-
Domain : bpcleproc.in
Parent department: BPCL
Department : CPO (M) -ProcurementGroup 3
Department officer : D Manimaran
System ID : 13140 Tender Reference No. : CRFQ1000257169
Tender Title : GLOBAL 2- BIDTENDER
FORDESIGN,SUPPLY,INSTALLATION,TESTING &COMMISSIONING OF 4
NOS.AUTOMATIC
24STATIONELECTRONICCAROUSELWITHINTEGRATEDELECTRONICDOWN
STREAMFACILITIESINCLUDINGVISION UNITFORMANGALORE,BAITALPUR,RAIPUR
& NRLLPG PLANTS.
Tender Date : 15/06/2016
Tender Description : 1. Global TENDER for Design, Supply,
Installation, testing & commissioningof 4 nos. Automatic 24
station Electronic Carousel with Integrated ElectronicDown Stream
facilities including vision unit & Annual Maintenance
Contractfor 3 years at BPCL Mangalore, NRL, Baitalpur & Raipur
LPG Bottling Plant,is floated in Two part bid through E-Tender
system, consisting of BidQualification, Technical plus Commercial
qualification & Price Bid floatedtogether.2. Evaluation of
offers and award will be on location-wise lowest landed costbasis
including AMC for 3 years. Bidders should qualify in BQC, Technical
&Commercial bids , in order that their price bid is opened.
First the BidQualification Criteria will be evaluated. Technical
cum commercial bids of onlythose vendors who meet the BQC will be
taken up further. Price bids of onlytechno-commercially qualified
bidders will be opened.3. A Pre-bid meeting is scheduled for
24.06.16 at 11:00 hrs IST at the office ofBPCL. All prospective
bidders can participate in the same. All queries to reachus before
pre-bid meeting date. No queries will be entertained post
pre-bidmeeting date.BPCL reserves the right to extend the Due Date
of Tender.4. Forms/ Attachments to this tender may be noted while
bidding.5.Please note that foreign bidders quotes should be either
in USD or EUROonly. Please mention the currency in which you have
quoted (USD/EURO).6.In price bid, wherever CST is applicable,
vendor has to quote the CST (withform-c). Octroi/Entry tax shall be
paid extra at actuals against documentaryevidence in original.
Tender Document
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 1 of 75
-
7. Contract will be placed by us. Actual Call-Off Shall be
placed from MatsE&PNOIDA/LPG SBU/NRL. Payment shall be
processed by the Originator ofCall-off/ BPEC & NRL for their
requirement. For the NRL requirements , M/sNRL will be placing the
contract/order & payments will also be made by them.8. Price
will be firm till execution of order and no escalation will be
entertainedon any ground. BPCL reserves the right to vary the
quantities of the tender.9. Packing and Forwarding: The materials
should be properly packed so as towith stand all transit hazards
till our sites.10.OCTROI/Entry Tax : Octroi/Entry Tax, if,
applicable will be reimbursed tovendor extra at actuals against
documentary evidence.11. Unloading & stacking will be arranged
by consignee. However, advanceinformation regarding expected date
of delivery to Site In-charge must be givenwell in time for making
unloading arrangements under advice to originator ofcall-off.12. IN
CASE OF ANY CLARIFICATION PERTAINING TO E-PROCUREMENT PROCESS, THE
TENDERER MAY CONTACT THEFOLLOWING PERSONNEL OF M/S BPCL.PROCUREMENT
LEADER :MR.MANIMARAN DASARAJLANDLINE NO. : 022 24176408 / MOBILE
NO. 8220002889 / E-MAIL :[email protected]
MANAGER : MRS. SRINIVAS SONIALANDLINE NO. : 022 24176418 / MOBILE
NO. 9820067543 / E-MAIL :[email protected]
Envelope Bidding Type : In 2 Part bidding Envelope Bidding
Option : Document fees andEMD + Technicalbid + Price bid
Bid validity period (in days) : 180 Type of contract : Goods
Project duration / delivery orcompletion period (in days)
: 180 Form of Contract : Supply
Bid submission configuration
Bidding access : Open/Press
Base currency : INR Bidding type : Global
Bidding currencies : INR,EURO,USD
Key configuration
Bidding variant : Buy Mode of pre-bid meeting : Offline
Pre Bid Meeting Venue :
CENTRAL
PROCUREMENT
ORGANIZATION(MKTG),
BPCL, A INSTALLATION,
SEWREE FORT RD,
SEWREE(E), MUMBAI
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 2 of 75
-
400 015, INDIA PHONE
022 24176408/24176418
Dates configuration
Document downloading startdate
: 17/06/201609:00:00
Document downloading enddate
: 14/07/201614:00:00
Bid submission start date : 25/06/201617:00:00
Bid submission end date : 14/07/201615:00:00
Pre-bid meeting start date : 24/06/201611:00:00
Pre-bid meeting end date : 24/06/201614:00:00
Bid opening date : 14/07/201615:01:00
Document / EMD / Security fee detail
Tender fees : Not Applicable EMD amount : INR :750000.00EURO
:10021.00USD : 11138.00
EMD payable at : BHARATPETROLEUMCORPORATIONLIMITED,MUMBAI
Emd Clause :
Earnest Money Deposit
(EMD) ( also referred to as
Bid Security): You shall be
required to submit the
Earnest Money Deposit
(EMD) of Rs. 750000/-(
seven Lakhs,fifty thousand
only) for Indian bidders &
11138 USD or 10021 Euro
for foreign bidders , as
applicable in physical form
by the way of demand draft
drawn on any Nationalised
or scheduled bank in favour
of M/s Bharat Petroleum
Corporation Ltd. and
payable at Mumbai at our
office in a sealed cover
addressed to Procurement
Leader Gr 3, with following
boldly super-scribed on the
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 3 of 75
-
outer cover CRFQ number,
Item, Closing date,Time,
Name of the tenderer. It
should be dropped in the
tender box or sent by
Registered Post/Courier to
the following address so as
to reach before the due date
& time of the tender.
Wire transfer shall be
allowed only for foreign
bidders.Exemption for
EMD would be in line with
govt. policy for MSE/NSIC
vendors.
EMD Payment Method : Demand Draft
Documents
Sr.No. File name File description
Filesize (in
MB)Date and time Status
1 DECLARATION13140.pdf
declaration 0.083 10/06/201623:14:52
Approved
2 GPC (with PMAArbitration clause &
Holiday Listing Link)on12.10.15.pdf
GPC 0.308 10/06/201623:14:52
Approved
3 SPC 13140.pdf spc 0.092 10/06/201623:14:52
Approved
4 Integrity pact 13140.pdf Ipact 0.325 10/06/201623:14:52
Approved
5 Instructionsto_the_vendors13140.pdf
ITB 0.388 10/06/201623:14:52
Approved
Bidding forms
Documentfees andEMD
EMD Form
EMD Form
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 4 of 75
-
Details Bidder'sResponse
EMD Amount offering
Currency
EMD Payment Method
Instrument No.
Payment Date
In case of wire transfer by foreign vendor, pl submit
details
In case of MSE vendor for the tendered item , submit EMII
document & itshould mention the tendered item
Documentfees andEMD
EMD Form
Details Bidder's Response
EMD Amount offering
Currency
EMD Payment Method
Instrument No.
Payment Date
EMD Form
Technicalbid
BID-QUALIFICATION CRITERIA
BID-QUALIFICATION CRITERIA
S.No Bid-Qualification Requirement BiddersResponse
BID-QUALIFICATION CRITERIA (BQC)
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 5 of 75
-
1 1.The Vendor should be a manufacturer of 24 station electronic
carouselwith integrated electronic down- stream facilities
including vision unit. Thevendor should have supplied and
successfully commissioned at least onenumber of 24 station
electronic carousel with integrated electronic down-stream
facilities including vision unit in the last seven years prior to
duedate of tender.Documents required:Vendor should furnish copies
of thepurchase order/s along with successful commissioning
certificate from thebuyer in proof of above.Indian vendor to submit
central excise registrationcertificate for manufacturer &
foreign vendor to submit certificate from thecountry of origin’s
chamber of commerce in support of them being amanufacturer of above
mentioned equipment.
2 2.The vendor should have achieved a minimum average Annual
financialturnover of Rs.5 Cr (For Indian vendors) / USD 0.74
Million or Euro 0.67Million (For Foreign vendors) as per Audited
financial statements(including Balance Sheet and Profit & Loss
account), during the last threeconsecutive accounting years prior
to due date of tender The vendor’s networth should be positive as
per last available Audited financial statements(including Balance
Sheet and Profit & Loss account). The net worth isdefined as
TOTAL ASSETS MINUS TOTAL LIABILITIES.Documentsrequired:Audited
Balance Sheets & Profit & Loss account of the vendor forthe
last three consecutive accounting years (English language only)
prior todue date of tender.
Technicalbid
Acceptance Of ITB and GPC and SPC
Acceptance Of ITB and GPC and SPC
SrNo
DocumentName
FileName
I / We have read, understood and accepted the followingAnnexure
of the Tender Document. (To read theDocument please click the
corresponding Download link)
1 GeneralPurchaseConditions
gpc.pdf
2 Instructions toBidders
ITB
3 specialconditions
SPC
Acceptance Of ITB and GPC and SPC
Technicalbid
Annexures for acceptance and upload after duly filled, signed
& Stamped.
Annexures for acceptance and upload after duly filled,
signed & Stamped.
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 6 of 75
-
Annexures for acceptance
SrNo
DocumentName File Name
I / We have read, understood and accepted thefollowing Annexure
of the Tender Document. (Toread the Document please click the
correspondingDownload link)
1 Declaration Declaration.pdf
2 IntegrityPact (IP)
IP.pdf
Technicalbid
Particulars of Bidder for tender
Particulars of Bidder
. .
1. Name of the Tenderer
2.(a) Office Address/ PAN no.
2.(b) Factory Address
2.(c) Tel No - Office
2.(d) Tel No - Factory
2.(e) Fax No - Office
2.(f) Fax No - Factory
3. Email ID (The email ID should be valid for the full tender
period and the informationshared/ advise issued/ other mails sent
to this ID shall be treated as official communicationfrom either
sides)
4.Name/ designation of personnel handling the email IDs
PL MENTION COUNTRY OF ORIGIN & LOAD PORT Please confirm the
Item Number /Description and Part Number / BTN Classification /
Custom Tariff Number (FOR FOREIGNBIDDERS)
Sales Tax Registration No
Particulars of Bidder for tender
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 7 of 75
-
. .
a) State Sales Tax
b) Central Sales Tax
c) Service tax registration
Technicalbid
A.DETAILS OF RELATIONSHIP WITH BPC DIRECTORS
PART- A (Applicable where Manufacturer is Sole Proprietor)
Description Bidder response
1.Name of Tenderer
2.a.Office Address
2.b.Residence Address
3.Telephone
4. State whether manufacturer is related to any of the
director(s) of BPC
5.If Yes to 4, state the name of the Director and
manufacturer
Put NA whichever is not applicable
PART- B (Applicable where the manufacturer is a partnership
firm)
Description BiddersResponse
1. Name of the Partnership firm
2.Address :
3.Name of Partners
4.State whether any of the partner is a Director to BPC
5. If Yes to 4 ,state the names(s) of Directors.
DETAILS OF RELATIONSHIP WITH BPC
DIRECTORS
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 8 of 75
-
6.State whether any of the partner is related to any of the
Director(s)of BPC
7.If Yes to 6 state the name(s) of Director(s) and the concerned
Partnersrelationship with him/her.
Put NA whichever is not applicable
PART - C (Applicable where the Manufacturer is a Public or
Private Ltd. Co.)
Descrition BiddersResponse
1. Name of the Company
2.a.Address of Regd. Office
2.b.Address of Principal Office
3.State whether the company is a Pvt. Ltd. Co. or Public Ltd
Co.
4. Names of Directors of the Company
5.State whether any of the Director of your Company is a
Director of BPC .
6.If Yes to (5) state the name(s) name(s) of the Director
7.State whether any of the Director of your Company is related
to any of theDirectors of BPC.
.If Yes to (7) state the name(s) of Director and the concerned
Director's (of theVendor) relationship with him/her.
Put NA whichever is not applicable
For the current list of BPC directors, please check on our
website www.bharatpetroleum.in
Technicalbid
DEVIATION
Sr.No.
Tender clauseNo.
BPCL Requirements/specification
Deviations withJUstification
DEVIATION
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 9 of 75
http://www.bharatpetroleum.in
-
Technicalbid
GENERAL DESCRIPTION OF DESIGN, SUPPLY, INSTALLATION, TESTING
ANDCOMMISSIONING OF 24 STN ELECTRONIC CAROUSEL
DESCRIPTION Bidder'sConfirmation
1.1This Specifications mainly indicates the parameters,
conditions andrequirements of BPCL as per which the manufacturer
has to design, procure rawmaterials, manufacture, shop test/inspect
and supply the equipment suitable forfilling, testing, conveying
& transporting LPG cylinders. The specifications areintended to
give the vendor the functions and the operating characteristics
towhich the equipment shall be manufactured.
1.2The design capacity of 24 machine Electronic Type Carousel
shall beguaranteed for minimum 1570 Cylinders per hour for filling
of 14.2 Kgs capacityat a carousel speed of 55 seconds per
revolution and 1000 Cylinders per hour forfilling of 19 Kgs
capacity filling, with minimum 95% filled cylinders havingfilling
accuracy of(-)50 to (+)50 gms range. The overfilled and under
filledcylinders beyond +/- 50gms should not exceed 5% of the gross
filling.
1.3 The quantity of LPG leakage during each detachment/cut off
operation fromeach filling gun to be advised to BPCL.
1.4 The carousel type 24 machine Electronic Filling Machine is
to be designedrequiring minimum manual intervention with production
and monitoringfunctions carried out with the help of PLC, ensuring
automatic and continuousfilling operation of the LPG cylinder.
1.5 Vendor must confirm the guaranteed system accuracy which
will be proven atthe time of handing over the system and the same
shall be guaranteed for Indianclimatic conditions (viz.
temperature/ moisture/ dust/wind/ open sheds). Due tohandling
conditions prevailing in Indian markets the cylinders may not hold
thesame dimensional tolerances after repeated circulation. The
carousel should beable to fill the cylinders as long as the
cylinders are able to stand on the foot ring/ conveyor & the
latching system of carousel should be designed to latch
thecylinders on to the platforms. The guns should also be made with
self aligningfacility to accommodate such cylinders. The system
should perform satisfactorilyunder the ambient temp range of 5 Deg
C to 50 Deg C.
1.6 The Scope of Supply & Works for the 24 station
Electronic Carousel fillingsystem shall include design, procurement
of raw materials, manufacturing, testingand delivering equipment
and accessories and as follows:-
i. The ELECTRONIC Carousel Filling system shall consist of the
following:-
a. 24 Electronic Filling Machines mounted on a steel frame with
rails includingfoundation bolts & central column, swivel joints
for instrument air, LPG, power .
b. Distribution piping network for each filling machine,
GENERAL DESCRIPTION OF DESIGN, SUPPLY,
INSTALLATION, TESTING AND COMMISSIONING
OF 24 STN ELECTRONIC CAROUSEL
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 10 of 75
-
c. Suspension/supporting structure for SC type cylinders -24
nos.
d. Automatic centering and clamping device – 24 nos.
e. Automatic filling head for SC type of valve – 24 nos.
f. Electronic control system with data communication i.e. Power
& data transferarrangement for complete carousel system, data
storage, self diagnostic,electronic hardware & software etc
complete PC ofHP/COMPAQ/IBM/HCL/WIPRO/DELL Brands , with minimum
followingconfiguration
I7 or higher with latest CPU configuration 8 GB or higher RAM
& 1 GB cache
2 TB hard disk
29" High resolution LCD flat screen monitor
Inbuilt DVD / Combo Drive Multimedia system
Keyboard and optical mouse (3 Button)
Licensed Windows OS latest
Including laser jet color printer min 22 Pages per
minute(HP/CANON/WIPRO/EPSON/PANASONIC/TVS Network interface
card10/100 base-T, minimum 3 extra USB 3.0 ports for future use,
hot Standbymachine with KVM switch (sharing key board mouse &
monitor) with pre-loadedoperating system along with workstation
cabinet.
Hard disk device of 2 TB (or more) with Spin Speed of min 7200
rpm andsufficient for storing at least 60 Working days data
(considering two shiftoperation of 8.5 Hours each, 1.5Hour Overlap,
6 Days per Week).
g. Tangential or Radial Type Automatic Ejection Unit – 01
no.
h. A Central Encoding station for tare weight input – 01 no.
i. Provision for Tare weight entry.
j. Filling guns & hoses for all filling machines 24 nos.
k. Carousal drive unit with FLP motor – 01 no.
l. Post filling Automatic Electronic Check Scale of 1600
cylinders per hourcapacity, to check weigh the filled cylinders
with a provision of rejecting theunder& over filled cylinders
–1 no.
m. Pneumatic/ Photo Sensors and internal wiring.
n. Uninterrupted power Supply Unit (UPS) for minimum 30 minutes.
Minimum2000VA. Recommended Makes EPM, DB POWER, HIREL, APLAB, APC,
GE,ABB.
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 11 of 75
-
o. The necessary pipe manifold, valves including differential
pressure valve,pressure gauge, safety valve, micro filter, earthing
devices for the rotary carouselframe , machine and drive unit etc.
including bolts & nuts complete.
p. Other accessories like photo sensor, diverters/pushers,
complete.
q. Supply of all communication cables for equipments in the
filling shed.
r. Equipments for SQC. Automatic SQC sequencing with least count
of 10 gms tobe provided.SQC checking shall include checking of
cylinder weight, valve leak,O-ring leak. MIS to be generated for
cylinder weight, valve leak, O-ring leakalong with the time and
date of checking of cylinder. Serial number of cylindershall also
be part of MIS which shall be punched by the operator.
s. Spares for commissioning and trouble free operation of the
entire systemsduring the warrantee period of two years.
ii. Each filling machine shall be provided with automatic
filling guns for ‘SC’types of valves. ONE EXTRA GUN TO BE PROVIDED
WITH EACHCAROUSEL TO FACILITATE SERVICING OF GUNS.
??? iii.??????? All the necessary air service units comprising
of filter,regulator and lubricator units along with all the
interconnection piping to all theequipment shall be under the scope
of Vendor.
iv. Approval of Chief Controller of Explosives of Petroleum
& Explosives SafetyOrganization (PESO) Nagpur, India for the
Electronic carousel system to beobtained & submitted with the
offer by the vendor or to be provided beforedispatch of
equipment.
v. A detailed drawing showing complete arrangement of the system
along withmeasurement should be enclosed.
vi. 6 sets of Erection, Operation & Maintenance Manuals in
CD form and 3 setsof hard copies for each system.
vii. 6 sets of detailed drawing for civil foundation and general
arrangementdrawing for each Carousel filling system.
viii. 6 sets of Electrical and pneumatic circuit diagram for the
entire Carousalfilling system.
However, the Vendor shall be responsible to complete the work in
all respectsand in doing so, provide/supply all facilities not
covered below specifically, butnevertheless required for the
satisfactory performance of complete system
ix. The following supply/works shall be carried out by BPCL.
a. All Civil Works. However, Vendor should furnish the details
of foundationdrawings for all equipment within 2 months from the
date of purchase order.
b. Erection/installation of all equipment supplied by the vendor
shall be carriedout under the direct supervision of the vendor and
BPCL will provide therequired semiskilled/unskilled manpower,
power/ instrument air. The vendorshould specify the actual
requirement of the same in advance.
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 12 of 75
-
c. Vendor should specify the equipment-wise requirement of
power/cables sizingetc.
Equipment : Power & Cable Size
Electronic Carousal Drive Unit
Other if any.(specify)
d. BPCL shall supply required Air connections for all
pneumatics. Vendor shouldspecify the equipment – wise air
consumption/requirement and pressure as givenbelow. However, vendor
should supply internal connections within theirequipment for inter
connection.
Equipment : Qty of Air & Pressure Required
Electronic Carousal Filling m/c.
Introduction/Ejection unit
Central Encoding station
Check Weighing Scale
Weight Correction unit
Valve Leak detector
O ring Leak detector
Others if any.(specify)
TOTAL AIR Requirement
e. Power cables from BPCL’s main power supply to carousel Drive
unit and toUPS shall be arranged and laid by BPCL. All other cables
including OFC/signalcables & connectors/ junction boxes shall
be supplied by vendor and shall be laidby BPCL as per direction/
supervision of vendor’s engineer. G.I pipe forOFC/signal cable
shall be provided and laid by BPCL as per direction ofvendor’s
engineer.
f . Any other items not specified in the Purchase Order and
essential for thesatisfactory commissioning of the total system
shall be under the vendor’s scopeof supply.
1.7 An operator will enter the tare-weight of the cylinder by
operating on thekeyboard of the Tare weight Central encoding
station and thereafter filling shallbe fully automatic.
1.8 The encoded tare weight shall automatically be transferred
to the cheekweighing system downstream of the carousals
1.9 The system is to be equipped with automatic electronic
equipment for allfunctions with option for any future extension,
modernization or any alteration
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 13 of 75
-
which could be taken up with the incorporation of cylinder
identification (byRFID ), palletisation etc.
1.10 All equipment should be suitable for filling 14.2Kg as well
as 19.0Kgcylinders.
1.11 The measured static (electric) charge generated during
filling of LPGcylinders to be advised to BPCL.
2. SCOPE OF SUPPLY BY VENDOR FOR ELECTRONIC CAROUSAL
Electronic carousal shall consist of but not limited to the
detailed list indicated inclause no. 1.6 The entire electronic
system shall be of FLP/Intrinsically Safeconstruction and fit for
use in Hazardous Zone 1, for Gas group IIA and IIB withambient
temperature rating of (–) 10 Deg C to (+)50 Deg C . All Electrical
andElectronic components of equipments being supplied must have
specific approvalconforming to the required parameters mentioned
above.
3. CENTRAL ENCODING STATION
3.1 There shall be electronic key-board in the encoding station
on which theoperator will punch the tare weight of the cylinder and
this tare weight willautomatically be transferred to the filling
machine as well as check weighingsystem without any error. The tare
input shall be maximum of two digits.
3.2 The key-board shall be able to punch a tare weight range
between 14.0 Kg to20.9 Kg tare weight cylinders. The key board
should have required nos. of keyfor punching tare weight. The
operator shall punch/encode only the last two digitson the
key-board to transfer the tare weight to the electronic filling
machine.
3.3 This equipment is mounted on a chain conveyor upstream of
the LPG fillingcarousal. The operator will key in the tare weight
of the cylinder. The display forthe check scales will be in two
digits after the decimal (xx.yy) e.g. 17.95, 16.10,18.35 etc.
The OEM/ Supplier, type & certification of load cell is to
be advised and theaverage life of the load cell used in check
scales /filling machines is to beinformed.
4. CAROUSEL
4.1 The Carousel can be a steel platform supported by a number
of runningwheels fixed underneath the frame and running on a steel
rail fastened to thefloor. Alternatively, the wheels may be mounted
on the ground and the platformmay rotate above. The carousal shall
rotate around a central column, whichserves as the axis of rotation
as well as a distributor of LPG, power/data/signalcables and
compressed air to the individual filling machines.
4.2 The Carousel shall have a frame size for accommodating 24
filling machinesmounted on its rotating table. The minimum
guaranteed filling capacity shall bemin 1570 LPG cylinders / hour
with 14.2 Kg capacity at a carousel speed of 55seconds per
revolution and 1000 cylinders/hour with 19 Kg net weight filling
incylinders of 33.3 and 45.5 liters water capacity respectively.
The SC Valve isprovided at the centre of the cylinder. Please see
the attached drawings for detailsof cylinders.
4.3 Each filling machine with its filling head shall be of
modular type and act asan independent unit along with its own
controls and shall receive LPG, air and
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 14 of 75
-
electricity feed from the central column.
I. The base frame shall be fitted with 24 electronic filling
machines including aCentral column, LPG/Air/Power distributor
rings, with individual LPG and Airisolating valves, & gas stop
valves for individual filling machines.
ii. The power distribution in Central Column carrying power to
all fillingmachines and communication signals among filling
machines/Check Scale/PLCshould be of Flame Proof construction with
guaranteed positive segregationbetween FLP and Intrinsically Safe,
if separate channel for IS is provided.
iii. The carousal shall rotate around the central column, which
will serve as anaxis of rotation and distributor of the LPG,
electricity and compressed air to thefilling machine,
iv. In center column, there should be positive segregation
between LPG and airportion. This can be obtained using proper leak
proof seals, specifically coated &finished central pipe stems
which should be rust resistant. Similarly, there shouldbe positive
segregation between Power/communication channels and LPG/Air.
v. The control/isolation valves used for LPG isolation should be
fire safe, anti-static types. Necessary certificate in support of
Fire Safety shall be produced.LPG. Hoses and compressed air hoses
should have anti-static properties.
vi The driving unit shall have speed regulation for controlling
rotation speed ofthe carousal to match with the filling time of LPG
cylinders. Carousel will beoperated at 55 seconds per
revolution.
vii. The electronic filling machine shall be of modular
construction and electronicweighing PLS type and shall be
incorporable anywhere in the LPG filling system.
viii. The 24 Nos. electronic filling machine shall include:
a. Automatic lowering/raising of the LPG filling head. Automatic
connection/disconnection clamping of filling head.
b. Automatic cylinder centering.
c. Clamping of cylinders covering the circumferential joint
using arms/jawsoperated by pneumatic cylinders/valves.
d. Automatic filling operated by electronic weight
controller.
e. No leakage from the filling gun if the cylinder valve is
covered with safety capor gun is not latched on the cylinder
valve.
f. The filling machine shall have a weight controller
communicating with themain PLC which transfers the tare weight of
cylinders entering through theCentral Encoding Station and
controlling all pneumatic movements.
g. Auto calibration facility and auto tareing /zero setting to
be provided. Themachine shall also have encoding via PLS/ RFID.
h. In case of malfunction or drift outside the set parameters,
the system shall haveautomatic shut off facility.
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 15 of 75
-
I. Each filling machine shall be provided with quick closing
isolation valves toisolate both LPG & Air supplies to the
scale. All air connections should be quickdisconnecting type push
in connectors. Air tubing shall be flexible and anti
staticconstruction of the scale should be such that maintenance can
be carried outeasily without disturbing other scales.
j. The supply of LPG, electricity and compressed air shall be
interrupted, ifrequired, for any individual filling machine(s)
without stopping carousal, whichensures possibility for repair and
maintenance during production.
k. The table of each filling unit shall be made of suitable
material to ensure nospark generation during cylinder movements.
All flexible copper jumpers forearthing shall be included in the
scope of supply of vendor. Continuity fromfilling gun to the rail
should be provided.
l. Each scale shall have individual FRL units to ensure
lubricated air supply to thescale. Also non- lubricated air supply
shall be available for use as pilot signal etc.
m. All filling machines shall have self-diagnostic
facilities.
ix. CABLES: All cables including fiber- optic /communication
cables andaccessories shall be supplied by the vendor. BPCL will
supply power cable tocarousel drives. GI pipe for Fibre- optic
/communication cables will be providedby BPCL and same will be laid
under the supervision of the vendor’srepresentative.
x. The Hardware architecture of the system should be compatible
with Windows7 or higher and able to exchange MS Excel/ txt
file.
Interface -Compatibility with SAP R/3 System and plant
automation system to beprovided and vendor to inform us the
structure of their database, & in whichdatabase the files the
filling data are stored, user id, password of the database sothat
if required BPCL can develop its interface if required.
a. A back up disc of software of supervisory control and other
spare cardsprogrammed with proven software to be provided at the
time of handing over thesystem.
b. Provision for accommodating the automatic bar code
reader/scanner/RFID fortare weight registering which may be
installed in future.
c. Residual gas should be recorded. Print command should be
optional.
d Machine wise accuracy data in form of +/- 0, +/- 50g, +/-100g,
+/- 150g ,+/-200g, , +/-300g, >400 .
e. PLC Make – Allen Bradley (Rockwell)/ Siemens / Honeywell / GE
Fanuc/Schneider Modicon / Yokagawa / Invensys / ABB / Emerson will
be preferredand 20% spare capacity in PLC to be provided.
f. Format of the MIS reports to be provided with the bid and the
same will berevetted again by BPCL after placing the order.
g. Complete filling operation will be automatic having
centralized control panelwith CPU to facilitate data generation on
all operations. Filling system should notget disrupted if
communication between carousel & Central control room
fails.
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 16 of 75
-
4.4 In addition to the above, the following features should be
incorporated in theCarousel.
I. Interlocking of Introduction/Ejection unit for :
a. Anti jamming output when exit conveyor is full of cylinders
for Ejectiondevice, for Oring leak & Valve leak detectors.
b. Introduction only when platform empty.
c. Ejection only when cylinder is filled and gun is
released.
ii. LPG Stop-Valve - Auto pneumatic.
iii. Emergency Stop - Easily accessible from front and
distinctly visible forindividual machine.
iv. Cylinder centering - Auto clamp with Teflon/Non –sparking
material/padsarms with jaws covering the circumferential parts of
cylinder with pneumaticcylinder control.
v. Earthing connection :
a. Filling head – braided copper wire along with hose with
insert.
b. Central column.
c. Guide rail.
d. Platforms of filling scales.
e. Frame.
vi. Security Guard - Mesh/steel plate on angle-iron frame all
around upto 2 inchabove the platform height.
vii. LPG Entry - From top/ bottom and differential pressure
bypass beforeCarousal entry. The details of bypass assembly is
annexed in the document. Thebypass control valve will be
pneumatic/micro- processor operated.
viii. Air Entry - from bottom/top
ix. Filter - 40 mesh SS strainers.
x. Pressure Gauge with needle valve & isolation valve -
Before & after Filter.
xi. Guide Rail - 1-section .
xii. 5 micron Air filters where-ever required for each unit will
be supplied by thevendor. The Filter/regulator/lubricator(
Filtration 5? - Dimension ) forintroduction, ring , valve leak
tester , Check scales to be provide with 25 NB sizeAir Filters
units for entry /exit so as to ensure that is no drop in air
pressure whenthe aforesaid equipments are in continuous
operation.
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 17 of 75
-
4.5 FILLING HEAD
I. The Filling head shall be suitable for filling SC type vales
fitted at the center ofon top of LPG cylinders of 14.2 Kg(33.3L)
and 19 Kg(45.5L) net weight.
ii. Filling head shall be pneumatically operated, assembled on a
special supportthat allows a partial free horizontal and vertical
movement to facilitate andguarantee leak proof connection of
cylinders even if they slightly off-centered.The pin travel length
of the filling head’s, valve pin shall be 2.8mm+/-0.2mm.
iii. If cylinders with cap on the SC valve get introduced on the
filling machine theflow through the filling head should not
start.
iv. Design of the gun should ensure no leak while filling
/idling.
4.6 SYSTEM MAINTENANCE ASPECTS
I. ? The machine shall be designed in such a way that routine
maintenance shallnot pose any operational problems and all parts
requiring major maintenanceshall be easily accessible. Facility of
lubrication of the central column is to beprovided.
ii. Central column & LPG distribution pipe & components
in filling m/c shouldbe pressure tested to 30 bars and be suitable
for working pressure of 20 bars.
iii. The table of each filling unit shall be made of suitable
material to ensure nospark generation during cylinder movement. All
flexible copper jumpers forearthing form filling head to the rail
& earthing grid is in the scope of supply ofthe vendor.
iv. Location of Isolation valve /Gas stop valve on distribution
pipe-ring should besuch that valves should not get hit by the
filling machine frame, if the fillingmachine tilts by action due to
impact of cylinder. Alternatively, either themachine should be
fixed or suitable protection is to be provided to these valves
asutmost safety measure.
5 AUTOMATIC INTRODUCTION SYSTEM
5.1 PNEUMATICALLY CONTROLLED Tangential or Radial type
introductionunit for automatic introduction of LPG cylinders from
the chain conveyor to thefilling carousal is to be provided.
5.2 Proper cylinder centering is to be ensured by means of
proper clampingarrangement. The clamping arms should be robust and
their guaranteed minimumexpected life is to be advised. Life time
guarantee would be preferred.
5.3 The introduction of cylinders to be in synchronization with
the speed ofrotation of the carousal. Also, the complete carousel
system is to be synchronizedsuch that carousel should stop
automatically in case introductions & ejections arenot
synchronized with the speed of the carousel or any cylinder topples
whileentering /ejecting from the filling platform to exit
conveyor.
5.4 A safety device is to be provided which will prevent
introduction of cylindersto the carousal, if a cylinder is already
present in the filling machine.
5.5 The clamping arrangement shall have the property of
anti-toppling and holdthe cylinders firmly along with filling
heads.
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 18 of 75
-
5.6 The complete introduction assembly should be robust, sturdy
& stable.
6. AUTOMATIC EJECTION SYSTEM
6.1 A pneumatically controlled tangential or radial type
automatic ejection unitfor ejection of filled LPG cylinders from
the filling machines on the carousal tothe outlet of the chain
conveyor is to be provided. No cylinder should topplewhile entering
the ejection conveyor and cylinders should move away before thenext
cylinder comes to the ejection conveyor.
6.2 A safety device is to be provided in such a way that if the
filling head has notgot fully disengaged from the cylinder, the
ejection process is automatically by-passed.
6.3 Ejection of cylinders should be individual with independent
ejection pusher ineach filling unit to isolate the machine without
stopping the carousal. In case ofcommon ejection unit, it should be
sturdy & suitable for such continuousperformance & meet the
system performance.
6.4 The complete Ejection assembly should be robust, sturdy
& stable and anystructural failure will be rectified by
replacement/modification in design withoutextra cost.
6.5 The speed of chain conveyor will be minimum 18 m/minute.
7. AUTOMATIC ELECTRONIC CHECK WEIGH SYSTEM:
7.1 This equipment is mounted on a chain conveyor downstream of
LPG fillingcarousal. This check scale will have a capacity of 1600
cylinders per hour & willcontinuously check the weight of
filled LPG cylinders to determine the overfilled / under filled
cylinders.
The weighing platform shall be based on a load cell/strain gauge
technology.
The tare weight input from Central Encoding Station to filling
machines shallautomatically be transferred to the electronic
weighing system and the scaleshould be able to recognize the
same.
The scale should automatically work out the tare weight
considering the grossweight and pre-set net weight.
The scale should automatically be able to detect under/over
weight cylindersbased on the tare input and actual weight and
accordingly reject such cylindersand push them off the main
stream.
An explosion proof display to be provided near the scale. This
device shalldisplay the weight of cylinder currently under
weighment or the weight of theprevious cylinder that had just
passed on the scale.
The electronic unit to have a micro-processing/PLC system which
shall beprotected in an intrinsically safe enclosure suitable for
hazardous area Zone I,Class IIA & IIB and weather proof IP 65
and hermetically sealed IP 67.
Load cell capacity of check scales & filling scales should
be 200-300 kgs.
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 19 of 75
-
7.2 General Description
The Electronic Check Weighing scale shall have a capacity of
1600 cylinders perhour of min 14.2 Kg cylinders & consist
of:-
This device is to also adjust the actual capacity of the machine
as well as controlsudden jamming.
The weighing platform to be suitability designed to give more
stability to thecylinders.
A weight device with a digital display located on a control
panel beside theplatform.
A sorting unit composed of one ejector for ejecting out,
over/under weightcylinders.
Complete pneumatic and signal/communication circuits including
earthingconnection etc
Accuracy should be +/- 50 gms but it should have provision to
display inmultiples 10gm whenever required for checking.
Check scale should used as master incase of communication
failure for datalogging.
The cylinder should come to the main conveyor on its own till
the next cylindercomes for weighing and this cycle should continue
automatically.
The maximum cycle time for checking should be less than 2.25
seconds percylinder & the capacity should be 1600 cylinders per
hour min. for 14.2 Kgcylinders.
The net weight of LPG i.e 14.2 Kg or 19 Kg is set as default.
The system shouldallow changes in these default setting as &
when required.
Zero pre-setting when there is no cylinder on the platform.
The display unit should display the tare weight value after
taking intoconsideration of actual gross weight and the pre-set net
weight.
Based on tare weight input value from the Central Encoding
Station/Fillingmachines, the scale should be able to decode the
input and compare the tareweight value worked out by the system,
considering gross weight and net weight.The system should be able
to identify the over filled and under filled cylindersbeyond the
specified tolerance limits and remove the same from the main
line.
Under normal circumstances, the cylinder should automatically be
passed on tothe weighing platform and check weighed. In case there
is any problem in thesystem, there should be a manual override
provision for manual sorting so thatthe operator can intervene and
reject the over/under filled cylinders.
All check weighing process should be linked up with Central
Control panel alongwith PLC and personal Computer with software for
report generation.
7.3 Manual Sorting
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 20 of 75
-
To enable manual sorting of cylinders in case of system failure,
additionalprovisions are to be made. i.e. Provision is to be made
for a rejection button, ifthe cylinder is not filled within
permissible tolerances. An operator can press therejection button
so that the rejected cylinder is removed from the main conveyorto a
separate conveyor for rectification of under/over filled
cylinders.
7.4 Check Weighing System Requirement
The check weighing system shall be fully automatic with a min
capacity of 1600cylinders per hour of 14.2 Kg.
The system shall have automatic transfer of tare weight,
automatic sorting outwithin preset parameters and statistical
report function.
Cylinders that do not fall within the set tolerance shall be
automatically sorted outvia the PLC and all relevant data from the
check scale shall be transferred to thecentral computer system.
Further, the following facilities are to be incorporated:
Decode input including automatic sorting out of incorrectly
filled cylinders to aseparate conveyor loop for correction.
Prepare a statistical report of correctly filled cylinders,
overfilled cylinders andunder filled cylinders
8. FILLING MACHINE SHOULD HAVE FOLLOWING SPECIFICATIONS:
The filling machine shall have guaranteed output of 95% accurate
cylinders withaccuracy of (-) 50 to (+) 50 gms
a. Level +550 mm from the floor level of filling shed.
b. Direction of rotation- Clockwise/Anti clockwise (to be
confirmed after Awardof Job)
c. Accuracy shall be (-) 50gms to (+) 50 gms. or better.
d. Method of Filling – Gross weight
e. Gas stop valve to open after fixing of filling gun. NO GAS
FLOW FROMTHE FILLING GUN UNLESS THE GUN IS LOCKED ON THE
CYLINDERVALVE.
f. Pneumatic element shall be of standard makes of
internationally reputedcompanies. Authorized stockiest to be
available in India
g. Platform to have tubular guard.
h. Tandem pneumatic cylinder for flexibility to accommodate 14.2
and 19 Kgcylinders.
I Quick coupling with nylon or equivalent tubing with
anti-static property forpneumatics.
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 21 of 75
-
9 AUTOMATIC ELECTRONIC WEIGHT CORRECTION UNIT:
This machine will be similar to filling machine with filling
scale of Least count/resolution of 10gms .The filling &
evacuation provision of under/ over filledcylinders should happen
automatically through 3 way valve or similar safetyinterlock
arrangement and filling accuracy shall be +/-50g .
a. System should be able to detect over & under filled
cylinder wrt to tare weightand fill the cylinder with correct
weight. Manual punching of tare weight shouldnot be required for
cylinder correction , data should automatically get transferredfrom
Post Filling check scale to the cylinder correction unit. The
system shouldhave provision of manually correcting the cylinders (
if required at any stage incase of system malfunction /overload of
the system )
b. Also manual operation of three way valave or similar
operation with multipleGas Stop valves should be eliminated and
this operation of switch over fromfilling to evacuation and vice
versa should be automatic with suitable safetyinterlocks to avoid
simultaneous operation of filling and evacuation.
10. FILLING HEAD SHOULD HAVE THE FOLLOWING SPECIFICATION
Gun release: smooth release with hinged arrangement in jaws to
facilitate littledownward movement of jaws at the time of
release.
Pin travel: 2.8 mm +/- 0.2 mm
Material: Gun Metal (Copper alloy).
Head Cap: Gun metal (Copper alloy) threaded.
Pneumatic cut – off LPG inside the gun during gun release. No
leak from the gunafter de-latching from the cylinder valve.
Hose attachment: side elbow.
Self centering horizontal alignment arrangement with cylinder
valve.
11. VALVE/BUNG LEAK DETECTOR/TESTER:
11.1 Valve /Bung leak tester should have Sensitivity (0.5
grams/hour of LPG,equipment calibrated with commercial BUTANE# 0.5
gm/hr) and 100%repeatability to be established.
11.2 Minimum guaranteed capacity of valve/Bung tester should be
1600cylinders per hour which could be achieved through a single or
double headerdevice. No extra payment for multi header device.
11.3 100% repeatability is to be proven in the field at the time
of acceptance test.
11.4 Tolerance/sensitivity of valve leak tester should be such
that “no cylinder isto get rejected below leakage level of 0.4
gm./Hr” and all cylinders with leak of0.5 gms/hr must get
rejected.
11.5 Calibration, testing and inspection kit for each detection
system shall be
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 22 of 75
-
provided. For this the vendor should supply suitable test
cylinder with fittings (orfittings which could be fitted on BPCL’s
cylinders) which can be put onconveyor for checking on line
accuracy /performance of the valve /bung leaktester.
11.6 Test cylinders for valve leak detector – To be supplied for
different levels ofrange from 0. 6gm / hr to 0.3 gm/hr
11.7 Current leak detection system – Must not go out of range
between breaks /starts and stops.
11.8 Separate cylinders/fittings for Valve & Bung testing
should be provided.
11.9 Generation of 2% of valve leak cylinders shall not have any
significantimpact on the capacity of the complete carousel
system.
12. O-RING LEAK DETECTOR/TESTER
12.1 O-ring leak detector shall have a capacity of minimum 1600
cylinders perhour and Sensitivity (0.5 grams /hour of LPG).
12.2 Tolerance/sensitivity of O-ring leak tester should be such
that “no cylinderis to get rejected below leakage level of 0.4
gm./Hr” and all cylinders with leakof 0.5 gms/hr & more must
get rejected.
12.3 100% repeatability is to be proven in the field at the time
of acceptance test.
12.4 Calibration, testing and inspection kit provided for the
‘ValveLeak.Detector/Tester’ should be suitable for O-ring Leak
detection systemotherwise separate such calibration, testing kit
shall be provided .
12.5 Test cylinders for valve leak detector should be suitable
for on line O-ringleak testing otherwise separate cylinders are
desirable.
12.6 Current leak detection system – Must not go out of range
between breaks /starts and stops.
12.7 Generation of up to 10% of ‘O-ring leak cylinders shall not
have anysignificant impact on the performance of the complete
carousel system.
VENDOR TO provide the details of locations where their O-Ring
& Valve Leakdetectors are in operation.
13. BPCL will provide differential pressure of 8 to 8.5 Kg./Cm2
at pumpdischarge and 7.0 to 7.5 Kg./Cm2 differential pressure at
carousel.
The vendor will provide the necessary system required to keep
the differentialpressure in line with requirement of your system by
incorporating suitable device(flow control device/pressure control
device). BPC will provide necessary pipingfrom pump to the carousel
and from pressure control device to vessels. Theisolation valves
required on either side of the pressure control device will also
beprovided by BPCL. 40 mesh SS strainer will be provided by the
vendor.
Details of Bypass assembly indicating the scope of valves /pipes
/fittings isattached with document.
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 23 of 75
-
Higher requirement of differential filling pressure for the
performance of theoffered system is not desirable.
14. STATISTICAL QUALITY CONTROL (SQC) UNIT
Automatic SQC sequencing with least count of 10 gms to be
provided.cylinderweight, valve leak, O-ring leak to be checked at
SQC MIS to be generated forcylinder weight, valve leak, O-ring leak
along with the time and date of checkingof cylinder. Serial number
of cylinder shall also be part of MIS which shall bepunched by the
operator.
15. UN-INTERRUPTED POWER SUPPLY (UPS)
Vendor to supply UPS of adequate rating as the part of the
system.
The capacity of UPS shall be a minimum period of 30 minutes
(2000VAminimum)
UPS shall be installed in a safe area in the Office/Control
Room.
Power cable from UPS to the filling shed system shall be
supplied by vendor andthe same will be laid by BPCL.
Independent Surge Protection for power supply to all electronic
components anddata
/control communication system must be provided.
16. SAP INTEGRATION
The carousel data shall be integrated with the existing BPCL SAP
system.Vendor to develop all necessary protocols and software
drivers for integration ofcarousel data with SAP. All required
hardware / software to be provided by thevendor. Interface
-Compatibility with SAP R/3 System and plant automationsystem to be
provided and vendor to inform us the structure of their database,
&in which database the files the filling data are stored, user
id, password of thedatabase so that if required BPCL can develop
its interface if required.
17. GENERAL:
All solenoid valves and limit switches used in the system shall
be intrinsicallysafe and approved by Chief Controller of Explosives
of Petroleum & ExplosivesSafety Organization (PESO), Nagpur,
India.
All control electronics including electronic weighing systems
should be housed incertified intrinsically safe enclosures.
Load cells used shall be made intrinsically safe in conjunction
with certifiedzenner barriers.
All cables used shall be of armoured and shielded type as per
IS-1554 orequivalent international standard suitable for this
application.
All control electronics shall operate at very low power
requirements (Intrinsicallysafe) and shall be capable of working
upto +55 degree Celcius ambienttemperature.
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 24 of 75
-
Power supply will be have fluctuation of 220V +/-10% and
frequency at 50Hz +/-6%.
All the cylinder movements to be controlled pneumatically. For
operating thesepneumatic equipment. automatically,
electro-pneumatic devices like FlameproofSolenoid Valves of
required rating should be used.
Cylinder sensing and identification shall be done by using
intrinsically safe limitswitches.
The limit switches and tare weight punching key board shall be
intrinsically safe.
Vendor should give commitment to supply spares for ten years
from the date ofcommissioning.
All pipes/fittings /valves for LPG shall be of minimum #300 psi
and above as percode.
All butt welded joints should be 100% radiographed and shall be
cleared by Thirdparty inspecting Agency.
Only Spiral wound stainless steel gaskets to be used in LPG
pipeline joints.
All LPG Piping Central column and other components of filling
machine shouldbe pressure tested to 30 bar.
LPG hoses - Anti-static wire braided reinforced. LPG hoses as
per IS 9573/BS4089/EN 1762:1998. Earthing wire to be provided along
with hose. ( workingpressure 25 bars)
Isolation Valves: SS Ball Valves of fire safe and anti-static
type. (Necessarycertificate in support of "Fire Safe" to be
provided.) Min PressureRating 300#
VENDOR is to advise in the technical bids the list of equipment
& componentsout sourced for the system, their make &
country of origin.
18. Excluded from vendor’s SCOPE
Power connection shall be made available near the encoding
station and vendorto take connection to all other equipment from
this station by providing suitableFLP Junction Box.
The cable for power connection for the terminals upto the
carousel in the shedwill be provided by BPCL. Vendor to indicate
the size and specifications of thecable However internal cable
within the system in the filling shed shall beprovided by
vendor
BPCL will be provide air line of required pressure near
carousel, o-ring & valveleak detector . Vendor to supply &
lay airline & air filter units to all requiredconsumption
points.
The required LPG piping shall be provided by BPCL upto their
equipment.Vendor to match their piping with BPCL piping. For this
purpose, the vendorshall provide piping layout to BPCL.
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 25 of 75
-
Earthing grid in the plant is provided by BPCL. However vendor
to supplyearthing elements of equipment and conveyors, etc for
connection to the plantearth grid.
19. SPARES
Vendor to dispatch the spares required during two years actual
operation of theCarousal during warranty as per enclosed list to
each plant. The spares requiredto be replaced frequently due to
normal wear and tear are included in the abovelist and same is to
be kept at the plant. Additionally, any spare or part which hasto
be replaced during Warranty Period is also to be kept at a central
location &made available at the earliest.
20. DRAWINGS AND DATA REQUIREMENTS TO BE SUBMITTED BYVENDOR FOR
CAROUSEL, FILLING MACHINE, CHECK SCALE,ENCODER AND
ACCESSORIES:-
These documents shall have to be submitted by vendor in two sets
for bid and sixsets after placement of Order.
General arrangement drawings with outline dimensions including
details forfoundation design.
Part list of all equipment.
Certified performance curves.
Certified test records of all equipment,
Diagram of wiring connections.
Piping and instrument diagrams for LPG, Air, water etc.
Test certificates for bought out items.
Assembly and Installation details.
Erection, operation and maintenance manuals.
Erection drawings and Completed Data sheets
Material specifications.
21. PERFORMANCE GUARANTEE
All equipment and component parts shall be guaranteed by Vendor
againstdefective material, design and workmanship for a period of
24 months from thedate of commissioning or 30 months from the date
of receipt at site, whichever isearlier. Date of Commissioning
shall be considered as the date of proving thesystem by
successfully conducting SAT.
The Vendor shall carry out the performance test run of the
complete system atsite after satisfactory erection in line with the
detail given in the Data Sheet.Training to BPCL personnel shall be
given at site during erection/commissioning
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 26 of 75
-
period without any extra cost to BPCL.
Vendor shall be solely responsible for smooth and trouble free
performance ofthe plant as a whole during the guarantee period. In
case of any problem arisingduring guarantee period even after
taking over of the plant, Vendor shall have tocarry out any
rectification/replacement at his own cost.
22. FACTORY ACCEPTANCE TEST
Factory Acceptance Test (Dry run under simulated conditions) may
be witnessedby BPCL prior to dispatch of one system. For this
purpose, a team of 04 (Four)officers might visit the vendor’s works
to witness the tests as per scope ofinspection. However BPCL
reserves the right to eliminate the FAT if required attime of
award, ( pl note L1 price evaluation will be done including FAT
).Accommodation, local conveyance etc. to be arranged by the bidder
at no extracost. Acceptance of this test will not absolve the
vendor from the overallresponsibility of performance of the system
at BPCL plants. NO EXTRA COSTWILL BE PAYABLE, if this option is
exercised by BPCL. However, all systemswill be self tested at
factory premises of the vendor by in-house competentofficial
without extra charge and documents are to be sent along with
invoice.This includes:-
I. Verification of Explosion proof /intrinsically safe component
/ sub system,checking of Vision unit , introduction /latching
/filling/delatching /Ejection,operation of filling machine, safety
interlocks as specified in datasheet/specification,
assembling/manufacturing as per in house QAP.
ii. Checking of check scale accuracy and operation
parameters
iii. Checking of Automatic weight correction operation.
iv. Checking of ‘O’ ring/vale/bung leak testing operation and
ejection sortingsystem.
v. Checking Tare weight encoder and tare weight error rejection
operations.
vi. Review of manufacture test certificates all bought out items
viz., LPGPipelines, fittings, valves, flameproof motor, IS
components, solenoid valves etc.
vii. All certificates to be provided in ENGLISH.
The entire system shall be inspected by a Third party inspection
agency and thisshall be on Vendor's scope considering any one of
the reputed third partyinspection agency approved by BPCL viz. LRIS
/ DNV/ IRS/ EIL/ BV/ ULINDIA PVT LTD .All equipment shall be
dispatched only on certification andfinal clearance by third party
inspection agency / BPCL.
23. SITE ACCEPTANCE TEST (SAT)
SAT shall be conducted by Vendor and Witnessed by BPCL at plant
afterinstallation of complete system
Scope of inspection at site shall be:
1. Functional test under rotating conditions at site. All
performance parameterssuch as rated production (cylinder per hour),
filling accuracy (95% of cylinderswithin +/- 50 gms;), functioning
of Tare Weight Entry Unit& Vision unit,
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 27 of 75
-
functioning of Weight correction unit, detection of O-ring and
Valve LeakCylinders (for leakage of 0.5 gm / hr), repeatability of
detection of leakycylinders, recording of data in software etc.
2. Working of all safety interlocks.
3. Working of encoding station, transfer of data to fillings m/c
check scale etc.
4. Hydraulic pressure testing of central column and complete
assembled LPGpiping system including inlet manifold.
5. Functioning of electronic check scale.
6. Witnessing of running of complete conveyor system for its
smooth operation.Jamming of cylinders to be avoided.
7. The inspection procedures mentioned in Special Terms and
Conditions.
8. Verification of software data recorded in MIS for regular
production as well asfor SQC.
9. Verification of CIMFR certificate for flameproof
Enclosures.
10. Verification of PESO certificate and other statutory
certificates as applicablefor complete system.
Inspection (FAT & SAT) will be regarded as a check-up and
shall not relieve theVendor of any of the contractual obligations
and performance guarantee. Thethird party inspection charges shall
be as per the price bid format and tenderconditions.
24. APPROVAL OF DRAWINGS
Vendor will get all drawings approved from Corporation before
supply and theapproval of drawing by Corporation does not absolve
the vendor from hisresponsibility/ obligations towards the
performance guarantee of the entire fillingsystem covered under
this tender.
25. LOCAL STATUTORY APPROVALS:
a. Vendor will obtain statutory approval from Chief Controller
of Explosives ofPetroleum & Explosives Safety Organization
Nagpur India (PESO) within aperiod of six weeks from the date of
LOI/FOI/e-mail message. Approval mustindicate the acceptability of
the intrinsically safe equipment for AmbientTemperatures of (+)50
Deg C. Approval should be either general or specific forBPCL plant.
Interim approval will not be accepted.
b. In case the above approval is not obtained on time, we may be
constrained tocancel the order and claim damages.
c. Model approval from Legal Metrology department will also be
required.
d. In principle approval from Weights and Measures (Legal
Metrology)department and final approval/stamping on erection and
commissioning of thesystem. All expenses to be borne by vendor.
BPCL will reimburse/ bear onlystatutory stamping fee.
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 28 of 75
-
e. Any other statutory requirement/approvals.
f. Approval for Intrinsic Safe equipment from statutory
authority( likeBASEEFA/ CENELEC/ FM) of Country of Origin should
certify suitability forthe ambient temperature of +50 degree
Celsius.
26. DELIVERY
a. The delivery period shall be as 5 Months from the date of
LOI.
b. Two sets of manuals for erection/maintenance/service should
be provided/dispatched with the carousel and two such sets are be
provided while handingover the system.
27. ERECTION
Erection of carousel will be done in the following sequence:
The first phase of erection of the carousel will include all
mechanical, electrical,pneumatics, instrumentation & hardware
jobs - to be done by VENDOR.
PESO / safety approvals by BPCL.
Charging of gas & filling on commissioning the plant will be
done by vendor.Vendor will be given intimation in advance for
this.
28. WARRANTY
The vendor should familiarize themselves with Indian operating
condition likehumidity, dust, temperature, water sprinkler (fire
fighting system@ 15 LPM) inthe filling shed and other factors so as
to ensure that the system functions in linewith the specified
performance parameter under these conditions.
WARRANTY PERIOD:
The system supplied/installed should have performance warranty
for the periodof 24 months from the date of commissioning or 30
months from the date ofreceipt at site, whichever is earlier. Date
of Commissioning shall be considered asthe date of proving the
system by successfully conducting SAT. The system hasto perform
consistently within the specified parameters while handing over
thesystem after commissioning & stablising the operating
parameters). All Sparesand consumables required during the
performance warranty period will beprovided by the vendor free of
cost. BPCL will provide consumable like water,lubricants,
stationary & printer’s cartridge during warranty period.
Proving the system/site acceptance test will be done at plant
after commissioningand stabilizing the operations. These will
include verification of performanceparameters (Filling rate,
Filling accuracy, rejection of cylinders of wrong tareweight,
introduction & rejection operation, Check scale operation and
accuracy,‘O’ ring , valve tester operation and rejection of leak
cylinder and repeatability,verifying the cylinder filling
production as specified, Cylinder filling datacollection system etc
as per detailed parameters.
29. Vendor must dispatch the list of minimum spares that will be
maintained ateach plant during the warranty period and will be hand
over to plant in charge atend of the warranty period. Any
intermittent consumption during the warranty
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 29 of 75
-
period will be replenished within 15 days on consumption.
30. ANNUAL MAINTENANCE CONTRACT
a. We may enter into an Annual Maintenance Contract with the
vendor for aperiod of three (03) years after the warranty period is
over. Please indicate theannual cost of AMC separately in your
quote. The Maintenance Contract shallcover all the equipment
supplied by vendor
b. The AMC excluding & including the cost of spares and
consumables may begiven separately. Quarterly visit of min 03 days
may be considered and breakdown on per diem basis. The response
time will be 24 hrs. and required spare willbe made available from
the time of notification for both the warranty and AMCperiod within
48 hours. The scope of warranty and AMC both will cover thesupply
of spares also by vendor and BPC will not purchase any spare
formaintaining system supplied by vendor during the period of 2+3 =
5 (five) years.
c. Vendor to provide Comprehensive daily , weekly, monthly,
quarterly, halfyearly , yearly , beyond checks/ routine preventive
predictive and shut downmaintenance to be carried out for each
equipment& component and list of criticalcomponents which are
likely to get damaged/wear & tear/failure in a year foreach
equipment. The spares during warranty period to be provided prior
to eachpreventive maintenance / servicing activities. Maintenance
schedules to bedeveloped and implemented without any production
loss to BPCL
No extra payment shall be made to the vendor towards supply of
any spare partsor replacement/ repair of equipments during defect
liability period of two yearsfrom the date of successful
commissioning. However, after the expiry of twoyears of Defect
Liability Period , Vendor shall quote the Annual MaintenanceCharges
for subsequent 03 years. These charges shall include the repair
ofequipments, providing spares etc and shall be paid on quarterly
basis in fourequal installments of quoted rates at the end of each
quarter.
AMC shall be renewed by LPG SBU after end of every year subject
to conditionsmentioned in this tender. However, renewal of AMC will
be on the discretion ofBPCL.
The scope of work shall broadly consist of
I. INSPECTION
a) Adjustment of equipment
b) Optimization
c) Weighing-in
d) Lubrication of equipment e) Safety checks
f) Recommendations for optimization of equipment
g) Any other activity required for smooth operation of the
system supplied by thevendor.
II. PREVENTIVE M AINTENANCE
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 30 of 75
-
Preventative replacements of wearing parts according to
pre-determined
preventive maintenance plan
III. CORRECTIVE M AINTENANCE
Carrying out of necessary repairs according to need identified
by plant operatorsand maintenance staff
Plan & identify indent and maintain adequate spare parts
inventory in co-ordination with BPCL.
Carry out necessary replacement of parts
IV. TRAINING AND OPERATIONAL SUPPORT
Monitor the filling operation to secure correct usage of
equipment
Training and instructions to BPCL filling staff to secure
correct usage of fillingequipment.
V. REPORTING AND PLANNING
Working out complete service report once per month
Conduct Monthly meetings with BPCL maintenance manager to report
and planmaintenance and discuss the issues for optimizing the
productivity.
VI. PERFORMANCE
Vendor shall prove the system for the rated productivity of
minimum 1570Cylinders per hour for filling of 14.2 Kgs capacity at
a carousel speed of 55seconds per revolution and 1000 Cylinders per
hour for filling of 19 Kgs netweight filling, with minimum 95%
filled cylinders during the maintenance periodalong with other
parameters such as filling accuracy of (-)50 to (+)50 gms
range,Valve Leak, O-Ring Leak Detection system with
repeatability.
BPCL reserves the right to demand capacity performance tests
periodically &shall terminate the contract in case the
performance is not satisfactory.
Vendor shall take all necessary steps to prevent unscheduled
stoppages andwould make all out efforts to re-commission the
machine with least break downtime at no extra cost to BPCL.
Necessary labour shall be provided by BPCL toattend to the
same.
VII. SPARE PARTS
Spare parts during defect liability period of 2 years from the
date of successfulcommissioning shall be supplied by the vendor at
no extra cost. However, allspare parts inventory required for
maintaining the highest productivity level shallplanned identified
indented and maintained in co-ordination with BPCL.
VIII. GENERAL CONDITIONS
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 31 of 75
-
The Service Agreement shall be periodically reviewed .
BPCL reserves the right to terminate the AMC by giving 3 months
notice.
The Rates offered shall remain firm during the period of
contract
The Vendor shall bring his own hand tools.
Vendor must adhere to applicable statutory laws issued by Govt
of India andprovisions applicable must indemnify BPCL against any
deviation or lapse on hispart
Vendor shall adhere to adhere all Safety Health Environment and
securityGuidelines issued by BPCL time to time.
Vendor shall provide necessary uniform PPE like helmet and shoes
at no extracost to BPCL.
Vendor shall indemnify BPCL against all claims and liabilities
arising out ofperforming this contract.
Vendor shall indemnify BPCL against act of negligence by his
personnel whileperforming this contract.
Free access to the equipment to the necessary extent will be
granted by BPCL.
Office for the maintenance staff with common amenities shall be
provided byBPCL
The work will be carried out in agreement with the BPCL service
manager.
The work must as far as possible be carried out outside working
hours to interfereas little as possible with the production.
The guarantee covers the work provided during the maintenance
service only.
31. PAYMENT TERMS
The payment terms shall be as per Purchase Order &
under:-
Supply Portion:
70% - payment against LC on despatch of the equipment.
30% - After erection & commissioning & within 3 weeks
after handing over thefull system & on submission of
performance bank guarantee for 10% value.
Erection & Commissioning Charges :
Supervision charges for erection of material, dry run &
commissioning shall bereleased after the commissioning &
handing over of the whole system
AMC Charges :
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 32 of 75
-
The payment towards Annual Maintenance Contract (AMC) will be
madeQuarterly after end of each quarter.
32. MANPOWER REQUIRED FOR ERECTION:
Vendor to advise us the details of skilled/ semiskilled/
unskilled man powerrequired for erection of the carousel
system.
33. TRAINING OF OUR STAFF
Three tier training for our operating staff/maintenance and
supervisory staff willbe carried out at our plant during erection,
trial, proving & handing over period ofthe system.
Technicalbid
DATA SHEET- 24 STATION CAROUSAL & ASSOCIATED UPSTREAM &
DOWNSTREAMEQUIPMENT
DATA SHEET- 24 STATION CAROUSAL & ASSOCIATED UPSTREAM &
DOWNSTREAMEQUIPMENT
SrNo ITEM BPCL REQUIREMENT
Bidder'sConfirmation
. Operating Conditions :24 Station Electronicmachine
carouselsuitable for filling14.2/19 KG SC TypeValve
cylinderssimultaneously
.
1 System performanceparameters
.
. i) Production Capacity 1570 Cylinders per hour for filling of
14.2Kgs capacity at a carousel speed of 55seconds per revolution
and 1000 Cylindersper hour for filling of 19 Kgs capacity
filling
. ii) Filling Accuracy 95% of cylinders within +/- 50 gms or
better
. iii) Valve LeakDetection
0.5 gm / hr
DATA SHEET- 24 STATION CAROUSAL &
ASSOCIATED UPSTREAM & DOWNSTREAM
EQUIPMENT
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 33 of 75
-
. iv) O-Ring LeakDetection
0.5 gm / hr
2 Cylinder As per Cylinder Data Sheet provided at theend of this
data sheet
. Dimensions .
3 Installation Under covered roof all sides open
4 Duty Continuous
5 No. of hrs/day 16 hrs /day for 300 days in a year
II Carousel FillingMachines :
.
1 Type Electronic type with individual Gas stopsvalve and
filling head.
2 Platform Level + 550 mm from floor level.
3. LPG Cylinder 14.2 Kg and 19 Kg
4 Working Pressure ofLPG
Max. 8.5 Kg/cm2 (Differential pressure)
5 Filling Time (Max.) atworking pressure of 16Kg/cm2
Vendor to Specify considering rotation time55 Seconds
6 Valve Details Refer to enclosed drawing
7 Type of Filling Gunrequired
Automatic lowering and centering type forSC Valve with pin
travel of 2.8 +/-0.2mm.
8 Accuracy of filling(Min.)
+/- 50 gms. Or better
9 Filter 40 Mesh SS Strainer.
10 Bourden type 0-25 KgPressure Gauge
To be provided before & after the filter
11 Guide Rail I – Section/Square Section.
12 Carousel drive (AntiStatic)
Preferable – Tyre/Belt driven with hydraulicmotor or Gear type
with electric motordriven. Vendor to specify.
13 Introduction unit Pneumatic / hydraulic operated or Gear
typewith electric motor driven unit withautomatic introduction of
cylinders
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 34 of 75
-
synchronous with the speed of the carousal.A safety device to be
provided to preventintroduction of cylinders to the carousal
ifthere is already a cylinder present on thefilling machines i.e.
Introduction only whenmachines platform empty.
14 Ejection unit Pneumatic / hydraulic operated unit or Geartype
with electric motor driven for automaticejection of cylinders from
the carousal to thechain conveyor. A safety device to beprovided
such that if the filling head has notdetached from the cylinder
then carouselshould stop gradually . By this Anti jammingoutput is
ensured i.e. Ejection only whencylinders are filled and gun
released. Alsothe ejection has to operate only when theconveyor is
free.
15 Emergency stop Easily accessible from front &
distinctlyvisible .
16 Earthing connection a) Filling gun - braided copper wire
alongwith hose with insert
. . b) Central column.
. . c) Guide Rail
. . d) Platform
. . e) Frame
17 Safety Guard Mesh or M.S. Flat on angle iron frames allaround
1" above the platform.
18 Table Speed (To be specified by Vendor)
19 Range of speedadjustment
(To be specified by Vendor)
20 Filling accuracy +/- 50 gm. Or better.
21 Utilities required &consumption per hourof
operation.Compressed Airrequirement in LPM &Air pressure in
Kg/cm2
(To be specified by vendor) Air pressuresupplied is 5-6
Kg/cm2
22 Overall size of machine (To be specified by vendor)
23 Paint High quality anti-corrosive
24 Working height Tare weight controls to be accessible
fromfloor level.
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 35 of 75
-
25 Pneumatic controlcircuit diagrams
(To be specified by vendor)
26 LPG Pressure dropacross filling machines.
(To be indicated by vendor in Kg/cm2including quantity)
27 Operating Temperature(-10? C to 50? C).
(To be specified by vendor)
III Empty cylinder pushingarrangement.
.
1 Interlocking provision To be provided
2 Auto-ejection device To be provided
IV Details of CentralColumn & RotaryTable Design
.
1 Product feeddistribution & by-pass
LPG thru Top and air through bottom ofcolumn preferred
2 Sealing arrangementdetails
To be provided for positive segregation ofLPG and Air
3 Table supportingarrangement
Should be supported on rails
4 Table constructionarrangement.
Steel frame
5 Leveling arrangement Preferably by tripod
6 Material ofconstruction.
Steel
V Drive Arrangement : .
1 Drive motor type rating& characteristics
Hydraulic or electric with tyre/gear driveRating &
characteristics to be specified byvendor
2 Speed reducinggearbox make type size& complete
details.
Through Frequency control
3 Final anti-static drivearrangement details.
Arrangement to be indicated
VI Filling Head : .
1 Release Smooth release with hinged arrangement injaws to
facilitate little downward movementof jaws at the time of
release
Tender reference No : CRFQ1000257169 System ID : 13140
Tender title : GLOBAL 2- BID TENDER FOR DESIGN, SUPPLY,
INSTALLATION, TESTING & COMMISSIONING OF 4NOS. AUTOMATIC 24
STATION ELECTRONIC CAROUSEL WITH INTEGRATED ELECTRONIC DOWN
STREAMFACILITIES INCLUDING VISION UNIT FOR MANGALORE, BAITALPUR,
RAIPUR & NRL LPG PLANTS.
page 36 of 75
-
2 Liquid pressure 8.5 Kg/Cm2 (Differential)
3 Pin travel 2.8 + /- 0.2 mm
4 Flow rate 150 LPM
5 Material Gun metal
6 Head cap Gun metal threaded
7 Pneumatic cut off ofLPG inside the gunduring gun release.Hose
attachment- Sideelbow.
(To be specified by vendor)
8 Self-centeringhorizontal alignmentarrangement withcylinder
valve.
(To be specified by vendor)
VII General : .
1 Supporting rail size &fixing arrangement.
(To be specified by vendor)
2 Wheel details Steel wheel with sealed bearings.
3 LPG and Air hoses Should be anti-static
4 Details of allinstrument & otherfittings indicating
typemake & othercharacteristics.
To be specified by vendor in brief.
. Micro filter One unit of 5 micron filter with 1100-LPMcapacity
at 17.5 Kg/cm2 working pressure.
. Safety relief valve To be provided by vendor
. Dif