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Specifications for Industrial Public Annexure-1 0

Address (IPA) System for Process DOCUMENT NO. REV

Industry Sheet 1 of 33

1. INSTRUCTION TO BIDDER
1.1 The intent of this specification is to Design, Engineering, Manufacturing,
Inspection, Testing, Packing & Forwarding, Supply & safe Transportation of
complete New IP based Two way talkback Decentralized Industrial Public
Address System for Process Plant along with all accessories items/material
but not limited to Field Call Stations, Master Call stations, Loudspeakers,
System Cards/Modules, Battery & Battery Charger, Cables, Leads, OFC,
Erection Materials etc. as per the details given in this document to Process
plant site.
1.2 Receiving all supplied material at site, Unpacking, Installation, site Testing &
successful Commissioning of new IP based Industrial Public Address System
for Process plant.

2. SCOPE OF SUPPLY
The broad scope of supply for the job of revamping of Industrial Public Address (IPA )
system of Process plant shall be but not limited to following items:
Sr.No. Item* Qty.
3.1 Supply of Desktop type Master Call Station with at least 64 03 sets
keys for following locations:
a) Ammonia-2 Control Room
b) Urea-2 Control Room
c) Product Handling-2 Control Room
3.2 Supply of Desktop type Master Call Station with at least 16 01 set
keys for following locations:
a) Power Plant-Electrical Control Room
3.3 Supply of Explosion Proof Filed Call Station with 3 sets of two- 48 sets
way toggle keys / momentary rocker switch and 25W
Explosion Proof Loudspeaker with suitable amplifier for
following locations:
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a) Process Area under Ammonia-2 Plant


b) Process Area under Urea-2 Plant
3.4 Supply of Weather Proof Filed Call Station with 3 sets of two- 18 sets
way toggle keys / momentary rocker switch and 25W
Explosion Proof Loudspeaker with suitable amplifier for
following locations:
a) Process Area under Product Handling-2 Plant
3.5 Supply of acoustic hoods suitable for the use in Ex zone-2 to 20 sets
reduce sound in extremely noisy environments.
3.6 Supply of 8 Port I/O Module for interfacing Fire & Emergency 01 set
Alarm.
3.7 Supply of Telephone Connectivity Module. 01 set
3.8 Supply of Interfacing module to connect existing Industrial 01 set
Public Address System of Plant-1.
3.9 Supply of required quantity of processor/Line/Speech 01 Lot
cards/modules suitable for above system. (Bidder to indicate
Model, Type, Dimension & detailed Catalogue of each
card/module and offered qty. of each car/module) for following
locations:
a) Ammonia-2 (24 FCS & 1 MCS)
b) Urea-2 (32 FCS & 1 MCS)
c) Product Handling-2 (24 FCS & 1 MCS)
d) Power Plant-Electrical (Only 1 MCS)
3.10 Supply of fully wired Floor Mounted Panels for housing all 3 sets
cards/modules, connectors, LIU Box, Ethernet Switch minimum
(Managed HUB), OFC to Ethernet Connector, CAT6 cables, (4 sets if
connecting leads & accessories suitable for above system for require for
following locations: Power Plant-
a) Ammonia-2 (24 FCS & 1 MCS) Electrical)
b) Urea-2 (32 FCS & 1 MCS)
c) Product Handling-2 (24 FCS & 1 MCS)
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Address (IPA) System for Process DOCUMENT NO. REV

Industry Sheet 3 of 33

d) Power Plant-Electrical (Only 1 MCS)


3.11 Supply of fully wired Floor Mounted MDF panel for termination 3 sets
of 5 pair armoured cables of FCS coming from plant field area minimum
fitted with mounting frame, IDC connector & accessories for (4 sets if
following locations: require for
a) Ammonia-2 (24 FCS & 1 MCS) Power Plant-
b) Urea-2 (32 FCS & 1 MCS) Electrical)
c) Product Handling-2 (24 FCS & 1 MCS)
d) Power Plant-Electrical (Only 1 MCS)
3.12 Supply of 48 V Power Supply Panel having suitable Battery, 4 sets
Battery Charger/UPS etc. having at least 08 hours power
backup for continuous use following locations:
a) Ammonia-2 (24 FCS & 1 MCS)
b) Urea-2 (32 FCS & 1 MCS)
c) Product Handling-2 (24 FCS & 1 MCS)
d) Power Plant-Electrical (Only 1 MCS)
Suitable size Power Cable from electrical feeder to these
power supply panels shall also be in bidder’s scope total
length 150m
3.13 Supply of 5 pair 0.8mm dia ATC armored communication 20000 m
Cable as per detailed specification given at Annexure-3, for
connecting new Field Call Stations to respective decentralizes
processor/exchange panel of following locations:
a) Ammonia-2 Control Room (24 FCS)
b) Urea-2 Control Room (32 FCS)
c) Product Handling-2 Control Room (24 FCS)
3.14 Supply of 6 Core Multi Mode Optical Fiber Cable with flame 4000 m
retardant outer jacket, Digilink / Panduit / Dlink / Tyco make
only, for connecting new decentralizes processor/exchange of
following locations:
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a) Ammonia-2 to Urea-2
b) Urea -2 to Product Handling-2
c) Product Handling-2 to Product Handling-1 (LIU at Old
IPA side)
d) Ammonia-2 to DM Plant (LIU at old IPA side)
e) Ammonia-1 (LIU at old IPA side) to Telephone
Exchange (For operation of “Configuration & Monitoring
PC”.)
3.15 Supply of Industrial grade HDPE Conduit Pipe, 32/26mm dia, 4000 m
wall thickness 3.0mm, 32mm OD, homogenous, conforming to
IS7328, material grade80, density 0.958g/cc, Colour: Green,
with water tight couplers (one for every 80m length –
qty50nos)

3.16 Supply of “Configuration & Monitoring PC” with required 02 set


hardware & software for configuration, monitoring & remote
diagnostic of the complete Industrial Public Address System of
Plant-2 which shall be installed at existing Telephone
Exchange Building & other shall be spare.

3.17 Supply of Wireless Crane Call Station with 16 keys, a 2 set


microphone and a high quality loudspeaker suitable to (OPTIONAL)
communicate with MCS of new IPA system with power supply
& other required hardware for wireless communication.
OWNER shall provide only 240 V AC power supply in Crane
cabin & system shall be designed accordingly. Range 180m on
both side of Wireless Access Point (OPTIONAL)

3.18 Supply of Radio Interfacing System & other required software 1 set
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& hardware for communication with IPA System in “Group Call” (OPTIONAL)
through existing Motorola make GP328(S) handheld Walkie-
talkie sets on existing allocated frequency by statutory
authorities (OPTIONAL)

3.19 SPARES 1 Lot


a. Master Call Station with 64 keys & all connecting leads–
02 set
b. Explosion Proof Filed Call Station with 25W amplifier – 05 nos.
c. Weather Proof Filed Call Station with 25W amplifier – 05 nos.
d. 25W Explosion Proof Loudspeaker - 05 nos.
e. 25W Weather Proof Loudspeaker -05 nos.
f. Electronic Cards used in FCS - 30% of each type
g. Electronic Cards other than FCS (e.g. processor module,
interface module, Communication module, amplifier
module) – 20% of each type or minimum one whichever is
higher.
h. Connecting leads – 30% of each type or minimum two
sets
i. MCS Connectors– 100% of each type.
j. Fuses – 200% of each type
k. Power Supply Rectifier – 01 no. of each type
l. Any other recommended spares
3.20 Any other material, cards, components, connector, panel, 1 lumpsum
computer, software, tools, hardware, accessories or any item
etc. required for successful operation of the new Industrial
Public Address system shall be supplied, installed &
commissioned by the bidder.
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Address (IPA) System for Process DOCUMENT NO. REV

Industry Sheet 6 of 33

* Detailed specification of all of the above items/cards has been mentioned at various
sections of this specification.

3. SCOPE OF SERVICES
The broad scope of services for the job of revamping of Industrial Public Address (IPA )
system of Process Plant shall be but not limited to following items:
Sr.No. Item* Qty.
4.1 Installation & Commissioning of Desktop type Master Call Station 04 sets
with all extended units at following locations:
a) Ammonia-2 Control Room
b) Urea-2 Control Room
c) Product Handling-2 Control Room
d) Power Plant-Electrical Control Room
4.2 Installation, Termination, Testing & Commissioning of Explosion 66 sets
Proof / Weather Proof Filed Call Station and 25W Explosion Proof
Loudspeaker for following locations:
a) Process Area under Ammonia-2 Plant
b) Process Area under Urea-2 Plant
4.3 Installation & Commissioning of acoustic hoods suitable for the 20 sets
use in Ex zone-2 to reduce sound in extremely noisy
environments.
4.4 Installation & Commissioning of 8 port I/O Module for interfacing 1
Fire & Emergency Alarm, Telephone Connectivity Module, and lumpsum
Interfacing module to connect existing old IPA type Industrial
Public Address System.
4.5 Installation & Commissioning of all processor/Line/Speech 1
cards/modules, Floor Mounted Panels, MDF panels, connectors, lumpsum
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Address (IPA) System for Process DOCUMENT NO. REV

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LIU Box, connecting leads, Power Supply Panels, Battery, Battery


Charger/UPS, “Configuration & Monitoring PC” etc. supplied for
the IPA system.

4.6 Laying, Glanding & termination of 5 pair communication armored 20000 m


Cable for connecting new Field Call Stations to respective
decentralizes processor/exchange panel of following locations:
a) Ammonia-2 Control Room (24 FCS)
b) Urea-2 Control Room (32 FCS)
c) Product Handling-2 Control Room (24 FCS)
4.7 Laying & termination of 6 core Multimode Optical Fibre Cable & 4000 m
HDPE pipe for connecting new decentralizes processor/exchange
of following locations:
4.8 Third Party Inspection charges as per Testing & Inspection clause 1
no.9 of this specification lumpsum
4.9 Any other job/services not indicated here but required for 1
successful commissioning & satisfactory operation of the new lumpsum
Industrial Public Address system shall be in bidder’s scope.
*Detailed job scope for the IPA system has been mentioned at various sections of this
specification. Payment of all service items shall be based on actual execution done by
the successful bidder.

4. SITE CONDITIONS
All equipments / parts of the offered system shall be capable of performing satisfactorily
operation under following site conditions:
Design Ref / Max temp. 50 oC
Minimum Temperature –1.5 oC
Relative humidity 100%
Seismic Zone as per IS1893:2002 Zone IV
Atmospheric pollution Ammonia Vapour & Urea dust
Altitude above sea level Less than 1000 M
Hazardous Area (for Ammonia & Urea Zone-2 & all equipments should
process area) conform to Ex-d, IIC, T3

All outdoor equipments shall be dust, damp & vermin proof suitable for continuous
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operation in open atmosphere against direct sun & rain.

5. CODES & STANDARDS


The above system shall meet the all requirement specified herein & shall give safe,
trouble free operation of continuous duty as it shall be used for uninterrupted round the
clock communication service to our critical process plants. The scope of this document
does not include the design aspects and quality checks during manufacturing. However,
the design, manufacture, testing and installation of the equipment shall comply with the
latest issue of relevant Indian Standard (IS) Specification and codes of practices. In the
absence of IS for any particular equipment or in case of imported equipment, relevant
IEC/TEC/ITU/UL shall be complied with.

6. OPERATIONAL, FUNCTIONAL & CONSTRUCTIONAL REQUIREMENTS:


The Industrial Public Address System shall be primarily used to enable communication
in the general course of work or in emergencies in industrial noise environment for
transmitting working instructions and messages to and between the employees. The
offered system shall have following operational, functional, constructional & general
requirements:
6.1 BASIC COMMUNICATION FUNCTIONS: In order to meet current and future
communication requirements, the IPA system of Plant-2 shall provide the
following basic functions.
6.1.1 Direct Individual FCS Call: By pressing a single “direct line” key (on FCS or
MCS), a pre-defined half-duplex connection between two call stations is
established. The connection, which is established immediately, is displayed at
the target station by the LED assigned to the corresponding key. The call is
terminated by releasing the key. It shall be possible to communicate between
two field stations without the interference of the MCS /operator.
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6.1.2 Group Call: By pressing a “Group Call line key” on a MCS, a connection is
established between all FCS of one plant area i.e. Ammonia-2 or Urea-2 or
PH-2 & message is broadcasted to all 25W loudspeakers. The call is
terminated by releasing the key.
6.1.3 All Call: By pressing a “All Call” line key on the MCS of Ammonia-2, a
connection is established between all FCS of Plant-1 & Plant-2 & a message
is broadcasted to all 25W loudspeakers & all MCS namely:
 All FCS (1W & 25W) & MCS of Plant-1( MCS & FCSs at Ammonia-1,
Urea-1, Power Plant, PH-1 & Offsites)
 All FCS & MCS of Plant-2 (New MCS & FCS at Ammonia-2, Urea-2
& PH-2)
The call is terminated by releasing the key.
6.1.4 Dynamic Group Call & Conference Call: After activating a “Dynamic group
selection key” on MCS, the line keys of the all the desired Field Call Stations
is pressed to define a new group & the connection is established by activating
the start/talk key and the announcement can be made to all FCS of the
defined group. Any FCS of above defined group shall also be able to talk to
Control Room MCS & other FCS of the group via second talk key of FCS after
pressing “Conference Call key” defined on MCS. MCS should have the facility
to monitor the conversation of field call station and if required MCS can also
particIPA te with them. The call is terminated by pressing a delete key.

6.1.5 Direct Call from New Master Call Station of Plant-2 to Old IPA Master
Call Station of Plant-1: By pressing a single direct line key on new MCS, a
pre-defined half-duplex connection between old Master Call stations of Plant-
1 ( MCS Model- MTSD DS-6 L.no.10450) is established & vice versa. The
connection, which is established immediately, is displayed at the old MCS by
the LED assigned to the corresponding key & vice versa. The call is
terminated by releasing the key.
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6.1.6 Alarm Tone for “Emergency Declaration”: The new IPA system shall be
designed to play a predefined tone for “Emergency Declaration” in the plant.
The signal shall be initiated by Fire & Safety Control Room. OWNER shall
provide the Potential Free Contact for the Alarm via existing Telephone Cable
upto the bidder’s equipment/module. The alarm tone shall be played for a
period of 3 minutes on all FCS & MCS of the new offered IPA system. Master
Call station shall have overriding feature to deactivate the same. In absence
of overriding by MCS the alarm tone shall continue for three minutes of alarm
initiation & became silent after 3 minutes. The time duration of alarm tone
shall be programmable by “Configuration & Monitoring PC”.

6.1.7 Alarm Tone for “Emergency All Clear”: The new IPA system shall be
designed to play a predefined tone for “Emergency All Clear” in the plant. The
signal shall be initiated by Fire & Safety Control Room. OWNER shall provide
the Potential Free Contact for the Alarm via existing Telephone Cable upto the
bidder’s equipment/module. The alarm tone shall be played for a period of 3
minutes on all FCS & MCS of the new offered IPA system. Master Call station
shall have overriding feature to deactivate the same. In absence of overriding
by MCS the alarm tone shall continue for three minutes of alarm initiation &
became silent after 3 minutes. The time duration of alarm tone shall be
programmable by “Configuration & Monitoring PC”. The time duration of alarm
tone shall be programmable by “Configuration & Monitoring PC”.
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6.1.8 Direct “All Call” & “Group Call” from Analog Telephone: “All Call” shall
also be possible through Analog Telephone line of our existing EPABX
(HICOM 350H model of Siemens, Germany). OWNER shall provide four nos.
of standard analog subscriber line upto the relevant telephone interfacing
module of the new IPA system.
6.1.8.1 When the 1st phone numbers is dialed, the telephone interfacing
module should pick up the phone & pass on the phone
announcement (receiving sound) as “All Call” i.e. announcement
made by calling party on telephone shall be broadcasted in real
time to 1W speaker of all FCS, all 25W loudspeakers & all MCS of
Plant-1 & Plant-2 both i.e.
 All FCS (1W & 25W) & MCS of Plant-1[ MCS & FCSs
(with 25W loudspeaker) at Ammonia-1, Urea-1, Power
Plant, PH-1 & Offsites]
 All FCS (1W & 25W) & MCS of Plant-2 [New MCS & FCS
(with 25W loudspeaker) at Ammonia-2, Urea-2, PH-2 &
Power Plant-Electrical]
6.1.8.2 When 2nd phone is dialed the telephone module should pass
(relay) on the phone announcement (receiving sound) as “Group
Call” of Ammonia-2. Similarly 3rd & 4th line of analog phone shall
pass on the announcement as “Group Call” of Urea-2 & Product
Handling-2.
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6.2 GENERAL CONSTRUCTIONAL REQUIREMENT


6.2.1 The offered IPA System shall be a digital communication system for intercom,
PA and general alarm whose connections shall be established by means of
an IP-based Ethernet system.
6.2.2 The offered Industrial Public Address system should be stored programmed
controlling digital communication technology, with completely non blocking
switching system. The system should have the facility to pick last configured
program from memory (S-RAM) if it finds problem in running program or
power supply and should be able to auto-start.
6.2.3 The structure of the Industrial Public Address system should be based on the
modular, pluggable system cards/modules comprising plug-in PCBs.
6.2.4 All cards/modules should be mounted in standard rack
(MDF/cabinets/panels). The panels should have front & back door opening
facility with proper facility for cable routing, glanding and termination etc. The
structure of the panels should be such so as to restrict the entry of dust,
insects, rats etc and have protection class IP41. All rack/cabinets/panels/MDF
panels shall be of Rittal make only.
6.2.5 Rack shall be offered without provision of cooling fan.
6.2.6 All field cable shall terminate in a separate MDF panel in each control room.
The MDF panel of each control room area shall be suitable to accommodate
40 nos. 5 pair 0.8mm dia ATC, armoured communication cables. Each MDF
shall be fitted with 400 (200+200) numbers of Krone Make 2/10 IDC
Disconnection Module (Equivalent to Krone Product Code-6089 2 011-02) &
Stainless Steel Back Mount Frame Module to mount IDC connectors. Line
Side (IPA module Side) IDC connectors shall have be provided Single pair
protection plug & Earth Bar for voltage and current protection.
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6.2.7 All communication, processor modules, MDF, LIU panel, power supply, UPS,
Battery etc. shall be located in respective Control room building.
6.2.8 The system shall be designed for a bandwidth of 300Hz to 7kHz for giving
excellent speech performance in industrial plant full of noise and acoustically
problematic areas.
6.2.9 All equipment shall be conforming to EMC as per relevant IEC/EN.
6.2.10 The call priority should be programmable through “Configuration & Monitoring
PC”.
6.2.11 All necessary processor/Line/Speech cards/modules shall be supplied with
the system. The same shall be suitable to operate at 48V DC with ambient
temperature of 50 oC.
6.2.12 The offered System & components shall be of proven make with latest model.
6.2.13 Master Call Station and all Field Call Station shall be without handset type.
6.2.14 Bidder shall supply required quantity of processor/Line/Speech
cards/modules suitable for above system. (Bidder to indicate Model, Type,
Ports, Dimension & detailed Catalogue of each card/module and offered qty.
of each card/module) for following locations & FCS & MCS quantities:
Sr.No. Area MCS FCS
1. Ammonia-2 1 no. 24 nos.
2. Urea-2 1 no. 24 nos.
3. Product Handling-2 1 no. 18 nos.
4. Power Plant-Electrical 1 no. Nil
6.2.15 The system shall be modular with facility to extend upto 48 nos. future FCSs
in each control room i.e. Amm-1, Urea-1 & PH-2. Necessary chassis, wiring,
connectors etc. except subscriber card/module shall be provided in the
offered system i.e. the system should be designed in such a way that
additional FCS can be installed in each control room area upto 48 nos. FCS
by installing only additional subscriber card/module/adopter & configuration
modification through “Configuration & Monitoring PC”.
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6.2.16 Bidder shall design & supply minimum 3 sets of fully wired Floor / Wall
Mounted Panels for housing all cards/modules, connectors, LIU Box,
connecting leads & accessories suitable for above system for Ammonia-2,
Urea-2 & Product Handling-2.
6.2.17 Additional panel for hooking up single MCS of Power Plant may also be
supplied by the bidder, if required. Otherwise bidder to use existing OFC
system available at Power Plant for old IPA system or supply & lay its own
OFC for MCS of Power Plant.
6.2.18 Bidder shall design & supply minimum 3 sets of 48 V DC Power Supply Panel
having suitable Battery, Battery Charger/UPS etc. having at least 08 hours
power backup for continuous use of IPA . Bidder shall submit the sizing
calculation for the Battery, Battery Charger/UPS with the bid.
6.2.19 Bidder shall demonstrate the backup hours given by the offered Power
Supply backup system by actual loading at site.
6.2.20 Bidder shall supply 5 pair communication cable as per detailed specification
given at Annexure-3 for connecting new Field Call Stations to respective
decentralizes processor/exchange panel. Cable laying shall also be in
bidder’s scope. 90% of the communication cable shall be laid on existing
overhead cable tray & 10% shall be saddled on plant steel structure.
6.2.21 Existing corporate LAN of OWNER shall not be used for IPA system at all.
Offered IPA system shall have its own Ethernet System.

6.2.22 Bidder shall supply & lay 6 Core Multi Mode Optical Fiber Cable with flame
retardant outer jacket, Digilink / Panduit / Dlink / Tyco make only, for
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connecting new decentralizes processor/exchange of following locations in


ring topology.
a) Ammonia-2 to Urea-2
b) Urea -2 to Product Handling-2
c) Product Handling-2 to Product Handling-1 (LIU at Old IPA side)
d) Ammonia-2 to DM Plant (LIU at Old IPA side)
e) Ammonia-1 (LIU at Old IPA side) to Telephone Exchange (For operation of
“Configuration & Monitoring PC”.)
6.2.23 Bidder shall also connect its OFC cable based Ethernet network with existing
OFC cable based Ethernet network of IPA system of Plant-1. All related
hardware for this connectivity shall be supplied & commissioned by the
bidder.
6.2.24 Cable laying shall also be in bidder’s scope. All OFC cable shall be laid in
Industrial grade HDPE Conduit Pipe & cable shall be laid on existing
overhead cable tray.
6.2.25 Power Supply (UPS, Battery Charger, DC converter) shall have provision of
overvoltage, over temperature, overload & short-circuit protection. All power
Supply panels & battery shall have same rating & capacity.
6.2.26 Individual fuses shall be provided for power supply going to each Master &
Field call station.
6.2.27 All cards/module used in system shall have protection features against short-
circuit.
6.2.28 Any other material, cards, components, connector, panel, computer, software,
tools, hardware, accessories or any item etc. required for successful
operation of the new Industrial Public Address system shall be supplied,
installed & commissioned by the bidder. The quantity, make & details of these
items shall also be indicated in the bid.
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6.2.29 90% Field Call station shall be mounted on existing plant steel structure &
rest 10% shall be mounted on concrete wall. So, suitable Mounting frame with
all installation hardware shall also be supplied with each Field Call station.
6.2.30 All Equipment shall be sturdy, impact resistant, dust & damp proof generally
conforming to minimum IP 66 degree of protection. All equipment &
accessories shall be given tropical protection against fungus, insects and
corrosion.
6.2.31 The equipment for outdoor shall be provided with FRP canopy.
6.2.32 Equipment shall be made tamper proof by use of non standard screws, which
can be opened only by means of special keys supplied by the manufacturer.
Minimum 20 sets of such special keys shall be supplied by the bidder.
6.2.33 The comprehensive list of spares along with the unit rates shall be furnished
by the bidder along with the tender document in addition to that of two years
recommended spares.
6.2.34 Necessary civil jobs such as grouting of Exchange panels, making masonry
holes shall also be in the bidder’s scope.

CONSTRUCTIONAL REQUIREMENT OF MAJOR PARTS


6.3 MASTER CALL STATIONS (MCS):
6.3.1 The Master Call Stations shall be compatible to the offered IPA system to
make direct calls to other call stations (FCS & MCS) as well as to make
announcements via loudspeaker.
6.3.2 The master call station/desktop call station shall have dedicated push button
for connecting to each field call station. All keys (push button) provided on the
MCS shall be programmable by “Configuration & Management PC”.
6.3.3 Master Call Station of Amm-2, Urea-2 & PH-2 shall have minimum 64 keys &
Power Plant-Electrical have minimum 16 keys.
6.3.4 Volume control provision shall be provided at the Master call station.
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6.3.5 A Master Call Station shall be made of good quality plastic housing with a
built-in loudspeaker, a gooseneck microphone & all keys with LED signaling.
The keys can be fitted with labels describing their individual functions.
6.3.6 The Master Call Station shall be supplied with all necessary hardwares i.e.
Ethernet extender, POE, junction box, connectors & connecting cable/leads
etc.
6.3.7 The Microphone of MCS shall be Electret Micro phone
6.3.8 The Master Call Stations shall be of latest model without any handset.
6.3.9 Bidder to submit filled in technical table for the offered MCS. Bidder may also
indicate any other vital technical data/features in the table.
1 Operating Voltage …..V
2 Loudspeaker amplifier output power 1 Watt at ........... Ohm
3 Number of keys on base module with number of ……………nos. Base
key in each base modules module with …… keys
4 Number of extension modules with number of ……………nos. extension
key in each extension modules module with …… keys
5 Operating voltage range ……..V DC
6 Maximum quiescent current ……..mA
7 Microphone dynamic impedance ……..Ohm
8 Input Sensitivity ……..mv
9 Frequency Range ……..kHz
10 Maximum Distance of Master call station from ….m
Subscriber Card/Module
11 IP Degree of protection
12 Communication protocol
13 Connecting lead type (Power & Signal)
14 Height x width x depth
15 Weight
16 Color
6.4 FIELD CALL STATIONS (FCS):
6.4.1 Filed Call Stations & Loudspeakers supplied for Ammonia-2 & Urea-2 shall be
ATEX certified permitted to use in IEC/CENELEC Zone-2, Gas Group-IIC &
minimum Temperature Class of T4 & Equipment category of Ex II 2G. FCS
chassis shall be with flameproof chamber (Ex-d), connection area shall be
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with increased safety Ex-e protection type & electronics unit shall be with
intrinsically safe Ex-ib. All Ex proof equipments shall be duly certified by
recognized certifying authority & certificate to be submitted with the bid.
6.4.2 Filed Call Stations & Loudspeakers supplied for Product Handling-2 shall
have dust and watertight, fiber glass reinforced polyester enclosure with IP66
rating.
6.4.3 FCS housing shall be made of Flame-retardant glass fiber reinforced
polyester in orange colour.
6.4.4 Field stations shall be capable of operating in areas of high noise without any
inference.
6.4.5 Field Call Stations shall have one number integrated 1W speaker, one
number Noise-compensating electret microphone, 3 sets of wear-resistant
two-way toggle talk keys (momentary rocker switch) for rapid set up of direct
communication links to MCS & other FCS upto 6 connections, fitted with
required number of electronic cards/modules/25W amplifier, internally
hardwired for power & signal.
6.4.6 FCS shall have Plug-in front unit with all functional parts including microphone
and loudspeaker for easy maintenance.
6.4.7 All cards/modules/amplifier used in FCS shall be modular with pluggable
connector for easy maintenance. All active components in explosion proof
FCS shall be in pressure-proof enclosure.
6.4.8 The volume control of FCS & loudspeaker shall also be possible through
“Configuration & Monitoring PC”.

6.4.9 FCS shall be designed for following parameters:


Operating Voltage Range : 42-66 V DC
Maximum quiescent current : 25 mA
Maximum operating current :100 mA
Maximum operating current :1A
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with 25W additional amplifier


Degree of protection : IP66
6.4.10 FCS shall have provision of incoming call and busy signaling by light emitting
diodes, call memory, adjustment of sensitivity of microphone, adjustment of
volume, bass, treble of 1W in-built speaker & 25W additional loudspeaker.
6.4.11 FCS shall be mounted on existing steel column of plant. Hence, supply of
necessary mounting arrangement & its welding shall also be in bidder’s
scope.
6.4.12 All Filed Call Stations shall be of latest model.
6.4.13 Bidder to submit filled in technical table for the offered Explosion proof FCS &
Weather Proof FCS separately. Bidder may also indicate any other vital
technical data/features in the table.
1 Speaker amplifier output power 1 Watt
2 Additional Amplifier Output 25 Watt
3 Number of two-way talk keys 3 sets
4 Operating voltage range ……..V DC
5 Maximum quiescent current ……..mA
6 Maximum operating current without 25 Watt ……..mA
booster amplifier
7 Maximum operating current with 25W additional ……..mA
amplifier
8 Sound pressure level ...dB at a distance of 30 cm
9 Microphone dynamic impedance ……..Ohm
10 Input Sensitivity ……..mv
11 Frequency Range ……..kHz
12 Maximum Distance of FCS from Subscriber
Card/Module with cable size@ 48V DC
13 Operating surface Temperature
14 Ex Protection Class, Gas Group, Temperature
Class & Equipment Ex Category
15 IP Degree of protection IP66
16 Output voltage of 25W Loudspeaker 100 V
17 Communication protocol
18 Cable glands Type & Size
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19 Height x width x depth


20 Weight
21 Color Orange

6.5 25W HORN LOUDSPEAKER:


6.5.1 25W Horn loudspeakers shall have corrosion proof, heat resistant, dust- and
watertight weatherproof casings of glassfibre-reinforced polyamide/LM6
Aluminum which can be mounted by swing mounting brackets made of
stainless steel. Earth terminal shall be provided for LM6 Aluminum housing.
6.5.2 The membrane should be easily replaceable without soldering, if required.
6.5.3 The loudspeakers can be matched to the 100 V output of the amplifier in
different steps.
6.5.4 Suitable size cable gland shall be provided to protect the horn against the
ingress of dust and water. Explosion proof horn of Amm-2 & Urea-2 shall have
Ex-d type cable gland.
6.5.5 Distributed amplifier system i.e. each 25W loudspeaker being fed from the
respective field call station should have required amplifier housed in the field
call stations.
6.5.6 Bidder to submit filled in technical table for the offered Explosion proof
Loudspeaker & Weather Proof Loudspeaker separately. Bidder may also
indicate any other vital technical data/features in the table.
1 Rated Capacity 25 Watt rms
2 Rated Voltage 100 Volt
3 Rated Impedance of Moving coil …. Ohm
4 Matching Impedance of Transformer ….. Ohm
5 Switching Power Matching for …………. VA
6 Frequency range …… Hz – …… kHz
7 Max. Sound Pressure level (25W, 1m) …. dB
8 Avg. Sound Pressure Level ….. dB
9 Protection acc. to DIN 40050 IP 66
10 Protection acc. to DIN EN 50014
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6.6 8 PORT I/O MODULE


6.6.1 The I/O module shall be used for interfacing Fire & Emergency Alarm.
6.6.2 The I/O module shall get signal (Potential Free Contact) by Fire & Safety
Control Room for Emergency Declaration & Emergency All Clear alarm
Generation.
6.6.3 The I/O module should give necessary command to IPA system for
generation of a pre-defined tone (to be provided in mp3 by OWNER).
6.6.4 I/O module shall be of minimum 8 ports.
6.6.5 The I/O module should be programmable by “Configuration & Monitoring PC”.

6.7 Acoustic Hood for Explosive Areas


6.7.1 The acoustic hoods shall be used for sound reduction in extremely noisy
environments & it shall ensure a high level of noise insulation to allow a clear
and understandable communication. The acoustic hoods shall be suitable for
minimum 20 dB Noise reduction.
6.7.2 The acoustic hoods shall be suitable for use with supplied model of Ex-proof
Field Call Stations.
6.7.3 The acoustic hoods shall be made of a sturdy, flame-retardant and a self-
extinguishing material and shall be suitable for the use in Ex zone-2.
6.7.4 The acoustic hoods should protect intercom stations against environmental
influences such as rain, snow, sun, or dust.
6.7.5 Necessary Mounting material shall also be supplied to mount the hood & FCS
on existing steel column of Ammonia-2 & Urea-2 plan.

6.8 TELEPHONE CONNECTIVITY MODULE


6.8.1 Telephone Connectivity Module shall link the IPA system to 04nos. Analog
Telephone line of our existing EPABX (HICOM 350H model of Siemens,
Germany).
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6.8.2 If any hardware is required in the exchange (EPABX) side, the same shall be
in bidder’s scope.
6.8.3 Analogue telephones line shall be with DTMF or dials pulsing.
6.8.4 “All Call” shall also be possible through Analog Telephone line of our existing
EPABX (HICOM 350H model of Siemens, Germany). OWNER shall provide
four nos. of standard analog subscriber line upto the relevant telephone
interfacing module of the new IPA system.
6.8.4.1 When the 1st phone numbers is dialed, the telephone interfacing
module should pick up the phone & pass on the phone
announcement (receiving sound) as “All Call” i.e. announcement
made by calling party on telephone shall be broadcasted in real
time to 1W speaker of all FCS, all 25W loudspeakers & all MCS of
Plant-1 & Plant-2 both i.e.
 All FCS (1W & 25W) & MCS of Plant-1[ MCS & FCSs
(with 25W loudspeaker) at Ammonia-1, Urea-1, Power
Plant, PH-1 & Offsites]
 All FCS (1W & 25W) & MCS of Plant-2 [New MCS & FCS
(with 25W loudspeaker) at Ammonia-2, Urea-2, PH-2 &
Power Plant-Electrical]
6.8.4.2 When 2nd phone is dialed the telephone module should pass
(relay) on the phone announcement (receiving sound) as “Group
Call” of Ammonia-2. Similarly 3rd & 4th line of analog phone shall
pass on the announcement as “Group Call” of Urea-2 & Product
Handling-2.

6.9 Configuration & Monitoring PC


Bidder shall supply & commission 02nos. “Configuration & Monitoring PC”
with required hardware & software for configuration, monitoring & remote
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diagnostic of the complete Industrial Public Address System of Plant-2. One


“Configuration & Monitoring PC” shall be installed at existing Telephone
Exchange Building & the other shall be kept as spare. The “Configuration &
Monitoring PC” shall be suitable to carry out following basic functions:
6.9.1 Configure the basic communication relevant characteristics of the offered IPA
system i.e. defining FCS on MCS key for direct call, define FCS for group call
& “All Call”, define links for FCS keys (6), volume level adjustment of FCS,
6.9.2 The “Configuration & Monitoring PC” shall have required software for
Monitoring of health of all cards/modules, protection fuse used for
module/card, FCS & MCS health, alarm system health, fault diagnostics & call
logs & report generation.
6.9.3 The system should have internal control system for fault diagnosis & fault
report generation.
6.9.4 The IPA system should have the facility to store the complete events of the
system on “Configuration & Monitoring PC”.
6.9.5 The “Configuration & Monitoring PC” & its software shall be based on latest
Windows OS platform.
6.9.6 The PC shall be in table top construction, with Intel i7 processor 4th
Generation, 8GB RAM, 500GB Storage Space, DVD RW Drive, 20-22”
diagonal LED backlit Monitor,, with MS Office software, with Anti Virus
Software (Norton/ McAfee), with 2nos LAN ports & parallel printer port.
6.9.7 Supply, installation & commissioning of communication components e.g. LIU
Box, OFC to Ethernet Converter, Managed Hub/switch, connecting leads &
other required accessories for connecting “Configuration & Monitoring PC”
shall also be in bidder’s scope.

6.10 INTERFACING MODULE TO CONNECT EXISTING old IPA TYPE


INDUSTRIAL PUBLIC ADDRESS SYSTEM
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6.10.1 Bidder shall design the new IPA system in such a way to provide smooth
connectivity with existing old IPA model IPA system of Plant-1 with matching
of protocol/ technical parameters etc. so that following communication
function can be achieved:
6.10.1.1 Direct Individual Call from any MCS of Plant-1 (i.e. any of 05nos. MCS of
Old IPA) to a new MCS of Plant-2 (i.e. any of 04nos. new MCS) & vice
versa in half duplex mode.
6.10.1.2 Broadcasting of real time announcement (ALL CALL) made from MCS of
Plant-2 to all FCS and MCS of Plant-1 (Old IPA) & Plant-2 (new IPA ).
6.10.1.3 Broadcasting of real time announcement (ALL CALL) made from an
Analog Telephone to all FCS and MCS of Plant-1 (Old IPA) & Plant-2 (new
IPA ).
6.10.1.4 Playing of pre-defined ALARM TONES on all FCS and MCS of Plant-1
(Old IPA) & Plant-2 (new IPA ).
6.10.1.5 Any hardware/software required for integration of existing system with
bidder supplied new system is in bidder’s scope.
6.10.1.6 Any Interconnection cable between IPA system of Plant-1 & the supplied
new IPA system of Plant-2 shall be in bidder’s scope.

6.11 POWER SUPPLY & BATTERIES


6.11.1 Separate power Supply, battery & battery charger shall be provided for each
Control Room i.e. Amm-2, Urea-2, Ph-2 & Power Plant-Electrical.
6.11.2 1ph 240V±10% 50Hz, ±5% AC power shall be provided by OWNER from
nearest Power Distribution Board for new charger/UPS panel to be installed
at Amm-2, Urea-2 & Product Handling-2. Supply, laying & termination of the
required size of armoured power cable shall be in bidder’s scope. The cable
length from nearest PDB to new charger/UPS panels shall be maximum 50m
at Amm-2/Urea-2/PH-2 i.e. total cable requirement shall be 150m. Cable
gland shall also be supplied by the bidder. The contractor shall indicate its
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load requirement during detailed engineering to make available power


arrangement.
6.11.3 There shall be four numbers 48 V Power Supply system having batteries with
100% capacity for Ammonia-2, Urea-2, Product Handling-2 & Power Plant-
Electrical.
6.11.4 Batteries shall be adequate to meet the power requirements of all features,
FCS, MCS and all modules of new IPA system as per this specification and
min. 25% spare capacity for future requirement.
6.11.5 Battery shall have back up time of 08 hours.
6.11.6 VRLA type Sealed Maintenance Free battery shall be provided.
6.11.7 Factors like ageing factor, temperature correction factor, maintenance factor,
additional safety margin shall be taken into account as follows:
Back up time – 08 Hr.
Design Margin – 20 %
Ageing Factor – 1.25
6.11.8 Voltages required at all other levels than above shall be achieved by
providing suitable transformer/ rectifier arrangement by the contractor, within
the cabinet. All further power distribution from charger/UPS panel shall be in
the scope of the contractor including cable & termination.
6.11.9 Only following make shall be used for Power Supply:
Power Supply DC Rectifier: Emerson
UPS : Emerson, Fuji
Battery : Emerson, Exide, Amara Raja

6.12 CABLES
6.12.1 Bidder shall supply 20000m of 5 pair 0.8mm dia ATC armored communication
Cable as per detailed specification given at Annexure-3, for connecting new
Field Call Stations to respective decentralizes processor/exchange panels.
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6.12.2 Bidder shall supply 4000m of 6 Core Multi Mode Optical Fiber Cable with
flame retardant outer jacket, Digilink / Panduit / Dlink / Tyco make only.
6.12.3 Bidder shall also lay OFC for connecting new decentralizes
processor/exchange of following locations:
a) Ammonia-2 to Urea-2
b) Urea -2 to Product Handling-2
c) Product Handling-2 to Product Handling-1 (LIU at Old IPA side)
d) Ammonia-2 to DM Plant (LIU at Old IPA side)
e) Ammonia-1 (LIU at Old IPA side) to Telephone Exchange (For operation of
“Configuration & Monitoring PC”.)
7. PERFORMANCE GUARANTEE
7.1 The vendor shall guarantee that any and all materials used in IPA system of
Plant-2 shall be in strict compliance with characteristics, requirement and
specification agreed upon and that the same shall be free from any defects.
Checking of Vendor’s drawings by owner shall not relieve the vendor of any part
of his/its responsibilities of proper fulfillment of the requirements. Vendor shall
guarantee OWNER against any defects in design, workmanship of the supplied
goods and performance for a period of 36 months from date of handing over
of the system. Should any defects/fault develop during the guarantee period in
any card, module, component, equipment or any other supplied item of IPA
system, the same shall be promptly replaced free of cost with a new one by
the vendor and all expenses including packing, transportation etc. of goods
necessitated for such replacement shall be borne by the vendor. No
card/module repairing shall be allowed / entertained. Acceptance by the
Owner or Inspectors of any materials or their replacement will not relieve the
Vendor of his/its responsibility concerning the above guarantee.
7.2 During the guarantee period, vendor shall depute a competent engineer within 24
hours of OWNER’s intimation to solve any problem occurring in the IPA system
or any of its components.
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7.3 In addition, vendor shall depute its engineer for regular health monitoring &
software updates for the IPA system on quarterly basis during the guarantee
period of three years.
7.4 After placement of order, PBG of 5% of order value shall be submitted for 42
months to cover guarantee period of 36 months + a claim period of 6 months to
support their product performance.

8. TEST & INSPECTION


8.1 The Industrial Public Address System and their components shall be tested &
inspected as per relevant as per latest standards, Data sheets and specifications
in presence of OWNER’s representatives & third party inspector by Bureau
Veritas/Lloyd’s Register/TUV/DNV/UHDE at manufacturer’s works. Third party
inspection charges shall be indicated separately at item no.4.8.
8.2 Following minimum test shall be conducted & test reports shall be submitted with
the equipment supplied :
a) Acceptance test
b) Visual Inspection & Measurement
c) High tension measurement
d) Isolation measurement
e) Measuring of protective conductor resistor
f) Measuring of leakage current
g) Performance test
8.3 Test and Inspection plan shall be submitted to the inspector for approval. The
inspector shall indicate additional tests to be witnessed, over and above the ones
specified in this specification.
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8.4 These inspections shall however, not absolve the bidder from his responsibility
for making good any defect which may be noticed subsequently.

9. TRAINING
9.1 Bidder shall provide training to twelve nos. of OWNER personnel (in 03 batches
of each having 04 persons for two days) at their Indian partner works/training
centre for operation, maintenance & trouble-shooting of Digital Industrial Public
Address Exchange free of cost including boarding & lodging.
9.2 Bidder shall also provide for operation, engineering, maintenance & trouble-
shooting, Configuration & monitoring software programming to THIRTY Owner’s
engineers/technician at OWNER Plant site.
10. DOCUMENTATION
S. DESCRIPTION WITH POST ORDER
NO. BID For For With Data
Review Record Book (Final)
1 Schedule of Bidder Documents 
2 Confirmation of Technical Compliance 
3 GA Drawing for racks/panels & MDFs   
4 GA Drawing for Master control station   
5 GA Drawing for Charger panel   
6 GA Drawing for FCS & loud speakers  
7 Sectional View Drawing  
8 Cubical Arrangement Drawing  
9 Battery Rack Arrangement Drawing   
Installation Plan/ Mounting Details/
10 Cable Cutout Details  
11 Bill of Material  
12 Speech diagram  
13 Block diagrams  
14 Wiring Diagram and Terminal Details  
15 Interconnection Diagrams  
16 Performance Curves of battery  
17 Inspection & Test Plan (ITP)  
18 Test Records  
19 Statutory approval certificate for each  
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S. DESCRIPTION WITH POST ORDER


NO. BID For For With Data
Review Record Book (Final)
item (CCOE or equivalent)
20 Calculations for : Battery Sizing   
21 Calculations for : Charger Sizing   
22 Calculations for : System Cables   
23 List of Commissioning Spares  
24 List of Mandatory Spares    
25 List of Maintenance Spares    
26 List of Special Tools & Tackles   
27 Installation Manual  
28 Operating/ Maintenance Manual  
29 Catalogues/ Brochures  
30 Equipment storage procedure at site  
Type test certificate (for similar
31 equipment)  
Notes :
1. "TICK" denotes applicability.
2. All drawings & documents shall be submitted in A4 or A3 paper sizes and in
English language only. Documents in higher paper size shall be submitted in
exceptional circumstances or as indicated in the Tender.
3. Final documentation shall be submitted in hard copy bound fine plastic coated
folder (Six prints) and soft copy ( two CDs/DVDs/PEN Drive ).
4. All data, drawings, documents, etc. furnished with the offer shall be treated as
data for information only. This shall not be contractual binding to OWNER
5. All drawings and documents shall have the following description written boldly:
-- Name of Client: ………..
-- Order Number with Project / respective Plant Name
e.g. Project Name: Industrial Public Address System
Plant Name: Ammona-2, Urea-2, and Product Handling-2 as applicable.
-- Code No. & Description
6. All final documents shall be submitted prior to despatch of equipment.
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11. COMPLETION PERIOD


11.1 SUPPLY: The bidder shall supply all components of the IPA system within 6
months of order placement.
11.2 COMMISISIONING: The bidder shall complete the installation, commissioning &
testing of the complete system including new cable laying & termination, removal
of old IPA system within 2 months of site handover. Site shall be handed over
within 20 days of receipt & acceptance of the complete material at OWNER plant
site.

12. SPECIAL INSTRUCTION TO THE BIDDER


12.1 Bidder to submit the Un-priced copy of the priced bid with items details given at
cl.no.3 & 4 of this specification.
12.2 Prices of additional supply item may be quoted at item 3.18 & for additional
services at item no.4.9.
12.3 Bidder to quote unit rates for 2 years Operation and Maintenance spares at item
no.3.17. Quantity to be mentioned as per recommended quantity criteria given at
item no.3.17.
12.4 The scope of this contract shall be on turnkey basis. Any field work or job even
though not mentioned in the scope of services but required for satisfactory
installation, commissioning & operation of IPA system shall be done by the bidder
without any price implication. The bidder shall depute sufficient manpower to
complete the job within 2 month of site handover. No separate mandays charges
for deputed persons shall be paid.
12.5 Bidder shall depute one competent person permanently to oversee all
commissioning activities & he shall be responsible for obtaining all necessary
permits, clearance, issue of material from OWNER’s store & record keeping etc.
12.6 Around 60% of existing FCSs are in working condition. So, bidder shall plan the
job in such a way that the operation of existing IPA system is not affected during
installation commissioning of new IPA system.
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12.7 Bidder shall submit activity bar chart for the job & shall be got approved by
OWNER. OWNER shall monitor the actual job progress based on activity bar
chart and if job progress is found slow, the bidder shall depute additional
manpower without any price implication.
12.8 Service bill of the bidder shall be cleared only after clearing all punch points &
final clearance from engineer-in-charge of OWNER.
12.9 Bidder shall submit all AS BUILT drawings after completion of job.
12.10 Bidder shall supply recommended tools and tackles and special equipment
required for the operation and maintenance of Industrial Public Address system.
12.11 Bidder to furnish confirmation that there is no deviation to RFQ specifications &
data sheet, and shall furnish the signed and stamped copy of Technical
Compliance Statement (attached as Annexure-2). In case of deviation/ signed &
stamped copy of Technical Compliance Statement not furnished, the offer shall
be rejected without raising any query to Bidder.
12.12 Bidder shall clearly highlight the discrepancies, if any, amongst various
specifications attached with the RFQ in their offer to seek clarification. In case,
no such discrepancies are brought out in the offer, the most stringent
requirement shall govern during detail engineering. OWNER’s decision in this
regard shall be final. No cost or time implication shall be admissible on account
of the same during detail engineering.
12.13 Bill of materials, if any, furnished in the offer will be retained for information and
records only. This is subject to review during detail engineering. All materials and
components as required to meet RFQ specifications and functional requirements
shall be included in bidder’s scope without any cost and time implication to
purchaser.
12.14 Offered Industrial Public Address System shall be provided with redundant
processing unit in hot stand-by mode.
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12.15 All Power Supply Module/rectifier/UPS of the Industrial Public Address System
shall also be provided with redundancy (N+N) to ensure 48 V power supply to the
IPA system in hot stand-by mode.
12.16 Bidder shall consider and include all devices and accessories required for
satisfactory operation of the system based on limitation of distances (approx.
1500m) between Communication module and farthest Field Call Station.
12.17 All equipment shall be supplied with suitable double compression cable glands,
heavy duty tinned copper crimping type lugs and mounting brackets etc. for
installation. The glands shall be suitable for the type and size of cable finalized
during detail engineering without any cost implication to the Purchaser. 20%
extra cable glands shall be supplied over & above the actual requirement for
future use.
12.18 At least 10nos. Thermal insulation barrier shall be supplied for installation of FCS
on hot surfaces of 60 oC.
12.19 Preparation of cable interconnection diagrams is included in the scope of the
bidder and price for the same shall be included under item no. 3.1 to 3.18.
12.20 Equipment numbering/ description, speech diagram shall be finalized at the time
of review of bidder drawings.
12.21 All speakers shall have an arrangement such as adjustable knob to vary the
amplification power. Amplifier in FCS shall be capable of driving 25W
loudspeaker connected to it.
12.22 Design of the system shall be such as to eliminate the acoustic feedback.
12.23 MCS shall be located in Control Room building on main console or Shift Engineer
Table. Bidder shall provide proper mounting arrangement to ensure non-
movement of MCS. Bidder shall also ensure that its cable/connector/jack are not
stressed & proper dressing of wiring as per control room atheistic shall also be
ensured by the supplier.
12.24 Bidder shall not quote any product / item which have become obsolete or going
to be obsolete in next 15 years time.
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12.25 All updates / upgrades, software patches to fix bugs shall be provided free of cost
for above period.
12.26 Bidder shall confirm that service support of the supplied product / items shall be
offered for at least 15 years from date of commissioning. Bidder shall guarantee
the availability of replacement spares for this period. This guarantee shall also
include all third party equipment supplied by bidder alongwith his system. The
bidder to submit written undertaking for the same to the owner.

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