16-QMP-05-3B

00 08.02.12 ISSUED FOR USE ARUS TBY

Rev. Date Description Prpd. Chkd. Appd.

Triune Energy Services Pvt. Ltd.

New Delhi

TECHNICAL SPECIFICATION FOR

INSTRUMENTATION

Std. / Doc. Number Rev.

9579-02-TS-103 0

Sheet 1 of 12

CHAPTER 6

TECHNICAL SPECIFICATION

FOR

INSTRUMENTATION

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Triune Energy Services Pvt. Ltd.

New Delhi

TECHNICAL SPECIFICATION FOR

INSTRUMENTATION

Std. / Doc. Number Rev.

9579-02-TS-103 0

Sheet 2 of 12

1.0.0 SPECIFIC REQUIREMENTS OF INSTRUMENT – PROTECTIVE DEVICES FOR MAINLINE

MOTOR PUMP SETS.

1.1.1 All the field protective devices and junction boxes mounted on mainline motor pump sets shall be weather

proof (min IP 65) and suitable for unprotected out-door installation.

1.1.2 Vendor shall supply all the protective devices like switches, detectors etc. and junction boxes which shall have

to be explosion proof to Class 1, Div. 1, Group C&D as per API RP 500C. Test reports from laboratory are not

acceptable. For explosion proofness, European/ American certification is also acceptable which shall be Eexd

IIB T4 for Zone 1 as minimum for all instruments, RTDs and junction boxes. The acceptable competent

authorities for certification shall be BASEFA; CENELEC; CSA;

PTB; FM; EN , ATEX and CCE.

1.1.3 All the protective devices shall be tested and calibrated before installation/ mounting.

Test and calibration certificates shall be furnished by vendor.

Installation/mounting and commissioning of all the protective devices including junction boxes will be

carried out by vendor.

2.0.0 SPECIFIC REQUIREMENTS:

2.1.1 Each of the mainline motor-pump sets shall be equipped with the following instrumentation and control items.

2.1.2 Explosion proof, 3 wire Duplex platinum RTD (as per DIN 43760 -with Eexd head) 100 ohms at 00 C,

temperature co-efficient of 3.85 x 10-3

Ohm/Ohm/degree C, and suitable for accepting continuous drive current

of 2 mA approx. (from owners PLC control system), mineral insulated construction housed in stainless steel

sheath temperature tolerance confirming to BS 1904 class B for the followings:

a) Pump case temperature detection : 1 No

b) Pump Bearing temperature detection (DE/NDE) : 2 Nos.

c) Motor windings temperature detection (Two numbers per phase : 6 Nos.

winding)

d) Motor Bearing temperature detection (DE/NDE) : 2 Nos.

2.1.3 The temperature range of the above RTDs shall be selected by the vendor to suit to the safe working of motor

pump set. Acceptable makes for RTD shall be M/s Thermoelectric, Netherlands/ M/s Technomatic, Italy/ M/s

Degussa, Germany and M/s Bush Beach, UK , M/s Emerson / Rosemount, M/s Thermo Engineering/ M/s

Minco .

2.1.4 Two numbers per pump set, explosion proof and weather proof, seal leakage detector switches with

hermetically sealed DPDT contacts of 1A at 24 V DC (for each contact) with suitable electrical entry, and

stainless steel float shall be provided. All the necessary installation piping, fittings etc. shall also to be

provided. Specification datasheet of level switch is attached as Annexure VI(b). Vendor shall have to submit

the duly complied specification data sheet.

2.1.5 Vibration transmitters for X & Y direction vibration monitoring of DE / NDE bearings & axial side for pump

along with key phasor as per attached data sheet as annexure VI (a) shall be provided for tripping the MLPU in

case the vibration exceeds the set point. Vibration transmitter shall have linear range corresponding to 4-20 mA

output signal. These Vibration transmitters shall be wired upto JB-2 as per cable schematic diagram VI (C).

Vibration transmitters shall be interfaced with owner PLC based control system.

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Triune Energy Services Pvt. Ltd.

New Delhi

TECHNICAL SPECIFICATION FOR

INSTRUMENTATION

Std. / Doc. Number Rev.

9579-02-TS-103 0

Sheet 3 of 12

2.1.6 Three nos. (one no. for all RTD’s signal of motor, one no. for all RTD’s & vibration signal of pump & one no.

for two nos. of seal leakage detector switches, and other protective devices etc.) of suitable explosion proof

and weather proof junction boxes with terminals, glands and plugs shall be provided and installed on base plate

of each Motor-pump set. All the field protective devices (as mentioned in clause 2.1.2, 2.1.3, 2.1.4, 2.1.5) shall

be wired up to the respective junction boxes. Refer cable schematic attached as annexure VI (c). The cables to

be provided shall have sufficient cores (wires) so as to extend all potential free contacts (including DPDT) and

RTD wires (including duplex elements) from the individual devices to the junction boxes. The cabling shall be

done through rigid conduit pipes and flameproof fittings and as per standard approved wiring practices for

hazardous area. Separate cable entry shall be provided in junction box for individual devices. The total number

of entries of junction box will be more than number of incoming cables from different field devices. It shall

also have two entries for the outgoing cables to be laid by owner for extending to owner’s control room. The

spare entries shall be plugged. Explosion proof/double compression cable glands, plugs shall be provided for

terminating the cables and plugging the extra cable entry positions. The terminals shall be minimum 40 or

more or the junction box to be used to carry analog signals i.e. RTD & Vibration signals and 20 or more for the

junction box to be used to carry digital signals i.e. seal leakage signals etc. The terminals shall be of

Phoenix/equivalent make. The following wire armored copper control cables PVC inner and outer sheathed

(owner supply) as per IS: 1554 will be running from the junction boxes to control room.

For motor RTDs & Vibration signals junction box (J.B-1) :

40C x 1.5 mm2 (OD: 32.0mm, OAD: 27.5 mm, UAD: 25mm)

For pump RTDs & Vibration signals junction box (J.B-2) :

40C x 1.5 mm2 (OD: 32.0mm, OAD: 27.5 mm, UAD: 25mm)

For Seal leakage detector and other switches (J.B-3) :

12C x 1.5 mm2 (OD: 21.5.0mm, OAD: 16.5.0mm, UAD: 14mm)

The space inside the junction boxes shall have to be sufficient for doing wiring and termination work.

2.1.7 Any other protective devices which vendor / OEM feel necessary for safe operation of each motor and pump set

shall be provided in the offer. Such protective devices shall also meet the requirements as specified in clause no.

1.1.1, 1.1.2 and 12.1.2 and be wired and terminated in JB-3.

2.1.8 In case of separate control panel for forced lubrication of bearings, vendor shall provide PLC / micro processor

based control system along with one set of programming unit or laptop, license copy of programming software,

necessary serial cables and connectors. Control system shall be housed in an enclosure suitable for hazardous

area classified as Class I, Div. I Group C&D as per API-RP-500C. Control system shall be interfaced with owner

PLC system. Necessary potential free contacts & serial interface (RS 485 Modbus) shall be provided for the

same.

Vendor shall also provide one set of each type of modules of control system including CPU card, Power supply

card, IO cards etc as spare. Programming unit, software and control system modules shall be supplied one set if

similar for all control system of MLPUs otherwise it should be supplied one set for each type of control system

of MLPUs.

2.1.9 All the field protective devices and explosion proof junction boxes with accessories shall be supplied in installed

and wired condition Or confirm to install and wire at site free of cost by the Vendor.

2.1.10 Vendor to submit detailed technical catalogue, make, model nos and copies of valid certificates for explosion

proofness and weather proofness for RTDs, seal leakage detector switches, vibration transmitters, junction boxes

along with the offer. Offers without the same shall be considered incomplete.

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Triune Energy Services Pvt. Ltd.

New Delhi

TECHNICAL SPECIFICATION FOR

INSTRUMENTATION

Std. / Doc. Number Rev.

9579-02-TS-103 0

Sheet 4 of 12

2.1.11 Vendor shall submit duly completed data sheet and summary of requirement attached as Annexure VI (a) to VI

(e).

2.1.12 Vendor shall submit the conformance for the cable schematic drawing (for instrumentation items) attached as

Annexure VI(c). In case of deviation, vendor shall furnish their cable schematic drawing showing field

protective devices, junction boxes, cable layout, cable type, cable glands etc along with the offer.

2.1.13 Vendor shall submit the detailed instruction manual/catalogue for all protective devices, and all

installation/termination/mounting drawings including those for junction boxes interconnection diagram of all

the cables running from motor pump set upto junction boxes within 15 days of the purchase order for our

review and approval.

2.1.14 Vendor shall have to submit the following documents at the time of despatch clearance:

• Functional test certificates along with model no., make and sr. no. of all the protective devices.

• List of documents supplied along with the equipment.

• Quality Control Certificate from the vendor’s quality control department.

• Copy of explosion proof and weatherproof certificates for the supplied instrumentation items including unction

boxes.

2.1.15 Vendor shall supply all the necessary certificates, manuals (for installation, operation and maintenance,

working principles etc.), drawings etc. of the supplied protective devices in 6 sets along with the supply of

equipment.

3.0.0 INTERFACING OF VFD WITH OWNER’S CONTROL SYSTEM

3.1.1. The VFD shall be interfaced with the owner’s Station Control system to enable monitoring and control of the

VFD system and it’s associated Motor. For this purpose, necessary signals shall be provided in the VFD for

interfacing the same with the PLC of the owner’s Control system and vice versa. The details of the various

signals are as under:

3.1.2 Signals from VFD to owner’s PLC

1) Analog signals:

a) 4 – 20 mA speed feedback signal

b) 4 – 20 mA current feedback signal

2) Digital signals:

a) Input HT Breaker On b) Input Transformer Fault c) Outpout transformer fault d) Loss of Speed Reference Signal

e) VFD fault f) VFD ready to start g) VFD / Motor running h) Panel Fan On i) VFD in remote j) VFD Temp Hi

k) Input / Output Transformer Temp Hi

3.1.3 Signals from owner’s PLC to VFD

1) Analog signals:

a) 4– 20 mA speed control signal

2) Digital signals:

a) VFD Start b) VFD Stop c) Start Permissive (To ENABLE / DISABLE Remote start of VFD)

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Triune Energy Services Pvt. Ltd.

New Delhi

TECHNICAL SPECIFICATION FOR

INSTRUMENTATION

Std. / Doc. Number Rev.

9579-02-TS-103 0

Sheet 5 of 12

d) Process Trip

3.1.4 Serial communication between VFD and owner’s PLC

Besides the above hardwired signals, serial communication over MODBUS (RS485) shall be established

between the VFD and owner’s PLC for transfer of various input and output signal data. The MODBUS

mapping details shall be submitted by the vendor within 15 days of placement of P.O. Vendor shall provide 02

(two) nos serial ports configured for this purpose. One port shall be connected with the owner’s PLC and the

other port shall be standby for use in case of failure of the first port.

The vendor shall submit their compliance for providing the above signals in the Format attached as Annexure

VI (d)

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Triune Energy Services Pvt. Ltd.

New Delhi

TECHNICAL SPECIFICATION FOR

INSTRUMENTATION

Std. / Doc. Number Rev.

9579-02-TS-103 0

Sheet 6 of 12

ANNEXURE -VI (a)

DATA SHEET FOR VIBRATION TRANSMITTER

PROJECT: Augmentation of Mumbai Sholapur Pipeline

CUSTOMER: HPCL

VENDOR: ………..

APPLICATION: Vibration Transmitters

T I O N

Mounting

Vendor to state Measuring Range (Linear)

Vendor to state

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Triune Energy Services Pvt. Ltd.

New Delhi

TECHNICAL SPECIFICATION FOR

INSTRUMENTATION

Std. / Doc. Number Rev.

9579-02-TS-103 0

Sheet 7 of 12

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Triune Energy Services Pvt. Ltd.

New Delhi

TECHNICAL SPECIFICATION FOR

INSTRUMENTATION

Std. / Doc. Number Rev.

9579-02-TS-103 0

Sheet 8 of 12

ANNEXURE -VI (b)

DATA SHEET FOR LEVEL SWITCH

PROJECT: Augmentation of Mumbai Sholapur Pipeline

CUSTOMER: HPCL

VENDOR: ………..

APPLICATION: Level Control

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Triune Energy Services Pvt. Ltd.

New Delhi

TECHNICAL SPECIFICATION FOR

INSTRUMENTATION

Std. / Doc. Number Rev.

9579-02-TS-103 0

Sheet 9 of 12

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Triune Energy Services Pvt. Ltd.

New Delhi

TECHNICAL SPECIFICATION FOR

INSTRUMENTATION

Std. / Doc. Number Rev.

9579-02-TS-103 0

Sheet 10 of 12

ANNEXURE -VI (c)

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Triune Energy Services Pvt. Ltd.

New Delhi

TECHNICAL SPECIFICATION FOR

INSTRUMENTATION

Std. / Doc. Number Rev.

9579-02-TS-103 0

Sheet 11 of 12

ANNEXURE -VI (d)

Compliance Sheet for VFD interface to Owner’s Control system

Sl. No I/O Description Contact Action

Provided Yes / No Remarks

DIGITAL INPUTS TO CONTROL SYSTEM

1 Input HT Breaker On NC when ON

2 Input Transformer Fault NO when fault

3 Output transformer fault NO when fault

4 Loss of Speed Reference Signal NO when fault

5 VFD Fault NO when fault

6 VFD ready to start NC when ready

7 Panel Fan On NC when ON

8 VFD / Motor running NC when running

9 VFD in remote NC when in remote

10 VFD Temperature Hi NO when Temp Hi

11 Input / Output Transformer Temp Hi NO when Temp Hi

DIGITAL OUTPUTS FROM OWNER’S CONTROL SYSTEM TO VFD

12 VFD Start Momentary NC to Start

13 VFD Stop Momentary NO to Stop

14 Start Permissive Permanent NC

15 Process Trip Momentary NO to Trip

ANALOG INPUTS TO OWNER’S CONTROL SYSTEM FROM VFD

16 Speed Feedback 4 – 20 mA signal

17 Current Feedback 4 – 20 mA signal

ANALOG OUTPUTS FROM OWNER’S CONTROL SYSTEM TO VFD

18 Speed control 4 – 20 mA control signal

SERIAL COMMUNICATION BETWEEN OWNER’S CONTROL SYSTEM & VFD

19 MODBUS Communication on RS 485 (02 nos. ports)

MODBUS mapping details also to be provided.

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Triune Energy Services Pvt. Ltd.

New Delhi

TECHNICAL SPECIFICATION FOR

INSTRUMENTATION

Std. / Doc. Number Rev.

9579-02-TS-103 0

Sheet 12 of 12

Annexure – VI (e)

SUMMARY OF REQUIREMENT OF INSTRUMENTATION ITEMS FOR EACH MOTOR-PUMP SET

Sl.

No

Description Qty Ma

ke

Mo

del

Range

/Set

Points

1 EXP & WP 3 wire duplex platinum RTDs for pump bearing (DE & NDE)

temperature detection with thermo-well and cable glands etc.

2 Nos. * * *

2 EXP & WP 3 wire duplex platinum RTDs for pump casing temperature

detection with thermo-well and cable glands etc.

1 No. * * *

3 EXP & WP 3 wire duplex platinum RTDs for motor bearing (DE & NDE)

temperature detection with thermo-well and cable glands etc.

2 Nos. * * *

4 EXP & WP 3 wire duplex platinum RTDs for motor winding temperature

detection with cable glands etc.

6 Nos. * * *

5 EXP & WP pump seal leakage detectors with seal leakage tank, all piping

jobs and cable glands etc.

2 Nos. * * *

6 EXP and WP vibration transmitters complete with probe for installation on

pump with cable glands etc.

Vendor to

state as per

clause 2.1.5

* * *

7 Explosion proof, weatherproof junction box complete with plugs, cable

glands, terminals etc.

3 Nos. * * -

8 Copper control cables for terminating individual sensors mounted on pump

and motor in junction boxes installed at base plate of motor pump set.

As required to be supplied by vendor

Note:¬

1 Data marked as (*) above shall have to be furnished by the vendor along with the offer.

2 Vendor shall specify set points for safe operation of mainline motor operated pumps, item-wise for all the above

tripping devices. Submission of the above information is essential

3. Vendor shall submit the details of additional protective devices other than above if any along with offer.