Technical Specification for Integration of SCADA System of Integrated

Process Shop with ERP System

Sl Scope of Work Description

Vendor shall be able to carry out Integration of

Interface data logging system through LAN with
SCADA to capture and monitor the processing
parameters during Chemical Processing on real
Intended time basis and automatic report generation and
1
outcome database management of processing and Test
records.
Processing data/parameters in this technical
specification refers to Time, Temperature, Voltage,
Amperes and pH.

Processing data from the following sources to

be exported to SCADA/ Any Relational DBs like
MSSQL, Postgres SQL, MySQL etc. of Integrated
Data export to Process Shop:
2
SCADA/MS SQL (i) Vapour degreaser
(ii) Heating oven
(iii) Dye Tank-Black
(iv) Dye Tank-Red
(v) Sealing tank
Extraction of data to Any Relational DBs like
MSSQL, Postgres SQL, MySQL etc. database from
the following sources:
Data extraction (i) ERP (Oracle 10g)
3 from different (ii) SCADA
sources (iii) Vapour Degreaser
(iv) Heating Oven
(v) Dye Tank-Black
(vi) Dye Tank-Red
(vii) Sealing tank
Creation of Web Application for following
processes:
(i) Operation Instruction Sheet (OIS) as per
Annexure-1. OIS shall be linked with ERP
Creation of web through particular operation number of
4 application for corresponding part number. Provision for
data handling new OIS creation and manual updation of
details and sketch in OIS shall be provided.
(ii) Process Traveler of Anodising (SAA, CAA &
HAA) and Hard Chrome process as per
Annexure-2
All data for Process Traveler in ERP, SCADA, MS
SQL to be linked to Route card job order number
and operation number.
Data access
5 All data for Operation Instruction Sheet (OIS) in
linking
ERP, SCADA, Any Relational DBs like MSSQL,
Postgres SQL, MySQL etc. to be linked to Part
Number and Route card operation number.
Sl Scope of Work Description
Vendor shall ensure following operational
sequence through its web application:
(i) User will fill following data inputs to start
web application:
(a) Route card JO number
(b) Operation number
(ii) Application shall automatically fetch
relevant information (as represented in
Annexure-2) from ERP (i.e. Route Card
data) & OIS.
(iii) User will manually fill ‘Lot size’ in web
application and starts the processing.
(iv) During Processing: Real time graph display
of processing parameters on computer
screen with data from SCADA during
processing
(v) Creation of trends analysis graph (Time vs
Temperature, Volts, Amps, pH) based on
data log for interval of every 5 minutes
(default). Option for sampling interval
required, the same to be chosen by user
based on requirements. Link shall be
available against the particular operation to
open the graph.
(vi) After processing the relevant data to be
fetched from SCADA at appropriate places
in formats as per Annexures mentioned at
Operational
Sl no 4 (ii) to (v).
Sequence of
6 (vii) User shall be able to forward filled formats
Data flow for
for inspection and testing on lot, with
Web application
digital signature of concerned personnel at
relevant places in process Traveler.
(viii) Offered Quantity (Lot size) to be auto-
fetched from ERP.
(ix) As per the lot size, the quantity to be
inspected shall be auto fetched in the
Process Traveler based sampling plan given
in OIS.
(x) Application allows user to enter the
following details manually in web
application:
 Test results as per Annexures
mentioned at Sl no 4 (ii) to (v).
 Rework quantity
 Rejected quantity
 Accepted quantity
 Quality Remarks
(xi) After input of Accepted quantity and submit
at step (ix) digital signature and stamp of
concerned personnel shall affix at relevant
place of process traveler and web
document is closed/saved assigning
sequential process traveler number to the
report.
(xii) Related OIS in prescribed format shall be
attached automatically at the end of
completed process traveler (report).
Sl Scope of Work Description
Following fields to be automatically updated back in
ERP system linked to JO number & route card
operation Number of Route card:
(i) Rework Quantity
(ii) Rejected Quantity
Back flow of
(iii) Accepted Quantity
7 processing data
(iv) QC remarks
in ERP
After updation back in ERP system the concerned
operation number of JO Number shall be cleared with
details (Qty. for Rework:, Rejected Qty:, Accepted
Qty:), Remarks affixing digital signature & Stamp and
a link to open the completed Process Traveler.
(i) Vendor shall provide easily accessible web
link(s) for visual analysis of the completed
process.
(ii) The web link shall be automatically created in
ERP (at related operation number of Route Card)
Access link for
upon completion of step mentioned at Sl no 5.
retrieval of
8 (iii) The web link shall open the filled process
completed
traveler in readable format for the completed
reports
process.
(iv) The web link shall also create graphical trends
of processing data/parameters. Option to select
intended process parameter(s) shall be
provided.
Training for operators and maintenance personnel
on system operation and troubleshooting.
IT Personal for 1 week to be trained for
understanding Program structure & Change if any.
9 Training Training for new OIS creation.
Ongoing Support: Free online support for two
months and further ongoing technical support and
maintenance services for a period of one year on
chargeable basis per visit.
The Equipment / System supplied is warranted for a
period of 12 (Twelve) months from the date of
commissioning or 18 (Eighteen) months from the
Warranty date of receipt whichever is earlier.
10
Provide quick response within 24 hours of receiving a
complaint.
Supply detailed documentation for system setup,
operation, and maintenance including following:
(i) Creation of OIS
(ii) Process Flow Diagram of activity
11 Documentation (iii) Detailed wiring diagram for networking
(iv) PLC source code and ladder logic diagram or
equivalent
(v) Corresponding hardware O/M manuals (HMI,
PLC, Sensors, etc.)
Sl Scope of Work Description
Vendor Scope
Network Equipment: Routers, hubs, switches,
CAT6/Network cable and other networking equipment
for reliable communication.
Communication Devices: RTUs (Remote Terminal
Units), PLCs (Programmable Logic Controllers), and
other communication devices.
Power Supply: Uninterruptible Power Supply (UPS)
systems for critical components
Miscellaneous: Cabling, connectors, mounting
12 Hardware hardware, and other accessories.
requirements
Control panels for Vapour degreaser and Oven with
PLC, Instrumentation with RS485 communication
ports, 7” HMI, cabling and Programming.
HAL Scope
SCADA PC: Personal computer with operating system
Microsoft windows
Servers: Assistance in accessing/hosting the ERP
databases.
Power Supply: Uninterruptible Power Supply (UPS)
systems for critical components
Vendor scope:
SCADA Software: Licensed SCADA software capable
of monitoring and controlling remote sites.
Any Relational DBs like MSSQL, Postgres SQL, MySQL
etc.
Installation of python and python libraries.
Operation trials and debugging
Exporting Vapour degreaser and Oven data from to
SCADA
Extracting data from ERP (Oracle) and SCADA to any
Relational DBs like MSSQL, Postgres SQL, MySQL etc.
APIs and Middleware: Use APIs and middleware for
Software seamless integration.
13 requirements Database Management: Any Database Software
requirement other than Oracle 21c/Oracle 10 g.

HAL scope:
ERP Software: Licensed ERP software with modules
for integrating SCADA data – Available Oracle 10G
Database Management: Database software for
storing SCADA and ERP data.
Operating software Microsoft windows
Network Management: Software for managing and
monitoring the network infrastructure.
Security Software: Antivirus, firewall, and other
security software to protect the system.
Sl Scope of Work Description
Vendor Scope
LAN cable laying and termination (like cat6 cable or
any).
Real-time data monitoring & control capabilities
Exporting Vapour degreaser, Oven and Dye Tank
data from respective HMI’s to SCADA
Data Exchange: Establish protocols for data
exchange between SCADA and ERP systems
Extracting data from – ERP (Oracle), SCADA
(included Anodising and chrome plating lines,
Vapour degreaser, Oven & Dye tanks) to Any
Relational DBs like MSSQL, Postgres SQL, MySQL etc.
Exporting data SCADA to Any Relational DBs like
MSSQL, Postgres SQL, MySQL etc.
APIs and Middleware: Use APIs and middleware for
Integration
14 seamless integration.
requirements
HAL Scope
Support for data mapping between SCADA and ERP
systems, including field mappings and
transformation rules.

Provide sample data sets for testing and validation

purposes

Internet access with communication protocols

- for installation of python and python libraries.
- Operation trials and debugging.

Providing connection string (EZConnect) to access

ERP system (Oracle 10g) to fetch the required data

Historical Data: Store and retrieve historical data for

analysis and reporting.
User Accounts: Create user accounts for SCADA
ERP Access operators with specific access privileges
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Details Roles and Permissions: roles and permissions for
users to ensure secure access to ERP data.

System Testing: Conduct comprehensive testing of

the integrated system to ensure functionality and
reliability.
Performance Testing: Test the system under various
Testing and load conditions to ensure performance.
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Commissioning
Commissioning: Finalize the integration and
commission the system for operational use.
Complete the integration and commissioning within
30 days of contract signing.

License, Support License subscription/AMC of minimum 5 years of

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& Services tenure shall be covered.