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ENGINEERING
SERVICES
NEW DELHI
Annexure 1
Leak
Detection System
2PLP-CA
Volume
II Section 2.6
Rev.
Discipline
Instrumentation
Page : 1 of 22
ANNEXURE-1
1.0
The LDS Vendor shall undertake full responsibility for providing a complete and
evolutionary state of the art LDS System meeting the objectives, functional and specific
requirements described in the tender.
1.2
The LDS Vendors scope of supply and works shall include, but not limited to, all the
Activities of project management, design, engineering, training, factory testing (FAT),
supply, installation, commissioning, site testing(SAT), test run, packaging, forwarding,
transportation (freight), insurance, port handling, custom clearance, inland transportation ,
receipt & storage at site, warranty, quality assurance and quality control of the system, and
documentation with the turnkey responsibility and meet the requirements of the tender, its
objectives, functional and specific requirements described in the specifications.
1.3
Supply of all the items / equipment required to execute the LDS system complete in all
respects. However, if any additional items are required to meet the functionality of the
LDS system as per this tender, vendor shall supply the same without any cost and time
implication.
1.4
1.5
Submission of as built documentation, drawings and DVDs/ CDs of the complete system,
Documents and drawings.
1.6
Supply, Installation and commissioning of UPS system with min. five hrs. Back up for
LDS System (NRM) as well as RTU Locations (KMP and AKM).
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Discipline
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The electrical works associated with the powering and earthing of equipment at site.
1.8 Supply and laying of all necessary cables, connectors for installation / interconnection of
supplied LDS equipment and connection with RTU equipment at all locations.
1.9
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1.18 After successful completion of warranty period, performance Test / Tuning shall be carried
out on half yearly basis for Two years. Contractor to quote in Lump Sump for the same
and these rates shall be valid of period of two years after successful completion of
warranty period.
2.0
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2.5.1 LDS vendor shall ensure that the equipment shall not be damaged due to blackouts/ burnouts.
Further LDS vendor to indicate: Steps to be taken for fail-safe operation of the system under
following conditions: a) Power failure
b) Air Conditioning failure
c) Start up procedure of the system
2.6 SYSTEM AVAILABILITY REQUIREMENTS
The LDS System Availability of 99.98% shall be ensured by the LDS vendor.
2.7 ELECTROMAGNETIC COMPATIBILITY - EMC
2.7.1 The equipment shall be efficiently screened against EMI, RFI and conductive interference and shall
not interfere with other equipment in the vicinity or installed in the same building.
2.7.2 The equipment shall be required to meet one of the relevant EMC standards (IEC, MIL, VDE, BS,
IEEE etc.).
3.0
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3.2.2 Operator supervisory actions (manual inputs, online LDS database, alarm acknowledgements, alarm
inhibit, etc.) shall be updated from the active Server between Server#1 & Server#2.
3.2.3 The failed LDS Server on recovery if it finds itself isolated from the active LDS Server in the Local
area network, it shall not become active LDS Server automatically. For user presentation, the data
source for LDS displays, reports, trends, alarms/ events etc at HMI workstations shall be from
active LDS Server. The HMI software shall operate in client-server mechanism where the HMI
shall make direct database connection to the directly accessible active LDS Server.
3.2.4 On re-induction of failed LDS Server, the operator shall be informed by a suitable event message
generated by the system that the Server is fully synchronized with the primary LDS Server. Based
on the decision by supervisor or system engineer, the restored machine shall continue to be hot
standby or it shall be possible by system engineer under suitable security password control to
change the status of restored machine as active primary machine also.
3.2.5 In case of active LDS Server failure and Server fail over, the standby LDS Server shall ensure that
there is no loss of data, alarms/ events and these information during the switchover period can be
accessed subsequently for preparation & processing, in spite of previously active LDS Server
failure.
3.2.6 History database and archiving files between active LDS Server and standby LDS Server shall
remain synchronized to maintain database consistency. When the LDS Server starts up after
recovery from failure, the real time and historical LDS database shall become identical to the
active LDS Server. The event indicating that this recovered LDS Server has become STANDBY
shall denote that LDS databases have been synchronized.
3.2.7 Each remote workstation [RWS] shall provide complete LDS HMI capability [displays, graphics,
and reports.
3.3.1 NRM:
The system at NRM shall consist of following hardware as a minimum:
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a) Two LDS servers, Server#1 & Server#2, each Windows based with hard disks & backup, main
memory, 20 colour LCD monitor, alphanumeric & functional Keyboards, mouse, Power supply units
etc. RAID 0 Configuration is favoured.
b) One no. of HMI Workstation, having single 21 LED screen monitor.
c) One no. of colour Laser Printer
d) Comm. interfaces including cables
e) Auxiliary equipment including cabling, connectors etc.
f) Suitable racks / panel to house the Servers, Switches, Power Distribution System etc. The racks shall
floor standing (to be sized suitability) with front and back glass door with 2 side panels, castors, Fans
with fan trey, AC/DB channel, shelves etc.
g) Operator console desks are to be supplied to house / install the HMI Workstations.
h) UPS system, suitable for Servers and Work Station.
3.3.2 KMP, AKM:
The LDS system shall be extended to KMP and AKM locations from NRM through RTU via OFC
Network. The LDS equipment at each of these locations shall consist of:
a) One Remote HMI workstation each with hard disks and backup, main memory, single 21 LED screen
colour monitor, alphanumeric and functional keyboards, mouse, power supply units, system cabinets etc.
b) One no. of colour Laser Printer
c) Communication Interfaces including cables
d) Auxiliary equipment including cabling, connector, tap offs, interfaces, etc.
e) Operator console desks are to be supplied to house / install the HMI WS.
f) UPS system, suitable for Work Stations.
3.4 SYSTEM CONFIGURATION
3.4.1 The system configuration at NRM shall be as follows: a) Two computer Servers i.e. Server # 1 and Server # 2 shall be configured as LDS servers.
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b) The HMI workstations shall provide complete LDS HMI capability and shall access LDS servers. HMI
functionalities shall not be affected by server switchover.
3.4.2 The system configuration at KMP and AKM shall be as follows: a) One HMI workstation with 21 LED colour monitor
b) The HMI workstations shall provide complete LDS HMI capability.
Offered System hardware shall have successful operation period of minimum One year on offered
LDS Software in Past Three years.
Hard Disc capacity for pipe line data Storage: Min. Two years storage or 500GB x 2, whichever is
maximum. (RAID 0)
3.5.2 PRINTERS
Printers shall be colour laser jet. Printer shall be able to print all LDS System Generated information in
Data, Trend, Graphic etc. forms. These printers shall have in built LAN driver cards so that they can be
directly connected to LAN.
3.6 SYSTEM SOFTWARE:
3.6.1 The operating system of LDS servers and other machines shall be Windows based and must be
having real time capabilities. Following licensed softwares shall be supplied and installed:
1 Server Operating System Installed at server with software DVD/CD
2 LDS software installed at server with software DVD/CD
3 Data Base Management Software installed at server with software DVD/CD
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3.6.3 The LDS package in the LDS servers shall be built around real time database management system to
provide fast access to support data processing functions, and other time-critical databases.
3.6.4 As a minimum requirement, LDS software shall have the following facilities:
a. System and Database configuration.
b. Generation and management of historic data for trending and archival.
c. Alarm handling, including storage, display and printout.
d. Generation, storage, presentation of mimic diagrams with dynamic information on HMI monitor.
e. Display Management for Alarm, Alerts, Mimic diagrams, Analog and digital values, Trend graphs, in
high-resolution colour graphic modes.
f. Free format report generation, storage and printout.
g. Data logging at periodic intervals, on operator request and automatically on occurrence of an event. h.
Redundancy, fail-over and recovery processes.
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Discipline
Instrumentation
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The supplied LDS system shall have necessary provision for interfacing (data interchange) with third
party applications like SCADA system. To achieve the above the following facilities as a minimum shall
be provided with the LDS system:
a.
Real time and history data shall be made available in database resident at the LDS servers at NRM.
The exact real time and history data to be made available in database shall be finalized during detail
engineering. However Data Base shall be capable to store the Data for a period of One year for each pipe
line application. The database shall be installed in both the LDS servers as per the required Hot standby
configuration and it shall be ensured that the database at both the LDS servers are synchronised. Data
Base at each LDS server shall be licensed / capable for at least more than one concurrent user.
b.
It shall be possible to read all real time parameter values, their quality tags, time tags and other
attributes using these APIs. It shall also be possible to write parameter values, their quality tags, time tags
and other attributes using these APIs. Once parameter values or their attributes are written into the LDS
real time database using these APIs (from a third party software), the LDS system shall treat these
parameters in the same manner as the LDS system acquired values for all purposes including storing,
archiving, controls etc.
3.7 APPLICATION SOFTWARE
The Application software licenses will be supplied along with delivery of the system hardware and
software. After delivery of the system, there will not be any time lock in the software. As part of system
SAT, this aspect will be checked. The supplied Application software will be such that no source code is
required for modifications / adding of the HMI Displays (reports, graphics), database, interfaces with third
party applications etc. Application software shall be easily maintainable and expandable by the
COMPANY, and shall have configuration editor to take care of various pipeline configuration changes,
changes in supplies and delivery points, addition/ deletion of units/ stations etc. and the corresponding
SCADA interface points for use by application software. The system shall be capable for configuring
and running multiple independent pipelines. As part of system FAT, system will be checked for two
independent pipeline networks. Application software (LDS) shall run on LDS computer servers at
NRM.
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Performance
Sensitivity
Qualitative
Performance
Criteria
Specification
Expected Min.
Performance by
Company
Minimum detectable
leak rate
0.5%
Response
for
Time
Time
100% of Leak
Response
for
10% of Leak
Response Time for 1 % Steady State: < 1
of Leak
Hrs.
Response
Time
for minimum
Leak of <
0.5%
Reliability
Incorrect
leak
declarations Overall,
Transient
Bidders
Response with
quantification
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Incorrect
leak
declarations Steady
state, Start up, Shut
down
Robustness
(For All Flow
conditions )
Bidder to
indicate
Bidder to
indicate
Bidder to
indicate
Bidder to
indicate
Bidder to
indicate
Bidder to
indicate
Bidder to
indicate
Bidder to
Accuracy
Leak Location error
indicate
Volume
II Section 2.6
Rev.
Discipline
Instrumentation
Page : 11 of 22
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Instrumentation
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Bidder to
indicate
Sensitivity
Qualitative
Performance
Criteria
Specification
Expected Min.
Performance
by
Company
Minimum
Steady State :
1 m3/hr
Response
Time
for
Theft
Bidders
Response
with
quantification
@1m3/hr
Company expectations on performance of Leak / Theft Detection System are based on:
1.
Company feels these Instrumentations are adequate to support Leak Detection System to
achieve above mentioned performance indicators.
2.
However, during the Instrumentation adequacy check by contractor, additional
instrumentations being identified to meet the performance indicators, shall be in the Scope of
Contractor only. Contractor shall supply, install and commission such Instruments and shall provide
the instrumentation signals up to control room.
3.
Additional instrumentation suggested shall be within the premises of Installations only, as Pipe
Lines passing through the terrain does not see any ONGC setup like Intermediate Pumping stations
etc.
3.9 Software Tuning:
In addition, software tuning shall also be applied as a part of leak detection software to minimize the
non-zero leak discrepancies resulting for causes other than leaks, such as instrument static error,
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timing skew errors etc. These tuning techniques shall also result in improved sensitivity of the Real
time model by ensuring that accuracy of calculations become dependent only on the repeatability of
measurements rather than on the absolute accuracy. Data validation after each update by LDS
system shall be performed to alarm and to filter out bad/ unreasonable data and default calculated
values shall be used so that the efficiency of on line modelling system does not get impaired.
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privileges related to system LDS system modifications. Operator: Alarms acknowledgement, Edit
leak thresholds, weightage factors etc., resetting of flow imbalances, alarm limits for LDS modules,
manual tuning, and manual override.
4.0 INSPECTION AND TESTING
4.1 Introduction
4.1.1 All factory tests will be witnessed by COMPANY and/or Company Representatives and/or Third
Party Inspection Agency (TPI).
4.1.2 COMPANY shall have free entry and access at all phases of the project to all parts of LDS vendor's
facilities associated with manufacturing and testing of system.
4.1.3 LDS vendor shall invite COMPANY well in advance with minimum 1 month notice of the date at
which the system is ready for testing.
4.1.4 The equipment shall be shipped after successful Factory Testing.
4.1.5 LDS vendor shall provide COMPANY with all reasonable facilities necessary to determine
compliance to the system specification.
4.1.6 LDS vendor to note that acceptance of the equipment and the system by COMPANY or
exemption of inspection & testing shall in no way absolve the LDS vendor of his responsibility to
deliver the LDS system meeting all the requirements specified in the specifications. LDS vendor
shall be responsible till the completion of the warranty, for any corrections / modifications including
supply and implementation of hardware & software to fulfill the requirements of the contract / up
gradation including supply and implementation of hardware & software to meet the functionality and
performance of the contract.
4.2 Testing
Testing shall concern all LDS equipment and LDS Software. The tests shall Consist of: a) Factory
Acceptance Testing (FAT)
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4.2.2.3 It shall systematically, fully and functionally test all the hardware and software in the presence
of COMPANY representative to ascertain compliance with the contract document and approved FAT
documents.
4.2.2.4 The LDS system testing shall cover the following aspects as a minimum:
a) Visual and mechanical testing to ensure correct, proper, good and neat workmanship.
b) Checking of complete database definitions for the proper system configuration.
c) Checking of displays, graphics and reports w.r.t approved HMI document.
d) Checking of correct functioning of keyboards operation for operator & engineering functions.
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pipeline data;
Page : 17 of 22
4.2.2.3 SAT shall involve integrated testing of complete LDS system. Site Acceptance Testing will be
done based on the stipulations in the approved SAT document.
4.2.3 Test Run / Performance Guarantee test run
Detailed in Installation and Commissioning.
DOCUMENTATION AND TRAINING
5.0 Introduction
The language used in all correspondence, documentation, literature, drawings, markings etc., shall be
in English only. LDS vendor shall furnish all relevant technical manuals, literature and other technical
data as required at the various stages of the project indicated in Tender
Document/Material requisition. All the drawings and documents shall be verified by the LDS vendor
before presenting the same for COMPANYs review. All these documentation shall be furnished in
hard cover loose ring folders. Prior to submitting the following documents for COMPANYs review/
records, the LDS vendor shall review, duly sign & stamp all the documents and ensure compliance to
the requirements of the contract.
5.1 Six hard copies and three soft copy of following documents shall be supplied by the LDS vendor.
5.1.1 Project Document (PD)
PD shall be custom defined for this project and include the implementation aspects of tender
requirements in the following sections. PD shall cover LDS implementation aspects like Complete
details of systems configuration, hardware and software requirements, Bill of Material, Interconnection
diagrams, system failovers & fail backs, Adequacy of measurement instruments for required input to
LDS, description of LDS/ third party software interface, System performance parameters, system
timeouts, Display updates, etc.
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5.1.9.1 LDS USER MANAUL: LDS user and maintenance manuals providing detailed instructions
for daily system use, various event messages, instructions for tuning, thresholds and filters
manipulation and error handling procedures.
5.1.9.2 LDS CONFIGURATION EDITOR MANUAL: LDS configuration editor manual shall contain all
the procedures to add /remove and change the configuration as and when necessary.
5.1.9.3 SYSTEM ENGINEERING MANUAL: System engineering manual to provide description
of LDS operating philosophy with details of functionality available to LDS software including
system engineering modification procedures and guidelines. This manual shall also cover the limits
associated with various inventory points, efficiency points, pressure/ flow points, LDS software
module status indicators etc.
5.1.10 The review by COMPANY however does not absolve the LDS vendor of his responsibilities
to satisfy the requirements of contract document and install & commission the LDS system
accordingly. LDS vendor is required to make necessary rectification in the LDS system to meet the
requirements of the contract document at any stage of system implementation, without any
implication of cost and schedule to the COMPANY.
5.1.11 LDS Vendor shall take care of the complete requirements of designing, generation and
implementation of LDS displays for monitoring & control, LDS reports, LDS alarms/ events, LDS
trending taking care of P&IDs and various pipeline parameters and covering the requirements outlined
in this specification for LDS implementation. The review code will be furnished by COMPANY only
when the complete document is furnished by LDS vendor.
5.1.12 LDS vendor shall furnish the point wise response to COMPANYs comments indicating the
document section/clause/page no. reference where the same has been included in the revised
document. The body of the document and corresponding pages will show the revision bars only at the
places where the revision has been carried out. COMPANY will be required to check the revised
document w.r.t. these changes only, while considering that rest of the document has remained
unchanged.
5.1.13 Training:
Details to be worked out during Detailed Engineering.
INSTALLATION & COMMISSIONING
6.1 The installation and commissioning of all the equipment at various sites including the activities of
electrical works with power supply distribution and grounding works.
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6.2 All the erection work shall be carried out as per the established recommended practices and best
workmanship.
6.3 LDS vendor shall bring all installation aids, test equipment and qualified and experienced personnel,
in order to carry out the job successfully.
6.4 All technical personnel assigned to the site by LDS vendor must be fully conversant with the specific
system and its software packages. LDS sub-vendors field personnel shall have both hardware and
software capability to bring the system on line quickly and efficiently and with a minimum of
interference with other concurrent construction and commissioning activity.
6.5 The commissioning spares for all the items/ equipment is included along with commissioning services
as required to commission the complete system. The consumables required during commissioning of
system are included as part of commissioning spares.
6.6 To the extent that the Standard of the works has not been specified in the Contract, the LDS
vendor shall use good quality materials, techniques and standards and execute the Contract with the
care, skill and diligence required in accordance with best engineering practices.
6.7 LDS vendor shall at his own expense supply and provide all the equipment, tools, temporary
works materials both for temporary and for permanent works, labour, supervisors, engineers and
specialists, movement of the supplied equipment at the site, required for installation,
commissioning, execution and completion of the works. The LDS vendor shall make his own
arrangements at his own cost for the transport where necessary of his staff and labour to and from
the Site of the works. LDS vendor shall co-ordinate with ONGC Security and arrange the necessary
photographs etc for getting gate passes etc. for his staff and labour
6.8 The LDS vendor's responsibility at site shall include all the activities necessary to be performed
to complete the entire job as per the contract requirements including the following as a minimum:
Storage, safety and security of the equipment and other materials including software at site.
Installation of the complete system including power supply, earthing, cable terminations,
calibration, civil & electrical works.
6.9 Commissioning:
30 days in advance of starting of commissioning, Contractor shall submit a proposal to the
Company giving complete detail of the program / procedures to be followed during commissioning.
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These documents shall be approved by the Company. Commissioning shall be started only when all
the facilities of the LDS are fully operational and the pre-commissioning activities as
specified/recommended have been successfully completed. Commissioning means uninterrupted
running of complete LDS systems for 72 hours as per process scheme at its design conditions.
Company would like to run all facilities together or in part as per their requirement. The log sheets
suitably prepared for different equipment / system shall be provided by Contractor shall be
reviewed / approved by the Company. These approved log sheets shall be used during precommissioning and commissioning of the plant. After 72 hrs. of stable operation of the plant, all the
log sheets shall be signed by the Companys and Contractors representatives. Success of the
commissioning shall be decided by the Company based on the hourly. Observations recorded in the
log sheets and the test results of sampling wherever required. After the successful commissioning
of the plant, Contractor shall also run the plant for minimum 720 hours to attend and rectify
operational bottlenecks if any to the satisfaction of Engineer-In-Charge before handing over the
LDS System to Company. In case of breakdown / malfunction due to system design for a prolonged
period, 720 hrs. Of operation shall be carried out a fresh again. In case of any such stoppages due to
Companies inputs / provisions cumulative 720 hrs. shall be accounted for. The Contractor shall
ensure that Vendors representatives for critical equipment remain present during precommissioning / commissioning and performance guarantee test run. It shall be Contractors
responsibility to involve Companys operational and maintenance personnel and impart necessary
training and know-how required for operation and maintenance of equipment/systems during precommissioning and commissioning activities.
Vendor is required to submit the PTR for successful implementation of one project in last 10 years
for RTTMS - Real Time Transient Monitoring System based on Mathematical Modelling of
Flowing Parameters in the pipeline on onshore oil or gas pipelines.
2.
The project(s), for which the experience is claimed by vendor, should have been satisfactorily
completed and / or handed over / commissioned.
3.
As a proof of experience / capability, the vendor shall furnish copies of the following documents:
i)
Detailed Work orders/Purchase orders indicating clearly the scope of work, schematic
drawings of as-built system, contract value, scheduled project completion date, etc.
and
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ii) Completion certificate / commissioning / handing over certificate for i) above, including
actual project completion date and the contact details of the authorized signatory of such
certificates.
4.
Offers of those vendors who themselves do not meet the technical specification of the LDS criteria
as stipulated in the scope of work can also be considered provided the vendor is a subsidiary
company of the parent company in which the parent company has 100% stake or parent company
can also be considered on the strength of its 100% subsidiary.
However, the parent/subsidiary company of the vendor should on its own meet the technical
specification of the LDS as stipulated in the SCOPE OF WORK and should not rely for meeting
the technical specification of the LDS criteria on its sister subsidiary/co-subsidiary company or
through any other arrangement like Technical collaboration agreement. In that case as the
subsidiary company is dependent upon the technical experience of the parent company or
viceversa with a view to ensure commitment and involvement of the parent/subsidiary company
for successful execution of the project, the participating vendor should enclose an Agreement (as
per format enclosed at Appendix B-10) between the parent and the subsidiary company or
viceversa and Parent/Subsidiary Guarantee (as per format enclosed at Appendix B-11) from the
parent/subsidiary company to ONGC for fulfilling the obligation under the Agreement.
Controller of the LDS software offered by the vendor should be from the same OEM of the LDS
Controller (Software) based on which Vendor has had past track record.
5.
Vendor shall be authorised by original equipment manufacturer of the LDS Controller (LDS
Software) and is required to submit the authorisation letter to ONGC for seeking qualification.
6.
Vendor shall demonstrate capability to provide After Sales Support after completion of the
project. Vendor is required to submit the supporting documents that they can provide their
Service support or supply of spares.