance features built-in.

7.2.3 SCADA System: The Controllers must be interfaced to the SCADA System and the user must be able to monitor all IO and program data, control the process from the Control Centre. The SCADA Servers connect to the PLC systems and Data Concentrators on the Control Network. The SCADA client operator terminals connect to the server on the Operator Network. Provision, should exist, for extending the SCADA client stations to remote IO areas at launch complex control rooms to enable operations from these locations. SCADA system should provide centralized database storage in real-time with facilities for online trending, alarm / event recording, data archival tools with necessary fault tolerance incorporated.

7.2.4 Remote Power ON/OFF of the Control System elements and monitoring of panel environment:

All the Remote IO systems provided at the launch complex at various distributed locations and control centre should be installed in necessary rack mounted enclosures. All the PLC racks, IO racks, servers and operator terminals shall be powered using dual redundant power supply outlets. Each of the independent power outlets should be controllable (Switching ON / OFF) remotely from the Control Centre. A Separate Network (independent of the above network) based system to be provided for meeting this requirement with necessary graphical interface to monitor environment parameters (Temperature, Humidity, Voltage, Current, System uptime, Trip status etc) and control power outlets using smart MCBs. This feature must be provided separately for Automation system1 and Automation system2.

7.2.5 Operator Training Simulator (OTS) System The OTS an independent and stand alone system is to be used as a training and

examination tool in support of initial and requalification training. The degree of simulation shall be such that the action taken by the operator on both the simulator and actual operation would be same when Control of system or handling




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of malfunctions is performed. Mistakes can be made and lessons learned without risking personnel or assets.

OTS shall be built with a Simulated IO system that is non-intrusive to the on-line system, allowing the user to minimize or eliminate changes to his control system configuration.

The OTS shall be duplicate control room operations with actual plant scenario. The control panels of the OTS shall be identical to those in the control room. The control panels shall have operational controls, alarms, labels, instrumentation, and other man-machine interfaces to ensure similar experience control room like actual plant and control room.

All controls, alarms, instrumentation, operational environment which are on panel shall be duplicated on OTS.

The OTS shall possess predefined initialization conditions which shall be available at any time on energizing the simulator. These conditions shall be different plant conditions for, startup, transition period, shutdown etc. It shall be able to insert and terminate malfunctions during these conditions. The simulator shall be capable of simulating those plant malfunctions expected to occur by either design or from operational experience.

The OTS shall also have feature to assign pre-allocated marks for operator actions during training exercise and print and publish a training report and certificate for the operator.

Training on OTS shall be provided by the OTS expert at our site.

Necessary support during the development of simulation of process dynamics using existing libraries and customized libraries (to be developed mutually).

OTS shall support and equipped with following functionality;

Multi-threaded, Simulation engine

Real time model execution – 100, 200, 500, 1000 msec

Data exchange with report generation feature is desirable




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7.2.5.1 Tentative BOM of OTS

S.No Item Automation System -1

Automation System -2

1. 10000 tag OTS software (SimSci of Schneider or Wood or equivalent)

1 1

2. Server along with required OS for OTS Software

1 1

3. Two tier Client Stations with required OS and reporting tools for trainer

1 1

4. Two tier Client Stations with required OS and reporting tools for trainee

1 1

5. Ergonomically Designed Operator Console

1 1

6. PLC and SCADA development software license (as required)

1 1

7. Training on OTS Lot Lot

8. Support during customized application development by an OTS expert as per the requirements of department

25 days 25 days




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8 Overall Configuration of the Automation systems

8.1 Geographical Distribution of Automation System:

The proposed system consists of two identical and independent automation systems. Each automation system requires set of four dual redundant/ hot stand-by controllers with respective remote IO units, separate set of redundant servers, client stations and network systems. The Controllers and the SCADA system for performing the Process Control Application are to be located at the Control centre and the remote IO units are to be placed at a distance of 8 Km from Control Center (at the Launch complex).

The Automation system-1 Controllers have their I/Os distributed at the remote control room (RL1) near to the launch pad and also at the propellant storage areas (remote locations RL2, RL3, RL4, in figure 3) slightly away from launch pad (1km). The Controllers need to interface to these I/Os on the IO network and perform the acquisition and control actions. Similarly Automation system-2 Controllers have their I/Os distributed at the remote control room (RL1) and also at the propellant storage areas (remote locations RL5, RL6, RL7, RL8 in figure 4).




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Figure 3 Geographical distribution of Automation System-1




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Figure 4 Geographical distribution of Automation System-2




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8.2 Proposed Configurations & Connectivity Diagram:

The PLC controllers must be of Dual redundant/Hot standby with bump less switchover. All the IOs are to be configured in TMR with necessary hardware voters and software logics for fault tolerance. One set of main, redundant and triplicate drop/nodes form one IO rack/ IO panel. Multiple such IO racks are to be configured as per IO requirements of the corresponding PLC system, the details of which are mentioned in the subsequent chapter. Each node/drop (CPU and IO) must be powered by dual redundant power supplies on the same backplane.

Some of the Inputs are available as single input from the field. These IOs are to be triplicated in the panel and given to the main, redundant and triplicate input cards (panel triplicated inputs, DIP/AIP/PIP). The inputs that are available as TMR inputs from fields are to be directly interfaced to the respective cards (field triplicated inputs, DIF/AIF). The details of panel triplicated and field triplicated IOs are given in the subsequent chapters. Software voting of the inputs will be implemented and the voted value will be considered by the application. The PLC CPU will post the computed output to the main, redundant and triplicate output cards. Hardware based 2oo3 relay voter will vote the outputs from the three digital output cards and the voted outputs will be fed to the field for energizing main and redundant solenoids. The detailed scheme is provided in the subsequent chapters.

The PLCs should also be able to exchange data with each other on the control network. The Data concentrator must acquire data from third party devices and distribute the processed data on the control network so that other PLCs on the network can access the data at the same scan cycle rate.

The Controllers should connect to the SCADA system (redundant servers) on the control network and the SCADA software must acquire the data (IO and program) and provide supervisory control for all the PLCs. The SCADA clients should be able to access runtime servers for monitoring, control and real time trending on the operator network. The operator network must be extended to the remote control room and other remote locations so that clients can communicate to server from the respective locations.

The total system configuration must be designed such a way that, single point failure should not be available anywhere in the system and should tolerate at least two dissimilar failures without affecting the functionality. The IO network, Control network and the operator network must be separate from each other and




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must be of dual redundant type. The total system (PLCs, Data concentrators, servers and clients) must be synchronized to Universal time using GPS receivers.

8.3 Overall System Specification of Automation System – 1 and Automation System – 2 and Automation System- 3

System Features Specification

PLC System

Controller redundancy

Dual Redundant/Hot Standby (Primary and Standby Controllers must be

positioned in separate backplanes and each PLC system must be housed in a separate

enclosure)

Controller Synchronization Event or Cyclic

Controller Switch over time from main to redundant

Less than a scan cycle and should be bump less

Controller to IO Rack distance Minimum 10Km

No. of IO Nodes/ Drops per Controller IO requirement must be configured without

exceeding 30 IO nodes

Deterministic scan Time with system software(synchronization, self-diagnostics, redundancy management, input acquisition and data output) and Voting logic for 30 IO nodes

Less than 100ms

Deterministic scan Time with system software, voting logic and application software of 250K lines of code

Less than 150ms




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Deterministic scan Time (with system software, voting logic and application software of 250K lines of code) including fault tolerance

Less than 200ms

Turnaround time of the system(Reaction time from input reading to output posting)

Must be less than two scan cycles

Controller rack backplane Should ensure power supply and

communication redundancy

Inter-PLC communication

TCP/UDP communication – Full duplex

Number of PLCs that can be configured for inter-PLC communication

Minimum 8

Diagnostic levels Information should be available at System

level and Module level

Operating system for PLC Programming software or IDE

Should be supported by latest Windows or Linux based OS

PLC simulator feature

Programming IDE should have simulation feature. User must be able to test the

application software with SCADA without the PLC hardware

High speed (rate equivalent to scan time) logging at Controller and data transmission to SCADA for trending should be possible

Minimum 2GB (total data size) must be supported

IO redundancy TMR configurable

(Input voting-software output voting -Hardware)

Back plane Power supply for each IO nodes/drops

Dual Redundant




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DC Power supplies (24V/10A) CPU Panel – Minimum 2 Nos

IO Panel( 3 IO nodes) - Minimum 8 Nos

Minimum No. of IO channels per IO drop 416 digital IO or 112 Analog

Hot swap ability

All IO modules and Power supply modules should be hot swappable

Posting of predefined values in case of PLC failure or communication failure between PLC and IO rack

Configurable by user at Channel level

Conformal Coating for all modules As per ISA G3 standard at OEM factory

Third party certifications TUV or CE or equivalent

Cyber security for PLC Compliance to the standard such as Achilles heel or equivalent certified by third party

SCADA (Corresponding PLC OEM supplied)

SCADA system Server –Client or better architecture. Response time of SCADA system must be 1second or better.

CPU to SCADA communication - Control network

Dual Redundant

SCADA server to clients communication redundancy –Operator network

Dual Redundant

SCADA server configuration with redundancy

Should be configurable as runtime servers, trend servers, alarms servers separately




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Switchover time from main to redundant server

Less than 10 sec

SCADA Engineering Server Development and deploying the project in runtime servers without disturbance to the operations must be possible.

Number of SCADA Tags Unlimited tags

Number of SCADA Clients Minimum 30

Number of Web clients Minimum 25

Operating system for SCADA software should be Windows or Linux

Should be supported by latest Windows or Linux based Operating system

Third party certifications International standard Certifications

Necessary version management tools and configuration control management tools (project comparison tools) shall be provided.

9 Controllers and I/O card specifications

9.1 Main Controller specifications

Feature Specifications

Controller redundancy Dual Redundant/Hot Standby

Controller Synchronization Event or Cyclic

Controller Switch over time from main to redundant

Less than a scan cycle and should be bump less

Controller to IO Rack distance Minimum10Km

No. of IO Nodes/ Drops supported per TMR IO requirement must be met




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Controller without exceeding 30 IO nodes

IO capacity per controller Minimum 10000 Digital IOs and 1000 Analog IOs

Memory Size-RAM Minimum 16MB for application program

Maximum Application Size 30% memory margin should be available for an executable code of 250K lines of code

RTC resolution 1ms

Scan Cycle Must be user configurable or cyclic

Real time Operating System Must support multitasking with different scan rates

Watch dog timer Must be user configurable

Programming languages supported IEC 61131 languages (especially structured text)

Built in communication ports USB or Ethernet for monitoring/debug port

PLC CPU to IO node/drop - Network connectivity

Must be able to support dual redundant IO network with 100 Mbps speed. Each IO node/drop should have dual connectivity to PLC CPU

PLC CPU to SCADA servers – network connectivity

Must be able to support dual redundant network to avoid single point failure for each PLC CPU

Communication Protocol for SCADA to PLC

Minimum 100Mbps must be supported

Time Synchronization NTP support must be available for time synchronization

Diagnostic features Detailed error log should be provided

Online Program Modification Provision must be available to change the logic and download to PLC without disturbance to the operations.

Memory Protection Provision must be available to avoid inadvertent downloading of logic to PLC

Remote restart feature User must be able to give cold restart through programming IDE

OPC compatibility Shall be supported

Retaining program context in case of Must be available




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power failure

Timers / Counters supported Minimum 255

9.2 IO Card Specifications

The various I/O cards that are envisaged in the overall system should have the following minimum specifications. The IO cards must be the same family as the main controllers

9.2.1 Digital Output card Specifications: Number of outputs 32/64

Sink/Source Output Source type

Output switching Solid-state

Switching voltage 24V nominal

Number of outputs that can be triggered simultaneously

All outputs

Maximum Current Per Channel 0.125A

Isolation � Between channel and backplane � Between group to group

500V DC 500V DC

Switching delays Less than 1.2ms

Internal protective circuit Overload protection must be available

Front Panel display Must indicate the health status and command status for all channels

No Inter channel interference Essential

Diagnostics at Module level Essential

9.2.2 Digital Input Card Specifications: Number of Inputs 32/64

Number of inputs that can be triggered simultaneously

All inputs

Sink/Source mode Sink

Isolation � Between channel and backplane � Between group to group

500V DC 500V DC




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Input voltage 24V nominal

Switching threshold � Low Range ( 0) � High Range( 1)

� Low <5 VDC � High >15 VDC

Input Resistance Min 2.4 K Ohms

Input Switching delay from ‘0 to ‘1’ 1 to 10ms

Front Panel display Must indicate the health status and ON/OFF status for all channels


Diagnostics at Module level Essential

9.2.3 Analog Input Card Specifications: Input type Current – differential type

No of channels 8/16

ADC Resolution 14 bit or better

Input Measuring ranges 0-25mA/0-20mA/4-20mA

Input Impedance 250 Ohms

Accuracy 0.2% or better at room temperature

CPU read time Less than 10ms

Update Time for all channels Less than 10ms

Input Filter Essential

Diagnostics � Module level � Channel level

� Essential � Essential

Isolation Between channel and backplane 500V DC

Common mode between channels 70dB or better

Front Panel display Must indicate the module and channel health status


9.2.4 Analog Output Card Specifications: Output type Current – differential type

No of channels 4/8/16

DAC Resolution 14-bit or better

Output range 4-20mA




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Accuracy 0.25% or better

Maximum Load Resistance 1000 ohms or as to meet TMR Configuration – refer to interface diagram*

Update Time 10 ms without ramp or better

Diagnostics � Module level � Channel level


Isolation Voltage channel and backplane 500V DC



*The maximum load resistance that must be supported by the AO card must meet the TMR configuration requirement for the output and associated read back as input to the TMR AI cards.

9.2.5 Pulse Input Card Specifications No of channels 4 or more

Counter Inputs (Voltage) 24V nominal

Counter Operating Modes Totalizer mode/Rate mode

Counter Resolution 32 bit

Counter Frequency Range 10 KHz and above

Switching threshold � Low Range ( 0) � High Range( 1)

� Low <5 VDC � High >11 VDC

Field to Channel Isolation 500V Dc

Internal protective circuit Essential

Indications and Diagnostics � Module level � Channel level




9.2.6 Programming Interfaces

The controller should be programmable by the user and the following features are expected




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Programming languages Support

IEC61131-3 compliant programming languages particularly Structured Text for user application task development.

Integrated development environment (IDE) for program development

Must be User-friendly. The user should be able to configure the controllers and IO cards as per the functional requirements, develop, compile, and download the application task.

Online debugging and real time monitoring The IDE should provide features for monitoring the watch variables in real-time, and debugging of application software.

Online modification of application logic The user should be able to modify the configuration or change the logic without disturbance to the operations

PLC simulator The user must be able to simulate and test the application logic without the PLC hardware. SCADA communication should be possible while testing in simulator mode.

All the device drivers, libraries for PID control and communication interface handling

Must be available for all the system modules and also the third party communication devices such as timing interfaces and serial interfaces

Provision for programming and downloading over network interface.

Essential

Number of PLC Programming licenses 10 per automation system ( AS1, AS2 and AS3)

Apart from the above features the IDE should have extensive context sensitive help facility for the programmer on the library functions, language references, diagnostic functions and other features. Provision for maintaining version control of the application software with the additional feature to compare the differences between versions is desirable.




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9.2.7 Diagnostic features

The controller should be able to provide the user through its own interface and to the SCADA system for online display to the user, the following diagnostic information and provide necessary information to overcome the faults.

� CPU should be able to collect all diagnostic information about accessories connected to it. The status of all the modules (controller, communication modules, power supply modules and IO Cards), Channel healthiness, overload status etc., should be indicated to the user. This information should be made available at SCADA system.

A comprehensive internal log facility for each controller to report all types of fatal errors (runtime, application triggered fatal errors and system faults) and major status events. This information should be available to the user preferably in the form of report.

9.3 PLC CPU to IO Connectivity

The Controller (each PLC CPU) should have dual redundant interfaces to connect with each IO Nodes/drop. Each IO node must have two independent paths connecting to the primary/master PLC CPU.

9.4 SCADA System Connectivity

The controller (each PLC CPU) should connect to the server on the dual redundant control network. Each controller should have the capacity to communicate at least 32,000 Digital tags and 3,200 Analog tags to SCADA. The scan time of the controller must include the SCADA communication load also.

9.5 Performance Characteristics The following performance characteristics are expected from the Controllers.




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9.5.1 The CPUs should be able to work at a deterministic maximum cycle time of 200ms (including application software) which should accommodate the following functions within the cycle with sufficient margin for future modifications / additions.

9.5.1.1 Data Acquisition tasks (from I/Os and from SCADA) including acquisition of the health status of various components of the Controller.

9.5.1.2 Voting of input data, Engineering value calculations for analog parameters

9.5.1.3 Acquisition of parameters over network from other controllers and the External Data I/F Unit interfaces

9.5.1.4 User application task

9.5.1.5 Output data generation

9.5.1.6 Output data to I/Os, SCADA and to other controllers / external communication interfaces (Data Concentrators) over network.

9.5.1.7 System internal health monitoring and other housekeeping activities

9.5.2 Should be able to recover from communication errors (from I/O interfaces or from external units) and perform the tasks within the given time.

9.5.3 Inter-PLC or Inter-Controller data transfer in full duplex mode should be supported, on the Ethernet network, with suitable driver interfaces, for user customization of the number of variables to be transferred along with user defined data buffer sizes of a minimum of 1 KB. Such transfers should happen cyclically. Provision should exist for exchanging multiple frames each of 1 KB size between Controllers. Similar such interface should exist between PLCs and the Data Concentrator also. Provision for multi-framed data communication between controllers and data concentrators should be available cyclically.

9.6 IO Interfaces configuration 9.6.1 Necessary interface circuits for fault tolerant operation of I/O

cards and channels and MIL connector receptacles should be supplied as part of the system. The inputs (analog and digital) that are available from the field as single input without redundancy must be triplicated at the IO rack and fed




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to the TMR input cards. Such inputs are referred as Panel triplicated inputs. The inputs (analog and digital) that are available in TMR mode from the field are to be fed to the respective input cards directly. These inputs are referred as field triplicated inputs.

9.6.2 The interface board for panel triplication (one board for one set of main, redundant and triplicant input cards) must ensure that even if one input card fails (open or short) the inputs to the other cards must not be disturbed. The interface boards for panel triplication, and the IO cards for the field triplicated inputs are connected to the Instrumentation junction box using MIL connectors. Prefab cables must be provided for connections between MIL connectors and interface boards. All the cables used for connections to the terminal blocks of IO cards must be prefab cables.

Digital Input:

The interrogating power (24V) to acquire the digital inputs (both panel triplicated and field triplicated) must be part of the IO panel. Fuses must be provided to protect the panel triplicated and field triplicated input cards.

Analog Input:

All the analog inputs in the system are of non-loop fed type (i.e. the card should not supply 24V in the current loop). The excitation power to all the analog sensors will be from an external power supply which does not come under the supplier’s scope.

Pulse Input:

All the pulse inputs in the system are of panel triplicated type. The interface board must not add any distortion to the input pulse signals.




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Digital Output:

Hardware voter must be provided for 2oo3 voting of the TMR outputs. The hardware voter must provide two outputs to the field to drive main and redundant solenoids of electro pneumatic valve (refer to hardware interface diagram for details). The power supplies to drive the solenoids do not come under the supplier’s scope. The command read back must be provided for the main, redundant and triplicant outputs separately. The relays used for digital output hardware voters shall have minimum 5 contacts of JSS or equivalent standard and have a minimum contact rating of 2A. (OEN Relay Part No: 67EP-24-6Cx-PC-NIT or equivalent or better)

Analog Output:

Hardware voter must take the main, redundant and triplicant outputs and give a single output to the field. Command read back must be provided for the voted analog output.

� Necessary Field / Load Power supplies for operating the Digital Outputs and interrogating Digital inputs and voting of other types of hardware should be part of the system with necessary dual redundancy. Remote diagnostics monitoring of power supplies health must be available. The typical specifications of the power supplies are given below:

� SMPS Type Power Supplies

� Built-in diode for output OR ing.

� Remote diagnostics monitoring.

� 24V DC, 10A, Load Regulation : 1%

� 230VAC Input, ±10%, 50Hz±2%

� Derating: Max. loading : 60% of the capacity

� Overload and Short Circuit protection.

� Dual Power Supplies which share power during normal operation modes and take care of total load during failure of one set of power supplies are to be used.




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9.6.2.1 The interface circuits required are to be provided as part of the IO racks. The details of the logic circuits may be worked out during the Detailed Engineering phase. All components that will be used to meet the interface requirements must be of standard type and should be approved by the department prior to the installation in the rack.

10 Data Concentrator

The Data Concentrator system should consist of one number of Hot Standby Controller (should be of the same family as the other controllers) connected on the Control Network, at the Control Centre with the following features.

10.1 The scan rate for the controller must be less than 100ms

10.2 Data Concentrators should provide interface for acquiring / sending data over

10.2.1 RS-422 Serial – 115.2Kbps with frame size 1KB

10.2.2 Ethernet using UDP/IP or TCP/IP – 100Mbps

10.3 Data Concentrator should be able to synchronize their system clocks with the Universal time by reading them over the network using NTP protocol.

10.4 The data concentrator should be able to process the data from the communication interfaces and provide the processed data to the Controllers (Four Main controllers) for performing their control activities. The data concentrator should be able to communicate (send data and receive data) at least at the Cycle Time of Main controllers on the Control Network.

10.5 The data concentrator should have provision to communicate with the SCADA runtime servers for data display, logging and archival and accepting supervisory control commands.

10.6 Necessary programming interfaces for Configuration and data acquisition of the communication interfaces should be provided.

10.7 Serial data Interface – RS422

Onboard feedback data related to pressures is obtained on RS-422 serial frame. Four such links are available at control center, which have custom frame formats, with 1024 (or more) bytes per frame. These serial data are




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available at a data rate of 100ms per frame continuously at a baud rate of 115.2 kbps (or better). The mode of the communication interface is asynchronous. The system should have necessary interfaces to acquire the above mentioned serial frame data (with dual redundancy) and transmit immediately after processing to the controllers for use in the control algorithms.

10.8 Serial data Interface – Ethernet

Custom onboard data is available through network data link (dual redundant) in UDP/IP frame or TCP/IP frame for full duplex communication at 100mbps rate. This data needs to be captured at the special communication interface, extract and process the data and provide it to the controllers for using in the control application.

11 SCADA System

The SCADA system is to be implemented in multi-tier architecture with the Server-Client or equivalent configuration. The servers or equivalent system should provide facility as a central repository of the real-time data, contain tasks for online and offline trending of real-time and historical parameters, event, report generation and alarm logging and provide user defined logics for the graphic user displays. All SCADA components should be of the state-of-the-art technology as on the date of supply. The SCADA Software package should optionally support MIS layer with remote Web based clients. SCADA Software package should be OPC Compliant.

11.1 Servers

The redundant servers should be provided with the following major hardware specifications.

S.No Name Description

1. Make HP / Dell

2. Model HP DL380 Gen10 or equivalent or better

3. Form factor 2 U rack form with Rail Kit




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4. Processor Model Gold 6136 or better

5. Processor Speed 3 Ghz or higher

6. Number of Cores 12 or better

7. L3 cache 20MB or better

8. Number of processors 2

9. RAM Memory type DDR4 or better

10. RAM Memory speed 2666 MHz or better

11. RAM Memory Capacity 16 x 4 GB or better

12. Storage Controller RAID Controller should not occupy PCI Slot

Support SATA/SAS/SSD, 2GB Cache

13. Internal Optical Drive SATA DVD-RW

14. Internal Hard Drive 2 x 300 GB for OS(Mirrored), 4 x 1.2TB SAS 10K or better

15. Power Supply type Hot Swappable, Redundant

16. Power Supply Capacity 800W or better

17. System Fans 6 Redundancy or better

18. Video Interfaces 2 VGA Port or better

19. Network Interface port 4 * 1Gb port(embedded)

1 Separate Remote Management Port with




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remote management software

1 No of dual port 10G SFP network adapter with compatible trans receiver

20. PCI Slots 3 usable slots

21. USB Port 3 or higher

22. Monitor Size 24’’ or better

23. Monitor Display Resolution 1920 * 1200 or higher

24. Monitor Display Interfaces Display Port, HDMI, VGA

25. Operating System Microsoft Windows or Linux Latest Version

26. Removable Media Necessary software installation media must be provided along with required licenses

27. Add on cards Additional cards may be considered if required by configuration

28. Warranty 3 Years(24 x 7) with defective media retention

The Engineering Server hardware for the SCADA System should be separate from the Runtime Server hardware.




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Details of Server requirements for Process Automation Systems are provided below.

S.No Description AS-1 AS-2 AS-3

1. SCADA Engineering 2 2 -

2. SCADA Runtime 2 2 2

3. Trend, Alarm and Report generation

2 2 -

4. Simulator/Spare 2 2 -

5. SCADA historian server ( additional specifications provided in chapter 11.5.1.2)

2 2 -

11.2 Development Capabilities

The development package should be able to provide facility to configure the SCADA Server based on the requirements of the user and the necessary tools to develop graphic user interfaces (both static and dynamic parts), configure and program Events/Alarms, Trend configuration, Report formatting tools, standard library tools for meeting the above requirements and provision to develop custom libraries. The following is the detailed requirement on the capabilities of the required development tool.

11.2.1 Mimic development IDE or tool should support the following features

11.2.2 Provide a collection of customizable shape libraries for mimic development.

11.2.3 Libraries can optionally have provision to combine related objects into groups which can be configured collectively to form a template.




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When templates are used in development, instance specific information must be passed to the template.

11.2.4 Support user configuration for dynamic / animation of the graphic objects in Runtime environment

11.2.5 Any update in the library must be automatically updated in all associated pages

11.2.6 The Graphic building utility should provide necessary support to import custom photographs as background images.

11.2.7 Provision must exist for creation of custom popup messages and event based popup messages with the following features

11.2.8 Graphical objects must respond to user click action and generate pop ups with relevant controls and messages for user interaction

11.2.9 Multiple level of pop up display is required.

11.2.10 These pop ups provide the user control over the elements and display relevant status messages

11.2.11

11.2.12 The pop ups creation, generation and modification control must be provided to the users

11.2.13 Each pop up and contained elements must be configured with privilege levels for interaction and display

11.2.14 Event based popup must be displayed based on user defined variable states or action event from the operator

11.2.15 The Development environment should provide concurrent development of the SCADA project by multiple programmers and finally merge the project for overall functionality before generating the runtime version.

11.2.16 The development package should provide facility to maintain versions of the total software being developed.

11.2.17 The development package should consist of an online help system with provision for context sensitive help.

11.2.18 The development package should allow updating the existing runtime system with a newly developed runtime system with minimal downtime to the runtime system.




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11.2.19 User defined Alarms and Events should be configurable for their properties and messages. All Alarms and Events should be immediately logged in a database time tagged

11.2.20 NTP based time synchronization support is required

11.2.21 The Alarm/ Event database access for online / offline viewing and extracting data should be provided. Necessary tools for customization of the Event/Alarm reports should be provided.

11.2.22 Provision for configuring trends (Online / Offline viewing) should be provided. User customizable trend data options to log trend data either periodically with resolution of 1s or better or based on the change of data with a minimum tolerance of 0.005 should be provided. Necessary tools for accessing the database, online or offline, for viewing or extracting the data should be provided.

11.2.23 Provision for generating user configurable reports which display the current and historic data. The triggering of these reports may be time based or event based.

11.2.24 Provision to assign security rights for the user interfaces.

11.2.25 Scripting feature must be provided in the SCADA system with the following features

11.2.25.1 User scripts can be stored in procedures for multiple reuse and centralized maintenance

11.2.25.2 Script function must perform basic arithmetic, logic and control tasks and display and manipulate data in graphics pages. Editor must be provided for writing, editing and de bugging of the generated scripts

11.2.26 Health of server and client tasks and resources utilization to be extended for display, monitoring and logging in SCADA

11.3 Runtime System Capabilities 11.3.1 The Runtime system should have the capability to refresh

the display data at 1 second or better interval and the user commands to be transmitted to the Controllers within 1 second.

11.3.2 The runtime system should have necessary fault tolerance features to perform the following activities in case of any failure of any task running in the server.




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11.3.2.1 Switchover automatically from Primary Server to Standby Server such that the changeover is transparent and occurs within 10s to both operator stations and the controllers.

11.3.2.2 Redundancy in Data Storage mechanism to maintain continuity in data in case of failures.

11.3.2.3 Commands (Analog and digital) issued by the operator must not be withdrawn during Primary and Standby Server switch over

11.3.2.4 Server tasks stopped due to any system or network failure must start automatically when the system normalizes

11.3.3 The Runtime system should allow changeover of the current user logged in without having to close the current display window. Should have provision to login a new user with different rights over the existing operator for performing any special operations if required. Provision should exist for default user login, which allows only view only functions.

11.3.4 The Runtime system should allow querying for online or recorded events / alarms / trends without any impact on the system performance.. These data should be generated as reports (text based or graphical) with user customizable formats.

11.3.5 The system must support logging of minimum 10000 variables as trends at 1 second or better rate and minimum 10000 variables as alarms

11.3.6 Runtime System should support building of a MIS layer on top of it by way of providing a software interface with suitable firewall support and necessary libraries. Optional Libraries for Communications support to external blue tooth / mobile devices may also be indicated, if available.

11.4 Performance Capabilities 11.4.1 The SCADA system should support reading a minimum of

3200 Analog tags per PLC within a given SCADA scan cycle time

11.4.2 The SCADA system should support simultaneous reading of minimum of 15000 Analog tags from all PLCs within a given scan cycle time

11.4.3 The SCADA System overall response time should be 1 second for display update and 1 second for execution of user command




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from the time the command is issued to the time it is posted on the Controller’s Output

11.4.4 The SCADA server must support minimum 30 Operator clients without any degradation in overall SCADA response time and data log time.

11.4.5 The SCADA server must support minimum 20 Operator clients as Web Clients for monitoring the process by experts.

11.5 SCADA Historian

11.5.1 Two numbers historian servers per automation system with necessary license other than the main SCADA servers must be provided for long term data archival

11.5.2 The historian server hardware must be equivalent or better than the proposed SCADA server hardware with more than 16 TB(4 x 4 TB) of storage space (expandable up to 48 TB) for data and 2x 300 GB for OS

11.5.3 The historian servers must log 5000 tags per automation system

11.5.4 Historian software

� The software should support collection, storage and retrieval of all types of process data types (float , integer, binary data, fixed and unlimited length string, large binary objects etc.). It should have ability to collect alarms and events in the same software.

� Data should be stored in a Database Management Software

� The data historian database shall acquire and store process data at full resolution, with options to store on time dead-band or value dead-band.

� It should support dead banding/filtering algorithms like exception and compression with which storage space required for storing data can be minimized




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� While there are always physical limiting factors such as disk space, there shall be no programmatic limit to the amount of data that may be stored on-line.

� There shall be no performance penalty for long-term data storage. There shall be no discernable difference in retrieval speed of data based on the age of the data. For example, the retrieval of two hours data stored two years prior shall be the same as for two hours of data stored one day ago.

� The Software should support Auto Discover of tags on the fly from SCADA/PLC and Auto Configuration of Tags.

� It must support sampling of tags at the same rate as the SCADA software

� The software should support calculation tags which can accommodate programming of complex calculations both pre-configured calculations and custom created calculations.

� Database should have provisions and tools for statistical analysis with various forms of functions over a specified time period. These functions should also include minimum, maximum, average, standard deviation, difference, total and rolling averages.

� The software should have feature of data buffering during communication failure between SCADA/Interface Servers and the Historian server. Buffered data stored must be automatically updated in Historian when the connectivity is restored.

� The Historian shall support redundant architectures for both redundant data interface nodes on redundant data servers and redundant Historian servers for high availability of data.

� Offered Historian should provide tools to add new tags or modify existing tag attributes and scan frequency without loss of existing data. It should support bulk modification of tags

� Database should provide the ability to authorize and control access to data and application functions. Only selected users can be authorized to access and modify configuration data.




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� Backup of entire configuration of Historian and archive data should be possible automatically based on On-Demand or Automatic i.e.Scheduled basis. This should be done without shutting down the Historian Server.

� Historian should have a feature to store quality of data for each logged value.

� The data historian shall have provision for transfer of historical process data with other Server databases like Microsoft SQL Server or Oracle. The historian database shall include an OLE DB Provider (Object Linking and Embedding for Databases) so that any other 3rd party SQL client can access the real-time or historical process data from the data historian.

11.5.5 Analysis, Monitoring and reporting feature of historian

• System shall have a graphical user interface that can be customized to meet the needs. The user interface will be easy to use and understand for the end user. It will require minimal user training. The Graphical Interface must have simple method to sub-divide the display into different groups for easy access

• Data shall be able to be accessed locally or remotely and analyzed with the vendors’ client tools or other tools such as Spreadsheets (Excel), Web Browser etc.

• The displays shall be updated dynamically and with minimum delay between Real Time and the application. No screen refreshing action shall be required.

• The portal shall allow displays to be created and edited without the need for coding.

• Standard Charts, Data grid, Pi diagrams, scatter plots etc must be available in the reporting module

• Should Support Role based report generation to ensure the right users are viewing the right data.

• Comparison of performance in terms of tabular data, trends, charts, etc. should be possible




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• Export and Import of data from the portal client display in CSV format or similar formats should be possible.

• Annotations for specific data items, or a set of data; instantaneous or over a period of time; should be possible.

• Search will be an integral part of the portal searching through information stored for Portal.

• Historian software must support native connectivity to develop reports in different reporting services software. The full licenses of this reporting software must also be supplied along with historian.

• The Software should support notification services like e-mail and SMS’s in case of any specific process parameter deviation.

11.6 Storage Server for Data backup

11.6.1 Two numbers of storage servers (one per automation system) must be provided storing and retrieving configuration items such as SCADA, PLC projects, operational documents, manuals etc with the following specification

S.No Item Description

1. Make HP / DELL

2. Model HP StoreEasy 1650 or equivalent or better

3. Processor Intel Xeon E5 2609v3 or equivalent or better

4. Processor speed 1.7 GHz or higher

5. RAM 16 GB or higher

6. No of Ethernet ports 4




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7. Network Speed 1 Gb

8. Storage Controller HPE Smart Array P440ar/2GB FBWC or better

9. Internal SAS connectors

2

10. Drive Bays 12 Large Form Factor and 2 Small Form

Factor

11. Hard drive capacity 6 * 4 TB (Large Form factor Drives) 2*300 GB

(Small Form factor Drives)

12. Number of hard drives 6 + 2

13. Form factor 2 U Rack mountable(with rail kit and cable

management arm)

14. Power Supply 800 Watts Platinum hot-plug redundant

15. Monitor 24’’ LED Monitor with 1920 * 1200 or better

16. Operating System Windows server 2016 Storage Server or better

17. Warranty 3 Years(24 x 7) with defective media

retention

11.6.2 External removable storage devices with flash memory (16GB or higher) must be provided for data back up and transfer. 5 numbers per automation system must be supplied

11.6.3 External removable storage devices of reputed brand with 3 years warranty (1TB or higher) must be provided for data back up and transfer. 2 numbers per automation system must be supplied

11.7 Network Management, Monitoring and Security Tools

11.7.1 Necessary Network Management and monitoring tools for online monitoring and remote management of the network (PLC and SCADA). The tools should support performance analysis of the




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network without adding any delays to the process control application related communication jobs. The tools should generate alarms and reports in case of network failure or degradation.

11.7.2 Full licensed version of software for protection of system from external threats must be supplied. These software must provide protection from virus and malware attacks. The details of these software will be finalized during detailed engineering based on the Software platform of the supplied system.

11.8 SCADA System Enclosures

11.8.1 Smart Server rack

11.8.1.1 Server panel with IP based monitoring features as the given configuration is required to be supplied with the system

Specification of server rack

Manufacturer APC, Rittal, Dell PowerEdge or equivalent

Service Housing of SCADA Servers

Location Filling Control Center

Quantity 4 (2 per automation system)

Height 42 U or higher

Width 600 mm or higher

Depth 1000 mm or higher

Security and Access Control System

Swing Handle /Mechanical Lock / Single Point / Common Key/Die Cast Metal

Smart Features

• Metered Rack PDU — advanced power distribution for real-time remote monitoring of connected loads,




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current, power, and energy monitoring at the rack

• User-customizable warning/overload settings

• Automated alarm notifications

• Automatic transfer switch

• Web interface for rack parameter monitoring

• User interactive display for local access

• Environmental monitoring port for external temperature/humidity probe




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Material • Dimensions (WxDxH): 800 x 800 x 2100 mm

• Solid all Aluminium frame construction with structures across the X, Y & Z axis with CRCA coverings of minimum 1.2 mm thickness.

• All aluminium frame construction shall have a load carrying capacity of minimum 1000 Kg.

• The cabinet shall be designed with top cover ventilated on all sides along the width and depth thereby enhancing exhaust of hot air via ventilation slots and rear honeycomb type perforation for maximum air circulation.

• Removable side plates of 1.2 mm thickness on both the sides.

• Equipment mounting angles shall be fully electroplated and adjustable depth wise with U marking for height.

• Gland plates thickness : 3mm

• Gasket for door & cover: Neoprene

11.8.2 Operator Consoles at Control Room

11.8.2.1 Sixty three number of control desks shall be provided with elegant, modular, aesthetic and state of the art design. These consoles shall house engineering stations, operator stations (SCADA-Clients), Human Machine interface (HMI-Intrinsically safe thin client), CCTV monitors, Keyboard & mouse and associated items, telephones etc. The consoles & chairs design and colour etc., shall be submitted for approval prior to procurement.




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Specification of control consoles

Manufacturer Pyrotech/ Evans/ Adarsha / better

Service Housing MMIs, CCTV, Telephones & Intercom communication etc.,

Location Control room

Model Pyrotech EXTRON Model or equivalent or better

Structure

• Made of heavy duty Extruded Vertical and Horizontal Aluminum profiles of 6063T6 grade. The Extrusions shall be duly powder coated with 40+ micron over all surfaces.

• All sheet metal parts must be finished with a durable, black, electrostatic powder coating with average application of 60-90 microns over all surfaces.

• The powder coating should pass 600 hours salt spray test (Mandatory for MS).

• Console should standalone on Single Beam structure.

• Console Base Foot surface should be made of Stainless Steel. it should be modular and weld free self sustainable structure system.

• The powder for coating shall be Greengaurd™ certified.

• To allow future extension and expansion; a weld free modular system to be proposed. Interconnecting joints should not be visible.

• The structure should be rigid enough to withstand 1500 N load on the edge. The structure should allow easy assembly of Hinged/Hook on Shutters, Gland




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Plate, Monitor arms in extremely rigid manner.

• Grouting of the desk is not allowed for site installation

Work Surface

• The material of the working surface shall be Acrylic Solid Surface with base made up of minimum 12 mm thick MDF. The top finish shall be fire retardant, Insulated, Water Proof, Scratch resistance and high hardness.

• Acrylic Solid Surface is homogeneous material throughout the depth, which compliance to GreenGuard.

• The worksurface has to be in continuous curvilinear shape so as to maintain the aesthetic appeal of the design.

• Front ergonomic edge shall be of Moulded (same material) which gives comfort to wrist/palm during working hours. It should not obstruct during operations. Shape of the Edge shall have an ergonomic slant with min 50 mm in depth.

• Front ergonomic edge shall be of Moulded (same material) which gives comfort to wrist/palm during working hours. It should not obstruct during operations. Shape of the Edge shall have an ergonomic slant with min 50 mm in depth.

Complex Formed Side Leg

• The profile of the side leg shall be formed by treating the Acrylic solid surface (min 6mm) to pliable temperature and forming a seamless profile, so that it remains hollow from inside to allow easy flow of wires.

• Top finish of work surface and the side legs shall remain the same.




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Extended Foot

• The structure shall be supported on SS formed legs to comply to ISO-11064 requirement of the control desk parameters.

• The foot shall be polished stainless steel. It will provide access to wiring cavity for easy flow of wire from the floor to the Side aesthetic leg and then to cabinet. All the fasteners should be hidden and nuts/bolts shall not be visible on the exposed surface.

Shutters

• The cabinet back shutter shall be removable so as to access the CPU cabinet, front shutter shall remain fixed with the structure.

• The shutters outer finish shall be 6mm thick acrylic solid surface.

• The edges of the back removable panel shall be properly finished and designed so that no level difference is seen between two adjacent shutters.

Cabinet

• The cabinet shall be provided with a rigid aluminium structure just below the table top. The bottom side of cabinet shall be raised by 50-100 mm to comply to foot extension parameters of ISO 11064.

• Cabinet shall house the CPU Slide out trays for easy accessibility of CPUs, the tray shall have load bearing capacity upto 25 kgs. The CPU tray shall be mounted on 3mm thick gland plate which will have perforations in it for proper ventilation.

• The cabinet shall also house industrial grade metal powder coated finish universal socket type power distribution unit for necessary power requirements.




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• Sharp edges at cabinet bottom to be avoided to prevent the operator’s foot from any kind of injury.

Chairs

Ergonomically designed to suit to the offered console as per control room standard

High/Mid Back Chair, PP Arm, Nylon Base,Gas Lift, Seat Back Net Tapestry - 100 No’s [Make Godrej or better]

Table 3 Specification of elements in console

Sl. No. Item Description Material Finish

1. Work Surface 12mm ASS Corian + 12mm MDF

Corian

2. Dashboard 12mm ASS Corian Corian

3. Structure Aluminium Extrusions Powder Coated

4. MS Components CRCA Sheet Powder Coated

5. Leg Bottom Support SS + MS Sheet Chrome Plated

6. Front & Back Shutter 6mm ASS Corian + 18mm MDF Corian

7. Power Wiring Power Distribution Unit As per site requirement.

8. Articulating arm MS Pole with Al. Casted Arm Black

9. RJ-45

Telephone Bays Only - White

10. Telephone ARM ABS ABS




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Sl. No. Item Description Material Finish

11. Rear Desk Illumination 14 Watts LED lights to be

provided. In each compartment

12. LOGO Vinyl Sticker(ISRO) Smooth

13. PDU Reputed brand As per site requirement.

14. RJ-45 & RJ-11 Reputed brand As per site requirement.

Note:

1. All bolts must be of SS material to avoid rust due to environment. Remaining

hardware shall be Nickle Plated with RoHS certificate. 2. The following test to be conducted during FAT , Drop test, Abrasion test, Powder

Hardness test and load bearing capacity of desk to be shown during Inspection time.

3. 2 nos of vinyl stickers to be provided for each operator station. 4. Lifetime warranty on structural stability. Five years warranty against any

manufacturing defect on complete desking solution. If any component failure/ malfunction is noticed in any of the above system, same shall be replaced at free of cost by the supplier.




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11.9 Operator Stations

The Operator Stations should be PC Based systems with following

major hardware specifications and state-of-the-art as on the date of supply.


1. Make HP / Dell

2. Model HP ProDesk 400 G4 or equivalent or better

3. Processor Model Intel Core i7 7700 7Gen or better

4. Processor Speed 3.6 Ghz or higher


6. Cache 8 MB or better



9. RAM Memory speed 2400MHz or better

10. RAM Memory Capacity 2x 8GB (16GB) or better

11. Internal Optical Drive SATA DVD-RW

12. Internal Hard Drive 1 TB SATA at 7200 rpm or better

13. Video Interfaces Display Port or better

14. Network Interface port 1Gb port or better

15. USB Port 3 or higher




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16. Monitor Size 24’’ or better

17. Monitor Display Resolution 1920 * 1200 or higher

18. Monitor Display Interfaces Display Port, HDMI, VGA

19. Operating System Microsoft Windows or Linux Latest Version

20. Removable Media Necessary software installation media must

be provided along with required licenses

21. Add on Network Ports 2 Nos of 1 Gb port or better

(additional cards may be considered if required by configuration)

11.9.1 The Operator Station should be loaded with the Client version of the SCADA package. The following are to be considered while supplying the operator stations.

11.9.2 The Operator Stations should support network redundancy at Operating system or SCADA package level.

11.9.3 The Operator stations should have provision to load the Controller’s programming interface along with the runtime client software to allow programming of the Controller / interfacing with the controller for debugging the application.

11.9.4 The Operator Stations should work with “Any Station – Any Display” logic where the control activity is governed by the rights of the operator logged into the station.

11.9.5 One Set of Operator Station per automation system should be located at the launch complex Operator Stations should be able to synchronize their local clocks with the Server Clock (Time Server or GPS clocks) over the network using NTP Protocol in real-time.

11.9.6 One Tablet PC/Laptop per automation system 1 and 2 respectively must be provided for PLC system configuration,




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troubleshooting and maintenance activities. This system must include the necessary license for PLC programming and SCADA monitoring.

11.9.7 Industry grade kiosk systems with touch screen and necessary SCADA licenses must be provided at six remote location(3 per automation system 1 and 2 respectively) for monitoring of process parameters

11.9.8 Mobile System monitoring station with following major specification, necessary SCADA software license and state of art as on supply must be provided along with the system


1. Processor Model Intel Core i5 7Gen or better

2. Processor Speed 2.4 Ghz or higher


4. Cache 3 MB or better



7. RAM Memory speed 1600MHz or better

8. RAM Memory Capacity 4GB or better

9. Internal Hard Drive 128 GB SSD Type

10. Network Interface port Wireless LAN IEEE 802.11ac

11. USB 3.0 Port 1 or higher




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12. Monitor Size 12.3’’ or better

13. Monitor Display Resolution 2736 x 1824 or better

14. Monitor Display Interfaces 10 Point Multi touch display

15. Operating System Microsoft Windows 10 pro or better

16. Accessories Cover with detachable keyboard, Stylus and

carry case/pouch

Details of Operator Station requirements for Process Automation System-1, Automation Systems-2 & AS3 are provided below.

S.No Systems AS-1 AS-2 AS-3

1. Operator Stations 34 34 4

2. Mobile programming Station(Laptop/Tablet)

1 1 -

3. Industrial grade Kiosk Stations

3 3 -

4. Mobile System monitoring Station

3 3 -

11.10 SCADA Software licenses

The following table gives the tentative list of SCADA software license to be supplied. The actual license count will be finalized after detailed engineering




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S.No Description AS-1 AS-2 AS-3

1. Unlimited SCADA Server license

6 6 2

2. SCADA Client license 25 25 4

3. 5000 tag SCADA Historian license

2 2 0

4. Web Client License 25 25 0

11.11 Control Network, Operator Network and SCADA Networ k

The SCADA network between Server and clients must be of star or better topology with industrial grade server rack mountable switch of the following specification


1. Make PLC OEM make or equivalent or better

2. No of Ethernet ports 48 or better

3. Ethernet ports Speed 1 Gbps or better

4. Uplink port numbers 2

5. Uplink port speed 1 Gbps or higher

6. Management interface USB, Ethernet

7. Power supply Dual redundant or better

11.11.1 The SCADA network must extend to all remote control rooms. The BOM must include the necessary elements (network switches, power




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supplies, enclosures, patch panels etc) required to extend this network to each remote control rooms as per the configuration of each automation systems

The SCADA network extended to each of remote location (4 per automation system 1 and 2 respectively) must have modules to enable wireless devices to connect to SCADA network.

11.11.2 The communication equipment used for Communication between Server to PLC Controller and PLC Controller to IO stations must be of industrial grade with sufficient interfaces for all connectivity and avoid single point failure.

11.11.3 All networks in the commissioned system should comply with practices and procedures as IEC 62443-2-1 guidelines along with necessary audit reports.




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11.12 Printers

Two heavy duty color printers meeting the following specification must be supplied for printing SCADA pages and program logic from Operator/ engineering stations in the network

S.No Name Brand

1. Brand HP/Cannon/Dell/better

2. Paper Size A3 and A4

3. Type Color, Laser

4. Resolution 1200 dpi or better

5. Print speed 20 page per minute or higher

6. Duplexing Auto duplexing

7. Interfaces USB, Network and Wifi




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12 CCTV Monitors

CCTV Monitors of the following specification must be supplied for viewing CCTV views from control desks

S.No Description Specification

1. Make HP/ LG / Samsung / Sony

2. Display size and type 24 inch LED

3. Resolution 1920 * 1080

4. Viewing Angle 160 Deg or better

5. Inputs HDMI, Component video, Composite video

13 Application Software Component Development

The application software for both PLC and SCADA systems will be developed by SDSC SHAR team. However to speed up the development activity, support from vendor may be utilized on man day basis at our premises. Vendor has to depute trained personal for both PLC and SCADA during the application software development at site.




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14 Housing Racks

14.1.1 All the Site equipment has to be housed in suitable racks with necessary hardware housing mechanisms included.

14.1.2 The Rack should contain necessary earthing protection mechanisms inbuilt for both protective ground and signal ground separately. The Rack should be provided with suitable mechanisms for intake of cool air and purging hot air as well protection against moisture condensing inside the rack / humidity control. Remote monitoring /control of rack environment must be available at the remote control room.

14.1.3 For each rack power should be taken from two UPS Sources for the Control equipment and other systems with necessary Fuse / MCB protections and current limiters wherever applicable. Single point failures and failures due to non-critical items should be avoided. The rack should have necessary lighting and locking arrangements in-built.

14.1.4 Rack health Monitoring: Status of necessary rack power supplies, bulk power supplies, fan, network switch, fan failure detection units, etc shall be monitored remotely in SCADA system. Necessary interfaces (Either serial, Ethernet or Digital Input Modules) may be considered for this purpose. Necessary digital input channels required for acquiring rack health parameters are not accounted in IO channel count provided in Table-1/ Table-2.

14.1.5 All external interfaces to / from the racks should be with MIL Circular Connectors. Wherever terminal blocks are to be used within a rack, these should be with WAGO terminals of clamp and cage type. Wiring inside the rack should be neat with necessary markings / ferrules provided for easy maintenance.




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Table 4 Details of RIO Panel

S.No Component (Make) Specification

1. PLC Panel enclosure (Rittal or equivalent)

1200 mm (W) x 400 mm (D) x 2000mm ( H ) with 100 mm plinth suitable for matching with existing base frame

2. Panel internal wiring cables (Lapp or better)

Will be finalized during detailed engineering

3. Cooling fan for panels with necessary filters ( Rittal or better)

2 fans per panel of 8 inch size with necessary sensor for remote monitoring of fan running status

4. Fan failure detection and regulation units( Reputed Brand)

One for each UPS

5. Top cover with additional perforation sheet ( Reputed Brand)

As per panel specification

6. MIL Connector fixing bracket Will be finalized during detailed engineering

7. Sub rack with swing arm assembly for keeping TMR interface boards


8. Terminal blocks inside panel ( Wago make with cage clamp)


9. Mounting plate for fixing the hardware components


10. 24V DC Power supply holding clamps Will be finalized during detailed engineering

11. MCBs for individual isolation of rack power supply, bulk power supply and illumination for panel and fan for each UPS ( Siemens/ Schneider )





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S.No Component (Make) Specification

12. Necessary Surge Protection Devices Will be finalized during detailed engineering

15 Remote Power ON/OFF Requirements and Panel Environment Monitoring System

15.1.1 All the Remote IO systems provided at the launch complex at various distributed locations and control centre should be installed in necessary rack mounted enclosures. All the PLC racks, IO racks, servers and operator terminals shall be powered using dual redundant power supply outlets. Each of the independent power outlets should be controllable (Switching ON / OFF) remotely from the Control Centre. A Separate Network (independent of the above network) based redundant system to be provided for meeting this requirement.

15.1.2 Schneider make smart link distribution system/equivalent system may be considered for this purpose

15.1.3 Smart IO Module shall have in built web pages for monitoring, control, energy metering, configuration, diagnostic and alarm notifications. It shall communicate the monitoring data to centralized software directly from the smart IO module via register addressing. Provision must be available for IP filtering for viewing of web pages.

15.1.4 The smart module must have provision to send emails / alerts for the following events: Change in state of connected components, running hours exceed, number of trips exceeded for protection and control devices

15.1.5 Smart IO module shall be equipped with plug in type input/output terminal blocks. Wiring shall be done in such a way that smart IO module shall be easy to replace by removing all connected wired without using any screw driver




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16 Fiber Optic Interface Requirements

16.1 All interfaces external to the buildings should be interfaced using fiber optic links. Each fiber optic links should be implemented with necessary end-equipment supporting dual or better FO cables, redundant configuration, with automatic detection of cable pair failure, isolation and recovery features.

16.2 Single mode FO cable must be laid from Filling Control Center in Zero Point to Remote Location1 and from Remote Location1 to all other Remote Locations. End cable gland, splicing and termination with associated enclosures and accessories are in the scope of this contract. OTDR test shall be carried out after completion of splicing and testing to measure the signal loss and reports to be submitted. Exact FO cable routing and termination shall be worked out as per the offered system configuration as part of detailed engineering.

Fibre optic cables Specification

Description Essential Specification

Manufacturer Schneider/Clipsal/Digilink/Amp/HFCL/ Tyco

Cable type 48-core single mode optical fiber cable, armored with multi tube design having central strength member

Fiber type Single mode fibers.

Total Fiber count 48 nos.

Number of Fibers per Tube & colour of fiber in tube

8 Nos. Blue, Orange, Green,Brown,Slate,White,Red and Black.

(Supplier can mention their offered colours if they are different)

Number of loose tubes & Tube colours

6 Nos. Blue, orange, green, brown, slate and White.




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Attenuation Attenuation at 1310 nm: <= 0.36 db/km

Attenuation at 1550 nm: <= 0.22 db/km

Fiber coating diameter 245 +/- 10 microns

MFD 9.2 +/- 0.4 microns

Clad diameter 125 +/- 1 micron

Inner sheath thickness 1.2 mm(min) HDPE - Black

Outer sheath thickness > 1.8 mm (min) HDPE - Black

Armour 0.150mm ECCS tape

Moisture barrier Water swell able tape or poly tape or Flooding Gel

17 General Requirements

The following other requirements should be provided to evaluate the proposed system and for acceptance testing of the system. The Environment conditions under which the Controllers should work are also indicated in this section.

17.1 Detailed Response time calculation study to be prov ided (Network, PLC, SCADA)

Detailed Response time calculations with necessary breakup data, system wise, should be provided for analysis of the offered system as well as for acceptance testing.

17.2 Test Modules for system validation

Necessary test modules to demonstrate the system performance during acceptance testing should be provided.




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17.3 Environmental Conditions

The Controllers should be able perform flawlessly under the following worst-case environmental conditions. However, the SCADA system at the control center will have normal environmental conditions.

Temperature : 0°C to 50°C

Humidity : 50% RH to 95% RH non condensing

AC Supply : 230V ± 10%, 50Hz ± 5%

Vibration : As per IEC61131 – 2 standards

Shock : 15 g peak, 11 msec

Environment Protection : Corrosion protection (G3 standard) conformal coating at OEM factory for the PCBs should be ensured




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18 Existing System Configuration

Process Control Systems at SLP for Pre-launch servicing of liquid stages of PSLV and GSLV are realized with Programmable Logic Controller (PLC) based Triple Modular Redundant (TMR) Control Systems and Client-Server based SCADA systems. The Automation system consists of three subsystems i.e. PLC System, Data Concentrator and SCADA System.

Existing propellant filling control system consists of two independent and similar control systems. Automation system1 for Earth Storable propellant filling consists of four controllers with respective IOs, Server-Client based SCADA system, Network System and Data Concentrator. Similar and independent Automation system2 exists for Cryo propellant filling.

The following diagram gives the configuration of Automation system-1:

SERVER M SERVER R

GASUH25N2O4PS4

TMR

LAN

DC

FCC

6Km

LC

TMR

IOs

4 Serial IO

Figure 5 Configuration of Automation System-1




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The following diagram gives the configuration of Automation system-2:

SERVER M SERVER R

LHFSCGSSLOFSNSS

TMR

LAN

DC

FCC

6Km

LC

TMR

IOs

4 Serial IO

Figure 6 Configuration of Automation System 2

18.1 SCADA System

This system consists of client server based SCADA on Suse Linux 8.0 version. The servers are redundant and Master server posts commands to the field and Slave server synchronizes and ready to take over any time. There are 24 operator clients which are reconfigurable to connect to display any mimic. The SCADA system supports all basic features like-Real time Database, alarm, real time trending, redundant network support with bonding, audit trails, concurrent engineering etc.




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18.2 PLC System

PLC system consists of 4 PLCs and each PLC consists of TMR CPU based Main CPUs and TMR based IO layers. CPU layer consists of 3 CPUs, each one executing the application logic downloaded from programming terminal. Programming terminal is windows 2000 based system which connected to PLC network exclusively for downloading and online monitoring of variables. One among the three CPUs takes over as master and the healthiest is the master using the concept called flying master. All three main CPUs acquire data from all three IO layers. Each CPU has two Ethernet network connectivity to SCADA.TMR IO layers are connected to main CPUs via Ethernet and each IO layer is having local CPU and communication module. Local CPU can’t be programmed by user, it is having internal software for voting and analog averaging. These IO layers are interfaced with field via interface boards.

18.3 Data Concentrator

Data Concentrator is Hot-Standby CPU for connecting to external interfaces like checkout for acquiring Telemetry data and IRIG-B for acquiring universal time. In this system Standby CPU sends the two telemetry frames received by its own interfaces within one scan cycle to main CPU. Main CPU has 4 telemetry frames every cycle and selects the best for processing. Each CPU has two Ethernet link connectivity to SCADA.

18.4 Network

Network connectivity between SCADA Server and Client is via TCP/IP using copper cable (Cat.5). Network connectivity between PLC and SCADA server is via TCP/IP using Single mode Fiber Optic cable. Network connectivity between main CPU and IO layer is via UDP using copper cable (cat.5) for local IO layer and Multi mode Fibre optic cable for remote IO layers.

18.5 Interface with field I/Os

All interfaces from field instruments are terminated at instrumentation junction boxes (IJBs). All field cables are terminated and signal conditioners are mounted in the junction boxes. Instrumentation Power supplies are used for commanding EP valves and excitation to Signal conditioners. The existing interface details for various I/Os are as given below:




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The inputs (analog and digital) that are available from the field as single input without redundancy must be triplicated at the IO rack and fed to the TMR input cards. Such inputs are referred as Panel triplicated inputs. The inputs (analog and digital) that are available in TMR mode from the field are to be fed to the respective input cards directly. These inputs are referred as field triplicated inputs

18.5.1 Digital Input interface

The open/close status of EP valves, pressure switches status and ON/ OFF status of pumps is acquired as digital values. The 2/3 voting logic is implemented in system software as SIFT logic. Any discrepancy of the individual channels is available at the main controllers and monitored at the operator terminals as part of the system health monitoring. For status monitoring of EP valves, three potential free contacts of micro-switches of the actuator are used for open & close status. The three inputs, each for open and close used in the 2/3 logic circuits implemented through in-built software based voter.

Status of intermediate relays of EP valve command and status of external voter relays are connected to I/O cards for monitoring. Failure detection is monitored at the operator terminals. The interface board configuration for panel triplication is given below.




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Figure 7 Typical TMR digital input cards with interface board for a single field input with triplication in IO Panel




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a) Digital Input Panel Triplicated

a. The IO Wiring should be as shown in the figure. Or any technical equivalent solution of similar functionality to be provided by supplier in line with the following components.

b. Components Involved in the Wirings are as follows

i. Wiring Arm.

ii. Prefab Cable as per the requirement of the module wiring Connections.

iii. Harting Connector Male and Female Connector to Interface between Wiring Arm and Digital Triplicated board.

iv. Harting Pins should be gold plated with dusthood coverings.

v. MIL Connector as per the existing system configuration along with Prefab cable connecting to Interface Board through the Harting Connectors.




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vi. Interface or Triplicated boards should be multi-layered PCB with Track ratings as per the current requirement of Modules and Contact ratings.

vii. Required Terminal Blocks groups and power wiring are to be considered as per the Wiring schematics of the supplier.

viii. Fuse protected terminal blocks shall be provided wherever required either for isolation or short circuit protection to avoid damages to boards / modules.

ix. All cables should be prefab cable with the identification marking on each core. No Single or individual cable is allowed for module and power supply wiring.

x. The cables should be tagged with unique number for each panel.

xi. The Number of triplication boards should be decided based on the requirement as per system configurations.

xii. Protection for failure of 1 module or power supply should not disturb the other module or should not indicate any discrepancy values.

b) Digital Input Field Triplicated



i. Wiring Arm.


iii. MIL Connector as per the existing system configuration along with Prefab cable connecting to the wiring Arm.

iv. Required Terminal Blocks groups and power wiring are to be considered as per the Wiring schematics of the supplier.




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v. Fuse protected terminal blocks shall be provided wherever required either for isolation or short circuit protection to avoid damages to boards / modules.

vi. All cables should be prefab cable with the identification marking on each core.

vii. The cables should be tagged with unique number for each panel.No Single or individual cable is allowed for module and power supply wiring.

viii. The Number of cables should be decided based on the requirement as per system configurations.

ix. Protection for failure of 1 module or power supply should not disturb the other module or should not indicate any discrepancy values.

18.5.2 Digital Output interface

DO commands are issued for operating Electro-pneumatic (EP) valves or pumps through the instrumentation interfaces. The preliminary 2/3 voting logic is achieved in the Remote I/O. Failure/discrepancy of the individual channels are available at the operator as part of the system health monitoring software. An external Hardware output voter using relay logic is configured wherein final voting takes place and its output actuates the field element in main and redundant configuration for main and redundant solenoids separately.

For this, a standard hardware relay voter module for 2oo3 voting is configured. The power supplies in the IO rack are used for energizing the relays in this hardware voter module. Power supplies for driving the field elements are the instrumentation power supplies. The interface board configuration for Digital output voting for single channel is given below.




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Figure 8 Typical TMR Digital Output interface board for a single channel




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Digital Output Panel Triplicated

i. The IO Wiring should be as shown in the figure. Or any technical equivalent solution of similar functionality to be provided by supplier in line with the following components.

ii. Components Involved in the Wirings are as follows

iii. Wiring Arm.

iv. Prefab Cable as per the requirement of the module wiring Connections.

v. Harting Connector Male and Female Connector to Interface between Wiring Arm and Digital Triplicated board.

vi. Harting Pins should be gold plated with dusthood coverings.

vii. MIL Connector as per the existing system configuration along with Prefab cable connecting to Interface Board through the Harting Connectors.




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viii. Interface or Triplicated boards should be multi-layered PCB with Track ratings as per the current requirement of Modules and Contact ratings.

ix. Required Terminal Blocks groups and power wiring are to be considered as per the Wiring schematics of the supplier.

x. Fuse protected terminal blocks shall be provided wherever required either for isolation or short circuit protection to avoid damages to boards / modules.

xi. All cables should be prefab cable with the identification marking on each core. No Single or individual cable is allowed for module and power supply wiring.

xii. The cables should be tagged with unique number for each panel.

xiii. The Number of triplication boards should be decided based on the requirement as per system configurations.

xiv. Protection for failure of 1 module or power supply should not disturb the other module or should not indicate any discrepancy values.




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18.5.3 Pulse input

The Pulse input module accepts up to 15 kHz at 24V level. Each sensor is connected in parallel to three PI modules. The module measures the frequency of the incoming pulses and time between rising edges of two consecutive pulses (Gating). The same module is also used as 16bit counter for totalizing.

Figure 9 Typical TMR pulse input interface board for a single channel

Pulse Input Panel Triplicated



i. Wiring Arm.




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iii. Harting Connector Male and Female Connector to Interface between Wiring Arm and Digital Triplicated board.


v. MIL Connector as per the existing system configuration along with Prefab cable connecting to Interface Board through the Harting Connectors.

vi. Interface or Triplicated boards should be multi-layered PCB with Track ratings as per the current requirement of Modules and Contact ratings.

vii. Required Terminal Blocks groups and power wiring are to be considered as per the Wiring schematics of the supplier.

viii. Fuse protected terminal blocks shall be provided wherever required either for isolation or short circuit protection to avoid damages to boards / modules.

ix. All cables should be prefab cable with the identification marking on each core. No Single or individual cable is allowed for module and power supply wiring.


xi. The Number of triplication boards should be decided based on the requirement as per system configurations.




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18.5.4 Analog Input

The analog signals interface board configuration used in the system is given in the figure below. These analog input sensors are either single or triple in field. Wherever they are triple in field, each input will be connected to one of the respective triple I/O directly. When a single sensor is available at field, it triplicates using a triplication module in control system rack and fed to all the three columns. The input at the AI card shall be always taken as 4-20mA.

Figure 10 Typical TMR Analog input interface board for a single channel

Analog Input Panel Triplicated

c. The IO Wiring should be as shown in the figure. Or any technical equivalent

solution of similar functionality to be provided by supplier in line with the

following components.

d. Components Involved in the Wirings are as follows

i. Wiring Arm.

ii. Prefab Cable as per the requirement of the module wiring

Connections.




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iii. Harting Connector Male and Female Connector to Interface between

Wiring Arm and Digital Triplicated board.


v. MIL Connector as per the existing system configuration along with

Prefab cable connecting to Interface Board through the Harting

Connectors.

vi. Interface or Triplicated boards should be multi-layered PCB with

Track ratings as per the current requirement of Modules and Contact

ratings.

vii. Required Terminal Blocks groups and power wiring are to be

considered as per the Wiring schematics of the supplier.

viii. Fuse protected terminal blocks shall be provided wherever required

either for isolation or short circuit protection to avoid damages to

boards / modules.

ix. All cables should be prefab cable with the identification marking on

each core. No Single or individual cable is allowed for module and

power supply wiring.


xi. The Number of triplication boards should be decided based on the

requirement as per system configurations.




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18.5.5 Analog output

AO commands are used for operating Continuous control valves (for PID loops) through the instrumentation interfaces. Analog output is switched in 1oo3 logic i.e. the outputs are multiplexed and only one output is used at a time. The connectivity is failure tolerant. The switching takes place by commanding the selection relays by DO command based on the current feedback read by the AI module. This voting and selection of one AO for field command is executed as a part of system software.

Figure 11 Typical TMR Analog Output interface board for a single channel

Analog Output Panel Triplicated

e. The IO Wiring should be as shown in the figure. Or any technical equivalent

solution of similar functionality to be provided by supplier in line with the

following components.

f. Components Involved in the Wirings are as follows

i. Wiring Arm.




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ii. Prefab Cable as per the requirement of the module wiring

Connections.

iii. Harting Connector Male and Female Connector to Interface between

Wiring Arm and Digital Triplicated board.


v. MIL Connector as per the existing system configuration along with

Prefab cable connecting to Interface Board through the Harting

Connectors.

vi. Interface or Triplicated boards should be multi-layered PCB with

Track ratings as per the current requirement of Modules and Contact

ratings.

vii. Required Terminal Blocks groups and power wiring are to be

considered as per the Wiring schematics of the supplier.

viii. Fuse protected terminal blocks shall be provided wherever required

either for isolation or short circuit protection to avoid damages to

boards / modules.

ix. All cables should be prefab cable with the identification marking on

each core. No Single or individual cable is allowed for module and

power supply wiring.


xi. The Number of triplication boards should be decided based on the

requirement as per system configurations.




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18.5.6 Interfaces with Allied Systems

For communication with Allied Systems a dual redundant Data concentrator is used at filling control centre (FCC) separately. The data concentrator acquires the serial data from Checkout, Telemetry and Timing and forwards this information to the corresponding main controllers and servers via control network.

Frame Format – RS422 data

Interface : RS 422 full duplex link

Speed : 115200 bits/s

Frame size : 1024 bytes

Data type : ASCII coded Binary

Async. Format : 7 bit, even parity, 1 stop bit

Redundancy : Hot Standby Frame rate : 100 mSec

STX

Frame

Length

STS

___

STS

DATA

…

DATA

CS RS

1B 3B 4B 4B --------- data ---------------- 4B 1B STX, RS Frame delimiters CS Checksum (addition of all bytes excluding STX and RS) B Bytes STS Status code




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19 Existing Rack Configuration:

19.1 CPU Rack:

The CPU rack consists of Main TMR CPUs, Ethernet Switches (Multimode), 24V DC Power Supplies (2 Nos), MCBs and Terminal blocks

19.2 IO Racks:

IO racks consists of TMR IO modules, 24V DC Power Supplies (8 Nos), Interface boards, MIL connectors, prefab cables for connecting interface boards and IO modules and also interface boards to MIL connectors, Group Authorisation relays, MCBs and Terminal blocks. In case of Remote IO Rack, one IO rack is having Ethernet switches for connecting to CPU layer.




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19.3 MIL connectors

The interface boards for panel triplication and the IO cards for the field triplicated inputs are connected to the Instrumentation junction box using MIL connectors. The MIL connector consists of mating and receptacle part. Receptacle is connected between I/O module to field connector in the I/O rack which should be supplied as part of the system and mating is connected between field connector to instrumentation junction box which is supplied by the department in order not to disturb existing field wiring.

The part number and specification of existing MIL connectors are given below, the proposed system must use these MIL connector type for interfacing with existing instrumentation system

S.No Module Type MIL Type Part Number




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1. Digital Input 41 pin Female MS3470w 20-41s

2. Digital Output 41 pin Female MS3470w 20-41s

3. Analog Input 32 pin Male MS3470w 18-32p

4. Analog output 19 pin Female MS3470w 14-19s

5. Pulse Input 10 pin Male MS3470w 12-10p

6. Digital Output – Power Supply 4 pin Male MS3470w 14-4p

Table 5 MIL Connector Specification at PLC Panel

System

41 pin 32 pin 19 pin 10 pin 4 pin

(Female) (Male) (Female) (Male) (Male)

Automation System 1 600 65 10 20 125

Automation System 2 600 50 10 15 100

SUM 1200 115 20 35 225

Table- 6 Tentative MIL connector count for existing Automation systems




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19.4 IO module distribution in the existing system

Details of IO modules distribution for each PLC system with rack wise and slot wise information is provided for your reference.

Table 7 Existing IO distribution inside the racks in Automation system-1

PLC-1/ PLC-2 (Both are having identical IO quantity )

Location

Rack N

o

I/O Rack Slot Number

S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13

RL1

1 DO_AO AI_AO AO AIP DIP DIP AIP DIF DIF DIR DO DI_AO DIP

2 AIP AIP DIF DIF DIF DIF DIR DO DIR DO DIR DO AIP

3 AIP PIP PIP PIP DIF DIF DIF DIF DIR DO DIR DO DIP

RL2

4 AIP AIP DIF DIF DIF DIF DIR DO DIR DO DIR DO DIP

5 AIP AIP AIP AIP AIP DIF DIF DIP DIR DO AIP

6 DO_AO AI_AO AO PIP PIP DIP DIP DIP DI_AO DIF DIF DIR DO




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PLC-3

Location

Rack N

o

I/O Rack slot number

S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S1 S13

RL1

1 AIP DIF DIF DIF DIF DIP DIP DIR DO DIR DO DIR DO




5 AI PIP PIP PIP PIP DIF DIF DIF DIF DIP DIR DO DIP

6 DOAO AIAO AO AIP AIP DIF DIF DIP DIAO AIP DIP

7 DIP DIF DIF DIR DO

RL4 8 DIF DIF DIF DIF DIP DIP DIP DIR DO DIR DO DIR DO

9 AIP AIP DIF DIF DIP DIP AIP DIP DIF DIF DIR DO

PLC-4 Location

Rack N

o


S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13

RL1



3 AIP PIP PIP PIP DIF DIF DIP DIR DO DIR DO DIR DO

4 AIP AIP AIP AIP AIP PIP PIP DIR DO DIF DIF DIR DO

5 DO_AO AI_AO AO DI_AO DIP AO AIP DIF DIF DIR DO AIP DIP




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Table 8 Existing IO distribution inside the racks in Automation system-2

PLC-1

Location

Rack N

o


S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13

RL1

1 PIP PIP DIF DIP DIP DIP DIP DIR DO DIR DO

2 DIF DIF DIP DIP DIP DIP DIP DIP DIR DO DIR DO

3 DIF DIF DIF DIF DIP DIP DIR DO DIR DO DIR DO

4 PIP PIP PIP DIF DIF DIP DIP DIP DIP DIR DO DIR DO

5 DO_AO AI_AO AO AIP AIP AIP AIP AIF DI_AO

6 AIP AIP DIP DIF DIF DIF DIF DIR DO DIR DO DIR DO

RL6

7 DIF DIF DIF DIF DIP DIP DIP DIR DO DIR DO DIR DO

8 DIF DIF DIP DIP DIP DIP DIP DIR DO DIR DO DIR DO

9 DO_AO AI_AO AO AIP AIP AIP DIP DIP DI_AO

PLC-2

Location

Rack N

o


S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13

RL1

1 AIP PIP PIP DIF DIF DIF DIR DO AIP


3 DIF DIF DIF DIF DIP DIP DIR DO DIR DO

4 DIF DIF DIF DIF DIP DIP DIR DO DIR DO




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5 AIP DIP DIP DIF DIF DIF DIF DIF DIP DIR DO DIR DO

RL7

6 AIP DIF DIF DIF DIF DIP DIP DIR DO DIR DO

7 AIP AIP DIF DIF DIP DIP DIR DO DIP

PLC-3

Location

Rack N

o


S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13

RL1

1 PIP PIP DIF DIP DIP DIP DIP DIR DO DIR DO


3 DO_AO AI_AO AO AIF PIP PIP DIF DIF DIP DIP DI_AO

4 AIP DIF DIF DIF DIF DIP DIP DIR DO DIR DO

RL8


6 DO_AO AI_AO AO AIP AIP AIP PIP DIP DIP DIP DI_AO

PLC-4

Location

Rack N

o


S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13

RL1

1 DIF DIF DIP DIP DIR DO DIR DO

2 DO_AO AI_AO AO AIP AIP AIF DIP DI_AO

RL9

3 DIF DIF DIF DIF DIP DIP DIP DIP DIR DO DIR DO

4 DO_AO AI_AO AO AIP AIP DIP DI_AO




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DI - Digital input (32 channels)

PI - pulse input (4 channels)

AI - Analog input (16 channels) AO - Analog output (8 channels) DO - Digital output (32 channels) DIR - DI read back for DO DIF – DI field triplicated DIP - DI panel triplicated DI_AO - DI for selection DO AIP - AI panel triplicated AIF - AI field triplicated AI_AO - AI read back for AO DO_AO - DO for AO selection RL1, RL2 up to RL9 - remote location1, remote location2 up to remote location9 S1, S2 to S13 – Slot1, Slot2 up to Slot13




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19.5 Tentative Bill of Materials of automation systems b ased on existing system configuration

Tentative Bill of Materials (BOM) based on existing system configuration is provided for your reference. However the actual BOM shall be provided by the bidder based on offered system configuration.

Item Automation System-1

Automation system-2

Automation system-3

Hot standby controllers 5 5 2

32ch Digital I/P modules 561 639 15

16ch Analog I/P modules 165 132 6

4ch Pulse I/P modules 57 36 3

32ch Digital O/P modules 180 177 3

8ch Analog O/P modules 21 24 3

24V DC 10A Power supply modules for Operation of relays and for Internal PLC supply

236 236 4

Controller backplanes 10 10 2

IO rack backplanes 78 78 3

Rack Power Supply modules 176 176 10

IO/Host Communication modules 98 98 13

PLC SCADA Communication Module 20 20 4

Interface Module for DO (2oo3 H/W Voter) with JSS certified or equivalent OEN make min 5 contacts relays (OEN Relay Part No: 67EP-24-6Cx-PC-NIT or equivalent or better)

240 boards 5760 relays

236 boards 5664 relays

4 boards 96 relays




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Automation system-2

Automation system-3

Interface Module for panel triplicate DI 43 69 1

Interface Module for panel triplicate AO with JSS certified OEN make relays 14 16 2

Interface Module for panel triplicate AI 55 39 1

Interface Module for panel triplicate PI 19 12 1

Prefab cables 1 lot 1 lot 1 lot

Receptacle part of MIL Connectors (refer MIL connector table) 1 lot 1 lot 1 lot

Network Switches for PLC systems (PLC to SCADA and PLC to Remote IO Systems) 30 30 2

IDE for PLC – S/W Licenses 10 10 10

Panel enclosures for housing PLC and necessary interface elements 57 57 1

Serial Communication modules 4 4 4

Remote Power On and Environment Monitoring System for each control room for both UPS ( Schneider make smart link distribution system / equivalent)

8 10 0

Servers 11 11 2

Server racks 2 2 0

Clients 36 36 4

48 port Cisco switches for Operator network 2 2 2

Network management tool 1 1 0

Portable Programming stations with necessary operator & programming license

1 1 0




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Automation system-2

Automation system-3

Industrial grade Kiosk operator stations with necessary operator license to be installed in field

3 3 0

Mobile system monitoring stations with necessary operator license 3 3 0

SCADA Client S/W Licenses 25 25 4

SCADA Server S/W Licenses 6 6 2

5000 tag Historian License 2 2 0

Web Clients 25 25 0

Storage Server 1 1 0

CCTV monitors (24 inch) 15 15 0

Network laser printers 1 1 0

Wireless Network devices for extending SCADA network to remote locations 4 4 0

Operator Trainer System/Simulator(OTS) 1 1 0

PLC Program Static Analysis Tool (PLC checker or equivalent) 0 0 1

Test jigs/ simulators for FAT / SAT 1 1 0

Tool for making Panel engineering and electrical circuits (EPLAN/ equivalent) 1 1 0

Antivirus software ( Symantec end point protection or equivalent or better) 1 lot 1 lot 1 lot