HINDUSTAN PETROLEUM CORPORATION
LIMITED
MOV Controls- Various Locations under NWZ
TENDER NO. 10000058-HB-11370
HINDUSTAN PETROLEUM CORPORATION LIMITED
TENDER NO: 10000058-HB-11370
TENDER DOCUMENT
FOR
Shifting of MOV Controls outside Dyke Wall
AT
Various locations under
NORTH WEST RETAIL ZONE
Page 1 of 13
HINDUSTAN PETROLEUM CORPORATION
LIMITED
MOV Controls- Various Locations under NWZ
TENDER NO. 10000058-HB-11370
Intent of Tender
Hindustan Petroleum has various locations which are currently operating location. Certain tanks
at these locations have been provided with Motor Operated Valves, commonly known as MOV.
The MOV has two components namely valve and actuator. Valve are varying as per the site
conditions ( as Gate valve, plug valve etc) of different sizes ,makes and actuators are also of
different makes and types at various locations envisaged in the tender.
It is proposed to bring out the control of the MOV outside the tank dyke wall with the following
end deliverables
On, Off push buttons at the valve ( which are present at the actuator level) will continue to
perform as per the original functionality defined for these push buttons.
Providing a Flameproof box with lamp indication on structural support in which Close push
button is envisaged and shall bear Red colour.
Valve shall close with the help of Close push button irrespective of the state i.e. Local or
Remote.
Hooking up the flameproof push buttons with existing actuator using FRLS cables.
The job needs to be carried out in the depot premises. However, during hot work precaution has
to be taken to prevent any incidents due to presence of any gas. Also since the depot is in full
fledged operation, hot work permission has to be obtained for working on a daily basis. The
contractor shall arrange for explosivity meter and check for presence of flammable vapour before
undertaking hot work. Full time supervisor to be provided at work spot and job shall be carried
out only after complying with all safety norms of the depot.
All safety precautions to be taken for carrying out the above job as per requirement.
The tenderer’s are required to go through the tender document thoroughly and carefully and offer
their most competitive rates for the job.
Scope includes but not limited to the following :
Design, Engineering, Supply of various items as per the scope of tender
Supplying of cable, cable laying from MOV to FLP push button station.
Page 2 of 13
HINDUSTAN PETROLEUM CORPORATION
LIMITED
MOV Controls- Various Locations under NWZ
TENDER NO. 10000058-HB-11370
Excavation of cable trenches and back filling, supplying and spreading of bricks and sand in
trenches for out-door cabling as per site condition and as per specifications.
Repairing of all civil works damaged during installation of electrical facilities and civil works
connected with grouting of equipment to the installed. This shall also include breaking of walls /
floors and chipping of concrete foundations necessary for the installation of equipment and
making good the same.
Supply of all labor, supervision, tools and tackles, consumables, materials and all other erection
accessories, not specifically mentioned herein but required to complete in all respects,
installation & testing and commissioning of all the equipment covered under this contract.
Transportation of all equipment from store to erection site / contractor’s store, unpacking,
checking and proper storing etc.,
Supplying & filling of sand in Cable trench.
All power and control cables supplied shall be as per relevant IS standards
Documentation-submission of datasheets and drawings, submission of as built drawings
Armouring for power and control cables shall be as per specifications.
All cables shall be suitable for system particulars, site conditions and environment conditions
specified.
Technical Specifications : ITEM DESCRIPTION
Page 3 of 13
HINDUSTAN PETROLEUM CORPORATION
LIMITED
MOV Controls- Various Locations under NWZ
TENDER NO. 10000058-HB-11370
S no. Description
Unit
Quantity
1
RMT
2230
RMT
370
M3
155
RMT
6100
Excavation in Normal Soil:
Staking out, marking the outline for excavation, excavation in
normal soil for general site grading by machinery or manually up
to 1.0 m below NGL for all depths as given below including
removal of stumps and roots to full extent removal of all
vegetation including bushes and grass, dewatering & leveling,
dressing and backfilling after cable is laid etc complete as per
specifications and instructions of Engineer in Charge.
2
Excavation PCC or Hard Rock:
Staking out, marking the outline for excavation, excavation in
PCC or hard rock for general site grading by machinery or
manually up to 1.0 m below NGL for all depths as given below
including removal of debris & leveling, dressing and backfilling
after cable is laid etc complete as per specifications and
instructions of Engineer in Charge.
3
PCC 1:2:4 :
Providing and laying PCC 1:2:4 using 20 mm and down size
graded stone aggregates. The job includes machine mixing,
providing framework, MS/plywood shuttering if directed by
Engg.-In-Charge, placing, compacting by hand ramming, curing
etc, all complete as per direction of Engg.-In-Charge. Removing
of shuttering to be done carefully without such shock and
vibration as to damage the PCC work & finishing the same with
cement slurry etc. The exposed portion of the PCC surface shall
be whitewashed.
5
Laying of cable in Trench:
Lying of cable 5 C x 2.5 sqmm as per detailed specifications with
sand and bricks. Scope includes laying of 5 core X 2.5 sqmm
YWY cable from MOV inside the dyke wall up to FLP switch
outside the dyke, Rates to include breaking the RR dyke wall/
brick masonry dyke wall / earthen dyke walls to take the cable
from below the RR masonry by providing 4 inch dia heavy duty
GI pipe etc. complete in all respects as per the instruction of EIC
(GI pipe will be supplied by vendor as separate item no. 12).
Page 4 of 13
HINDUSTAN PETROLEUM CORPORATION
LIMITED
MOV Controls- Various Locations under NWZ
TENDER NO. 10000058-HB-11370
6
FLP glands at MOV side & end terminations:
NOS
181
NOS
181
NOS
181
NOS
181
Supply and installation of FLP double compression glands of size
suitable for cable as described above. Rates to include supply of
FLP double compression glands, supply required lugs, crimping
of lugs, installation of FLP glands on MOV , termination of
cable inside the MOV at the port ( as per wiring diagram of
OEM of actuators) by opening the MOV cover . Vendor needs to
coordinate with the Actuators OEM regarding wiring diagram
suitable for the specified actuator model and cable shall be
terminated such that the valve closes irrespective of its state ie
Local , Remote. HPCL shall not provide any wiring diagrams,
circuit drawing etc for the actuators installed and the same shall
be taken by the vendor from the respective OEM’s of the
actuators. The scope of Cabling shall include supply, laying
ferruling, end termination, loop checking & commissioning.
7
FLP glands at FLP Push Button Station side :
Supply and installation of FLP double compression glands of size
suitable for cable as described above. Rates to include supply of
FLP double compression glands, supply required lugs, crimping
of lugs, installation of FLP glands on FLP switch, and
termination inside the FLP switch. The scope of Cabling shall
include supply, laying ferruling, end termination, loop checking
& commissioning.
8
Supply of FLP push button station:
Supply of FLP push button station as per the detailed
specifications attached. The FLP push button station shall act as
emergency shutdown button and close the valve irrespective of
the status of valve i.e. local or remote.
9
Installation of FLP push button station:
Job to include installation of the FLP push button station on the
structural frame by bolting/clamping, required arrangement for
mounting the switch on the frame to be made, Rates to include
clamping/bolting of the switch on the frame, providing earthing
of the FLP station and structure through green color earthing wire
(4sqmm) of approved make and connecting to nearest earth pit,
putting the board on the bottom of FLP switch as per Visual
Identity standards of HPCL indicating the tank number on the
Page 5 of 13
HINDUSTAN PETROLEUM CORPORATION
LIMITED
MOV Controls- Various Locations under NWZ
TENDER NO. 10000058-HB-11370
frame and the line description for usage of the switch to be
indicated near each individual switch.
10
Structural Steel:
MT
40
RMT
1500
RMT
85
Supply, fabrication, welding, erection and painting of structural
steel confirming to IS 2062 latest edition, consisting of channels,
beams, angles, flats, tubular sections, etc fabrication of steel
structures, structural frame for FLP switch mounting, sheds,
walk ways, platforms & cross over with stairs, etc as per
drawings, supply of bolts, nuts washers, shims, packs, putty, gas,
welding electrodes, and all other consumables as required,
cleaning and surface preparation of all steel surfaces with emry
paper/wire brush, supply and application of 2 coats of red oxide
zinc phosphate primer of 30 to 35 microns dft each, supply and
application of 2 coats of Synthetic enamel paint of 30 to 35
microns dft of approved shade. The height of frame shall be 1.3
m from the FGL and 0.45 m inside earth for grouting purpose.
The buried portion shall be coated with bitumen on all sides
before grouting the same in PCC.PCC shall be minimum 350 mm
x 350mm x 450 mm for each leg of the frame/member.
11
Copper wire 8 SWG:
Supplying & laying of Copper wire of 8 SWG for earthing of the
Push button station with nearest Earth pit in the vicinity.
12
4" GI Pipe:
Supplying & laying of 4" dia heavy duty GI pipe for passing of
cable under Dyke walls or as per the site requirements.
Page 6 of 13
HINDUSTAN PETROLEUM CORPORATION
LIMITED
MOV Controls- Various Locations under NWZ
TENDER NO. 10000058-HB-11370
Technical Specifications of FLP PUSH BUTTON STATION:
Product.
Flameproof – Weatherproof Enclosure of Indicating lamp with Stop Push
Button Station with separate cable terminal box duly wired upto the
terminal.
Flameproof.
Zone -1 & 2, Gas groups – I, IIA & IIB as per IS: 2148/1981, Temp. class
– T6.
Weatherproof.
IP 65 Degree of protection as per IS: 13947 (Part -1) 1993. IP certificate
for the same to be submitted
Material.
Cast Aluminum Alloy LM6.
Finish.
Inside & Outside Light Grey Epoxy Powder coated to shade 631 As per
IS: 5.
Earthing.
1 No. Inside & 2 Nos outside Brass/ S.S.(M6) screws with washers.
Hardwares.
Stainless Steel.
Gasket.
‘O’ Ring endless Neoprene rubber gasket.
Terminals.
5 Nos. for 2.5/4 sq mm clip-on type Terminals.
Cable Entries.
2 Nos ¾” ET cable entries from bottom side.
Indicating Lamp.
1 No. 240V AC LED type Indication Lamp.
Element.
2 Nos. 10A 415V AC 1N)+1NC contact element.
Actuator.
‘Stop’ Push Button of Red mushroom head press to Stop & Reverse turn
to release with pad locking arrangement in stop position.
Mounting.
Wall / Column type.
Approvals
PESO , CMRI. Certificate for the same to be submitted for approval before
procurement of the same.
Page 7 of 13
HINDUSTAN PETROLEUM CORPORATION
LIMITED
MOV Controls- Various Locations under NWZ
TENDER NO. 10000058-HB-11370
SPECIFICATION FOR CONTROL CABLE
Make
:
As per approved Make
Type of cable
:
Copper Cable
Construction
:
Solid bright annealed electrolytic copper
conductor, insulated and sheathed as per IS8130. multi stranded annealed bare electrolytic
grade copper conductor
Primary insulation
:
Extruded PVC compound as per IS 5381 type
C. Min thickness as per IS
Inner Sheath
:
Extruded PVC compound, type ST2, min
thickness as per IS 5831
Outer Sheath
:
Extruded PVC compound, type ST2, min
thickness as per IS , FRLS, Black Colour
Armour
:
Shall be provided of galvanized steel wire/flat
strip (1.4 mm. wire for 2-pairs and 4x0.8mm
strip for multi-pair)
Electrical Characteristics
:
Max. Resistance of the conductor of the cable
shall not exceed 12.3 ohm/km at 20 deg. C
Voltage Class
:
660 V
Core Identification
:
Core identification number shall be provided at
a distance of not more than 1 meter
Page 8 of 13
HINDUSTAN PETROLEUM CORPORATION
LIMITED
MOV Controls- Various Locations under NWZ
TENDER NO. 10000058-HB-11370
STANDARD SPECIFICATION FOR CABLE LAYING
Cables shall be laid aboveground in gantry or in some road cuttings etc if required the same shall
be laid underground. All aboveground cables shall be laid on the Cable tray with cover as per
the specification.
When the Cable is laid above ground, it shall be laid on the perforated cable tray with cover. The
cable shall be tied on the GI Cable tray with GI Clamps. No PVC ties or MS wire shall be used
for tying the Cable on the GI Cable tray. The Cable shall be laid on the tray with min. D spacing
(D being the diameter of the thicker Cable). Bunching of Cables or laying Cable on top of each
other is not permitted.
Separate Cable tray shall be used for laying Power & Signal/ communication/ Control Cables
The perforated GI Cable tray shall be supported at regular interval. The existing structural
support at Gantry, Tanks may be used for supporting the Cable tray. In case additional supports
are required the same shall be supplied & erected by the Vendor & shall be included in the cost
for cable laying.
Laying of the cables underground shall be in trenches of min. 1 mtr. depth in all types of soil
both hard & soft soil including dewatering, if required. Big boulders, sharp edges of the steel
sections, vegetarian, growth roots etc. if encountered shall be removed completely. Only soft
earth excavated shall be kept for refilling. Such earth shall be approved by the Engineering-incharge. Excavated trench shall be in true straight line as far as possible and bends if necessary
shall be provided. Such bends shall be gradual and not sharp in nature, the excavated trench
shall be approved by the Engineer-in-charge before laying cables In case, during excavation hard
rock is encountered which in the opinion of HPCL EIC/ Consultant cannot be excavated
further, then additional sand bedding of 150 mm shall be provided over & above the 150 mm
specified for the bedding. The decision of HPCL/ Consultant is final & binding in this regard.
Rate of cable laying shall include excavation, supply and laying of two layers ( 150 mm thick
each, below and above) of river sand conforming to IS 383 and a layer of good quality bricks of
compressive strength min. 35 Kg/Sq cm. on top of the second layer of sand & backfilling with
good quality excavated earth. Job shall also include cutting/excavation of RCC wherever
encountered & construction of RCC culvert/ cable alley in RCC 1:1.5:3 with reinforcement as
per design requirement. All care shall be taken to ensure that no underground utilities like cables,
pipelines etc. gets damaged. However, in case any underground utility like cables/pipes are
damaged, the same shall be repaired/ replaced by the Vendor immediately at no extra cost. Rate
Page 9 of 13
HINDUSTAN PETROLEUM CORPORATION
LIMITED
MOV Controls- Various Locations under NWZ
TENDER NO. 10000058-HB-11370
to include backfilling of the excavated earth & carting away surplus earth within the depot
premise as directed by HPCL EIC/ Depot Manager.
Before cutting the cables exact length as per the site conditions shall be measured and recorded.
Cut ends of the cable shall be wound by insulating tape to protect them from rain water etc.
Cable ends shall not be kept open for long.
The Cables shall be laid with minimum spacing of “D” (D being the diameter of the thicker
Cable) & 15 mm from the edge of the Cable tray. Power Cable shall be laid in separate trench
and Signal & communication Cabling shall be laid in different trench. The same may be laid in
common trench provided physical barrier in the form of bricks are provided in such a way that
both are laid min 300 mm apart. Power & Signal/ communication/Control cables shall be laid
separately .
Wherever the cables have to cross the asphalt roads, the job shall include cutting of the asphalt
and WBM roads including soling and necessary excavation to the required depth and back filling
the trench with river sand and restoring the asphalt / WBM roads to its original condition
including compacting and rolling the surface.
Road crossing shall be done through the Hume pipe. The existing Hume pipes may be used in
case sufficient space is available for laying the cables. Supply & laying of the NP2 Hume pipes,
if required, shall be in the scope of the Vendor.
Wherever the cables comes aboveground, a suitable size GI sleeve with bend shall be used. Such
pipe shall be laid 150mm below ground level and the projecting bend shall raise to 500mm above
ground level along the steel/concrete/brick columns. The sleeve shall be neatly clamped by MS
clamps of adequate size and wooden bushes. Necessary precautions shall be taken to make the
opening water tight by wooden bushes.
All the cables shall be neatly clamped on the cable tray and loose hanging cables shall not be
allowed.
Required loops shall be provided at both ends of the main cables. Cable shall be laid without
any joints.
Cable route markers at 20 m/c and at all the bends/ turnings shall be provided.
Bending radius of cables shall not be less than 12 times O.D. of cable.
All cores of cable shall be identified at both ends by means of PVC ferrule.
Line drivers & all other accessories required in this regard are included in the scope of work of
the vendor.
Cable laying shall also include termination of Cables at both the ends. Cable leads shall be
Page 10 of 13
HINDUSTAN PETROLEUM CORPORATION
LIMITED
MOV Controls- Various Locations under NWZ
TENDER NO. 10000058-HB-11370
terminated at both ends by crimped type soldering.
Rate shall also include megger test by 1000V megger for establishing the healthiness of cable in
the drum before removing the same, unwinding and straightening the cable & after laying of
cables.
INSPECTION, TESTING AND ACCEPTANCE
The cables shall be tested and inspected at the manufacturer’s works or alternatively at lab if the
cables are procured from traders . All the materials employed in the manufacture of the cable
shall be subjected, both before and after manufacture, to examination, testing and approval by
Third Party Inspection. Manufacturer shall furnish all necessary information concerning the
supply to HPCL/ Consultant. The Third Party inspector shall have free access to the
manufacturer’s works for the purpose of inspecting the process of manufacture in all its stages
and he will have the power to reject any material, which appears to him to be of unsuitable
description or of unsatisfactory quality.
After completion of manufacture of cables and prior to dispatch, the cables shall be subjected to
type, routine, acceptance and special tests as detailed below. HPCL/Consultant reserves the right
to witness all tests with sufficient advance notice from vendor. The test reports for all cables
shall be got approved from the Third Party Inspection agency before dispatch of the cables.
All routine tests, acceptance tests, type tests and additional type tests for improved fire
performance shall be carried out as listed in IS:1554 (Part I).
The test requirements for PVC insulation and sheath of cables shall be as per latest
revision of IS:5831.
•
Test for Resistance to Ultra Violet Radiation:- This test shall be carried out as per DIN 53387
or ASTM-G-53 on outer sheath. The retention value of tensile strength and ultimate
elongation after the test shall be minimum 60% of tensile strength and ultimate elongation
before the test. Test certificates with respect to this test (not older than one year) from
recognized testing laboratory to be furnished for review by Third Party Inspection agency
before dispatch clearance of cables. In case test certificates are not available, test is to be
conducted by vendor at his own cost in any recognized test laboratory or in house testing
laboratory, before dispatch clearance of cables. Sampling for this test is to be done randomly
once for each order, provided outer sheath remains same.
•
Acceptance tests as per IS-1554 (Part 1) and the following special tests to be performed on
the cables as per sampling plan. These tests are required to be witnessed by Third Party
Inspection Agency before dispatch of cables.
Page 11 of 13
HINDUSTAN PETROLEUM CORPORATION
LIMITED
MOV Controls- Various Locations under NWZ
TENDER NO. 10000058-HB-11370
a. Accelerated water absorption test for insulation as per NEMA-WC-5 (For PVC insulated
cables). Test certificate with respect to this test (not older than one year) from recognized
testing laboratory to be furnished for review by Third Party Inspection Agency before
dispatch clearance of cables. In case test certificates are not available, test is to be
conducted by vendor at his own cost in any recognized test laboratory or in house testing
laboratory, before dispatch clearance of cables. Sampling for this test is to be done
randomly once for each order, provided type of insulation remains same.
b. Dielectric Retention Test:- The dielectric strength of the cable insulation tested in
accordance with NEMA WC -5 at 75 =/- 1 deg C shall not be less than 50% of the
original dielectric strength (For PVC insulated cables). Test certificates with respect to
this test (not older than one year) from recognized testing laboratory to be furnished for
review by Third Party Inspection Agency before dispatch clearance of cables. In case
test certificates are not available, test is to be conducted by vendor at his own cost in any
recognized test laboratory or in house testing laboratory, before dispatch clearance of
cables. Sampling for this test is to be done randomly and once for each order.
c. Oxygen Index Test:- The test shall be carried out as per ASTM D2863 or applicable
Indian Standard Specifications. Sampling to be done for every offered lot/size as per
sampling plan.
d. Flammability Test:- The test shall be carried out on finished cable as per IS-10810 (Part
61 & 62). Sampling for these tests is to be done randomly once for each order provided
outer sheath remains same. The acceptance criteria for tests conducted shall be as
under:Part-61:- The cable meets the requirement if there is no visible damage on the test
specimen within 300mm from its upper end.
Part-62:- The maximum extent of the charred portion measured on the test sample should
not have reached a height exceeding 2.5 m above the bottom edge of the burner at the
front of the ladder.
e. Test for rodent and termite repulsion property. The vendors shall furnish the test details
to analyze the property by chemical method. Sampling to be done for every offered lot /
size as per sampling plan.
Incase the cables are purchased through Traders the same shall be sent to lab for testing purpose.
Page 12 of 13
HINDUSTAN PETROLEUM CORPORATION
LIMITED
MOV Controls- Various Locations under NWZ
TENDER NO. 10000058-HB-11370
APPROVED VENDOR LIST FOR HPCL TERMINAL/DEPOT AUTOMATION
PROJECT
ISOLATOR/ BARRIERS
Relays
FLP box ,Junction Box & Cable Gland
Signal cable & Control cable
Power cable, earthing cable
CABLE TRAY
Pipes
Pipes fittings & flanges
COMPRESSION FITTING
Isolators, SFU
Control/selector switches
Indicating lamps/ Push Button
Terminal blocks
MTL/ STAHL/ P&F
Omron, Tele Mechanique, Honeywell, Allan
Bradly, Paramount, Denki,OEN
Baliga, CEAG Flameproof control gears, Ex
Protecta, Flameproof eqpt. (p) Ltd, Flexpro
Electricals (P) Ltd, Sterling Switch gears
controls (po) Ltd, Sudhir Switch gears (P) Ltd,
Shyam Swich Gear Pvt. Ltd
Delton, Universal cable, RPG, Gemscab,
Polycab, , Radient cables, Havell, cords, KEI
Universal cable, Finolex, Fort Gloster ,CCI,
Delton, Cord,RPG, Havell, Gemscab, Polycab,
cords
GRAM ENGG./ HOPES METAL/ PREMIER
POWER PRODUCT/ INDIANA/ GLOBE
ELECTRICALS / MM ENGG.
Jindal pipes, Suryaroshni, Ratnamani, Indian
Seamless, Maharashtra Seamless, BHEL, Saw
Pipes
Gujrat Infra pipes, Tube products, Kwality,
Venus, Parveen Ind., Stewarts & Lloyds
EXCELISOR/ RELIANCE ENGG. / EXCEL
HYDRO PNEUMATIC
Siemens / L&T / Schiender electric/ GE power
controls/ Indo Asian Fuse Gear Ltd.
Siemens/ Sulzer /L&T /Alstom /Kaycee
Siemens /L&T /Control Switch Gear/ SchinderElectric /English electric/Technic
Elmex control / C&S
Page 13 of 13