engineering specification for control & instrumentation...

TOYO ENGINEERING INDIA LIMITED MUMBAI INDIA

ENGINEERING SPECIFICATION FOR CONTROL & INSTRUMENTATION IN PACKAGE UNITS

FOR

HINDUSTAN PETROLEUM CORPORATION LTD.

VISAKH REFINERY

HDHT PROJECT

JOB NO. : 6261

DOCUMENT NO. : 6261-KA-102

3 13.07.2009 Revised as per clients requirements

TMT BPA VMS

2 02.05.2009 Revised as per clients requirements

TMT BPA VMS

1 06/02/2009 Revised For Enquiry TSS BPA VMS

0 29/09/2008 For Enquiry TSS BPA VMS

Rev. no.

Issue Date Description Prepared by Checked by Approved by

ENGINEERING SPECIFICATION FOR

CONTROL & INSTRUMENTATION IN

PACKAGE UNITS

TOYO ENGINEERING INDIA LTD.TOYO ENGINEERING INDIA LTD.TOYO ENGINEERING INDIA LTD.TOYO ENGINEERING INDIA LTD.

ISSUED : 13 July 2009 JOB NO. : 6261 Sheet Sheet Sheet Sheet 2 of 34

DOC.No. 6261-KA-102 HDHT PROJECT Rev. 0Rev. 0Rev. 0Rev. 03333

C O N T E N T S

1. GENERAL 4

1.1 Scope 1.2 Definitions

2. INSTRUMENTATION 4

3. APPLICABLE CODES & STANDARDS 5

4. DESIGN PHILOSOPHY 8

5. INSTRUMENTS 12

5.1 Transmitters 12

5.2 Level measurement 12

5.3 Valve manifold 13

5.4 Pressure Gauge 13

5.5 Temperature Transmitter 13

5.6 Temperature Element 14

5.7 Thermowell 14

5.8 Temperature Gauge 14

5.9 Control / On-Off Valve 14

5.10 Mandatory Spares 16

6. CONTROL SYSTEM 16

6.1. General 16

6.2. Special Purpose Machines 17

6.3. General Purpose Machines 17

6.4. General Purpose Packages 18

6.5. Intrinsically safe system requirements 18

6.6 Software Design 18

6.7 Hardware Design 19

6.8 Hardware Installation 20

6.9 Alarm philosophy 20

6.10 Cabinet Design 20

6.11 Power Supplies 23

6.12 Susceptibility to Interference 23

6.13 Spare Capacity 23

6.14 Fault Protection 23

6.15 Earthing 24

6.16 Electrical / Instrument Interface 24

6.17 Vibration Monitoring System 24



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7. ANALYZER 25

8. CONSTRUCTION 26

8.1 Instrument Air Supply 26

8.2 Process Impulse / PneumaticTubing 26

8.3 Instrument Wiring 26

8.4 Marking 28

8.5 Cable Details 29

9. TEST & INSPECTION 33

9.1. Workshop & Field Test 33

9.2. System Functional Test 33

9.3. Test Equipment & Simulation Facilities 33

9.4 Field Instruments 34

10. DOCUMENTATION 34

11. STANDARISATION 34

Attachment-1: Mandatory spare part list - Instrument



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1. GENERAL

This document details the basic design criteria for the control and instrumentation for Package Units, associated with the DHT, Hydrogen Generation Unit, Sulphur Block, Offsites & Utilities, of HINDUSTAN PETROLEUM CORPORATION LIMITED, Visakhapatnam , Andhra Pradesh, India.

1.1 Scope

1) This specification together with the attachments covers the minimum requirements for the engineering, design and supply of instrumentation equipment and commodities forming part of package units. Requirements set forth in other specifications referenced in this document shall be considered part of this specification.

2) This specification provides only the qualitative specifications of commonly used instruments. Instruments not covered in this specification shall be submitted by the Package vendor for approval.

3) For specific requirements of control & Instrumentation for particular package unit vendor to refer to Specific Job Requirement for Instrumentation attached with

Enquiry. In the event of any conflict between this specification & Specific job

requirement document , the Specific Job Requirement shall be followed. 4) In the event of any conflict between these specifications, data sheets, related

standards, codes etc. the PMC/EC shall be consulted for clarification before proceeding with procurement/engineering. The Package vendor shall not deviate from this specification without the prior written approval from the PMC/client.

1.2 Definitions

Owner / Client Hindustan Petroleum Corporation Ltd (HPCL)

PMC Project Management consultant (TEIL)

EC-Contractor Lump Sum Turnkey Contractor whose services are obtained by Owner for Detailed Engineering, Supply, Construction.

Package Vendor

Manufacturer who is responsible for the supply/design & installation of materials, equipment and / or services related to package unit.

2. INSTRUMENTATION

General

1) Signal : The instrument transmitter signals shall be:

a) Electronic Transmitter: 4-20mA (loop powered) at 24VDC digital signal based on HART or

Foundation Fieldbus protocol.(Refer

clause no. 4 point no. 7)

b) Pneumatic : 0.2 1 kg/cm2g (only for local control loops)

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2) Power Supply : 110VAC (10%) 50Hz (3%) (UPS) for control & instrumentation

(refer to section 6.11)

Equipment Electrical Level

Control Panels supplied with Package Units 110VAC 50Hz (UPS)

Two wire transmitters (4-20mA) 24VDC

Discrete inputs and outputs 24VDC

Solenoid Valves( from UPS) 24VDC

Equipment/instruments located on field with electrical power required in the field

110VAC 50Hz (UPS)

Level gauge Illumination & Lighting in Local Control Panel 230VAC 50 Hz (Non-UPS)

3) Explosion Proof : EEx-ia IIC T4 for Instrumentation & junction box.

Ex-p (Type X) for Local panel.

If intrinsic safe certification is not available, then Flameproof (EExd IIC T4) shall be used. And same shall be brought to the notice to the Engineering Contractor.

4) Weather Protection: IP 65 minimum for all outdoor instruments, junction boxes & Local Panels

5) Electrical Connection: 1/2 NPT(F) for Transmitters

6) Pneumatic Tubing : Typically 1/4" NPT (minimum) for control valves/316 Size/Material stainless steel

Note: Actuators with diaphragms larger than 150 square inches shall have at least

a 1/2" actuator air connection.

7) Impulse Tubing : O/D x 0.065 wall thickness /316 SS.

Size/Material

8) Steam tracing : Typically bare copper shall be used.

9) Environment Protection

The following conditions shall be considered on the design in order to ensure the capability of functions for instrument: a) All equipment shall be tropicalized to eliminate mildew, fungi, and other

detrimental effects of a tropical environment. b) And shall be suitable for operation in a corrosive, salt laden, marine

atmosphere. c) Low ambient temperature: 15C High ambient temperature: 45C

10) Digital signals shall be generally energised in healthy conditions.

3. APPLICABLE CODES & STANDARDS

Design and terminology shall comply, as a minimum, with the latest edition prior to the

date of purchaser's enquiry with following codes, standard practices and publications:-

AGA American Gas Association Report No.3 - Orifice Metering of Natural Gas & other related hydrocarbon

fluids Report No.7 - Measurement of Gas by Turbine Meters.

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ANSI/ASME American National Standards Institute/American Society of

Mechanical Engineers. B 1.20.1 Pipe Threads General Purpose (Inch) B 16.5 Pipe Flanges and Flanged Fittings B 16.20 Metallic Gaskets for pipe Flanges, Ring Joint, Spiral wound

and Jacketed. ANSI/FCI American National Standards Institute/Fluid Control Institute

70.2 Control valve seat leakage classification

API American Petroleum Institute API 520 Sizing, selection and installation of pressure relieving

devices in refineries. Part-I - Sizing and selection Part-II - Installation

API 521 Guide for pressure relieving and de-pressurizing systems. API 526 Flanged steel Pressure Relief Valves. API 527 Seat tightness of Pressure Relief Valves. API MPMS Manual of Petroleum measurement standards. API RP 551 Process Measurement Instrumentation

Part I - Process Control and Instrumentation API 522 Transmission Systems. S 1101 Measurement of Petroleum Liquid Hydrocarbon by Positive

Displacement meter. S 2000 Venting Atmospheric and low-pressure storage tank

nonrefrigerated and refrigerated. S 2534 Measurement of liquid hydrocarbons by turbine meter

systems S 670 Vibration, Axial-Position and Bearing-Temperature

Monitoring Systems

ASME American Society of Mechanical Engineers ASME Sec-VIII Boiler and Pressure Vessels Code rules for construction of pressure vessels ASME Sec-I Boiler and Pressure Vessels Code. Section-I Power Boilers ASTM American Society for Testing and Materials.

BIS Bureau of Indian Standards BS British Standards

BS-5308 Part-II :Specification for PVC insulated cables. BS-7244 Flame Arrestors.

DIN German Standards DIN-43760 Temperature Vs Resistance curves for RTDs. DIN-19234 Electrical Distance Sensors; DC interface for Distance Sensor



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and Signal Converter. DIN-50049 Document on Material Testing

IBR Indian Boiler Regulations IEC International Electro technical Commission

IEC 60079 Electrical Apparatus for Explosive Gas atmosphere IEC 60085 Thermal Evaluation and Classification of Electrical Insulation. IEC 60332 Test on bunched wires or cables. Part III Cat. A IEC 60529 Degree of protection provided by enclosures.(IP code) IEC 60534-2 Industrial Process Control Valves-Flow capacity. IEC 60584-2 Thermocouple Tolerances IEC 60751 Industrial Platinum Resistance Thermometer Sensors

IEC 60793-1-44 Measurement methods and test procedures

Cut-off wavelength IEC 60801 Electromagnetic compatibility for Industrial Process

measurement and control equipment. IEC 61508 Functional safety of electrical/electronic/programmable

electronic safety-related IEC 61511 Functional safety : Safety Instrumented system for the

process industry sector

IS Indian Standard IS-5 Colours for ready mixed paints and enamels IS-319 Specification for free cutting Brass bars, rods and sections IS-1239 Mild steel tubes, tubular and other wrought steel fittings. IS-1271 Specification of Thermal Evaluation and Classification of

Electrical Insulation IS-1554 PVC insulated (heavy duty) electric cables working

Part I -voltage up to and including 1100V IS-2074 Ready mixed paints, air drying, red oxide - zinc chrome IS-2148 Flame proof enclosures for electrical apparatus for Explosive Gas

Atmospheres Flameproof Enclosures d. IS-3624 Specification for pressure and vacuum gauges IS-5831 PVC insulation and sheath of electric cables. IS-7358 Specifications for Thermocouples IS-8784 Thermocouple compensating cables.

ISA Instrumentation, Systems and Automation Society S-5.2 Binary logic diagrams for process operations. S-7.3 Quality standard for instrument air S-75.01 Flow equations for sizing control valves

ISO 5167 Measurement of fluid flow by means of Pressure differential devices inserted in circular cross-section conduits running full

NACE National Association of Corrosion Engineers

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NEC National Electric code NEMA National Electrical Manufacturer's Association ICS-6 Enclosures for Industrial control and systems. NFPA National Fire Protection AssociationNFPA-496 Purged and pressurized enclosures for electrical equipment. OSHA Occupational Safety and Health Authority. SAMA Scientific Apparatus Makers Association

4. DESIGN PHILOSOPHY

1) Instrumentation shall be complete in all respects and liberal to the extent of providing data on all operations and variables sufficient for the safe, efficient and easy operation, start up and shut down of the plant.

2) All electronic / electrical Instruments and equipments shall be suitable for area classification as per IEC codes and shall be certified by any recognized authority like FM, CSA, PTB, etc as per ATEX guidelines etc. All electronic / electrical Instruments and equipments shall be finally approved by statutory authorities in India (Chief Controller Of Explosives - NAGPUR).

3) The Design and installation of Instruments shall be generally in accordance with ISA / API recommended practices and other applicable standards like BIS, IBR etc. Instrument shall support availability and reliability of the plant. Vendor shall ensure safe and permanent access to each instrument. Necessary platforms, ladders etc. as required are in the scope of supply of the Vendor if applicable. Material specifications and practices shall, in general, conform to appropriate ASTM or equivalent standards. All standards and code of practices referred to herein shall be of the latest edition.

4) All instruments and equipments shall be suitable for use in a hot, humid and

tropical industrial climate in which corrosive gases and / or chemicals may be present. As a minimum, all instruments and enclosures in field shall be dust proof and weather proof to IP-65 as per IEC-529/IS-2147 and secure against the ingress of fumes, dampness, insects and vermin. All external surfaces shall be suitably treated to provide protection against corrosive plant atmosphere. Generally all instrument wetted parts in contact with the process fluid shall be 316 stainless steel (minimum), or of a material equal to or better than that of the related vessel or line.

For Instruments in hydrogen service ,special attention shall be given to possible

hydrogen permeation e.g bellows or diaphragms high nickel alloys to be avoided. Special attention shall also be given in wet H2S service to avoid hydrogen induced



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cracking. Certification to NACE MR0103 shall be specified for sour service. 5) Field mount Electronic instruments with integral LCD indicator and/or remote

indicators shall be 2 pipe mounting. FRP canopy shall be provided & installed for the same. For process measurements as well as trip initiators(2oo3) transmitters

shall be applied , Field switches shall not be used. 6) The design of electronic instruments shall be in compliance with the

electromagnetic compatibility requirements as per IEC 801 Electromagnetic compatibility for Industrial Process measurement & Control equipment.

7) Electronic transmitters which are in vendors battery limit & used only for monitoring purpose & not connected to vendors PLCs, shall be FOUNDATION Field Bus(latest version) compatible .Vendor to note that such transmitters shall be wired to a separate junction box with branch cable supplied by others. If these are Temperature monitoring inputs(not wired to MMS) then Package vendor to provide multiplexer along with Temperature element.

8) All line or equipment mounted instruments like control valves , pressure relief valves, thermowells orifice plates , level instruments etc. installed on pipes & vessels under IBR shall be certified by IBR or their authorized representative.

9) Tag naming & numbering philosophy shall be informed during detail engineering by Detail engineering Contractor & the Same to be adhered to/followed by package vendor for all instruments & panels.

(For e.g. : 90-TI-1101.90 denotes the unit number for DHT. For the number 1101, 11 denotes the last 2 digit of the P&ID where this TI appears, and 01 denotes the serial number of the TI in that P&ID. Each instrument type (such as pressure, temperature, level etc) appearing on the P&ID shall have own sequence of serial numbers.)

10) Units of measurements:

Flow Liquid m3/h (Chemicals : l/hr)

Gas Nm3/h

Steam kg/h

Level %, mm

Pressure kg/cm2g

Absolute pressure(vacuum ) mmHg, mmWC, kg/cm2-a

Temperature C

Density kg/m3

Length m / Alternate will be mm.

11) Marking

Each instrument shall have a stainless steel nameplate, permanently attached from the vendors factory

containing the following data.

- Manufacturers name



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- Instrument type and size - Model and serial numbers - Operating condition, e.g. voltage, pressure. - Instrument range & - The specified instrument identification numbers or Tag number

11) Connection Details

INSTRUMENT SERVICE

& /OR RATING

PROCESS

TAPPING SIZE

& TYPE

INSTRUMENT

CONNECTION

FLOW :

D/P Type Pipe Lines Welded NPT (F)

Diaphragm Pipe Lines 3 Flanged 3 Flanged

LEVEL

Guided wave Radar Top mounted

Vessel (300# min.)

4 Flanged

4 Flanged

Guided wave Radar Side mounted

Vessel/Stand Pipe (300# min.)

2 / 2 Flanged

2 Flanged

D/P TYPE Vessel/Stand Pipe

(300# min.)

3/4/ 3/4 Flanged

NPT (F)

Diaphragm Type D/P VESSELS (300# min.)

3 Flush Flanged

3 Flanged

MAGNETIC LEVEL

GAUGE

Vessels/ Stand Pipe (300# min.)

2 / 2Flanged

2 Flanged

GAUGE GLASS Vessel/Stand Pipe

(300# min.) 3/4 / 3/4 Flanged

3 / 4 Flanged

PRESSURE

CONVENTIONAL TYPE

Pipe Lines 3/4 Welded NPT (F)

Vessels 3/4 Welded NPT (F)

Diaphragm Type Vessels / Pipe Lines 3 Flanged 3 Flanged

Diaphragm Type Gauge

Vessels / Pipe Lines 1 Flanged 1 Flanged

TEMPERATURE

Thermowell Pipe Lines / Vessels

(300# min.on vessels)

1 Flanged

NPT



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12) Accuracy of Instruments

Note: 1. Vendor's standard accuracy is applied to local indicator type

Remarks: 1. Accuracy of instrument and special articles except for the above mentioned instrument shall be in accordance with the applicable codes/standards, or Vendor's standards as approved by Purchaser.

Type of Instrument Accuracy

-Differential pressure & Pressure transmitter SMART

0.075% of span within TD ratio of 1: 10 (Remark 3)

- Variable area type flow meter with transmitter

2.0% FS Note (1)

- Vortex flow meter 1.0% FS

- Coriolis Mass flow meter 0.2 % of Measured value for liquids or

0.5 % of Measured value for liquids depending on applicability

- Positive displacement flow meter

- Raw material and Product 0.2% FS

- Others 0.5% FS

- Turbine meter or Mass flow meter

- Raw material and Product 0.2% FS

- Others 0.5% FS

- Magnetic type flow meter 0.5% FS

- Ultrasonic type flow meter 1.5% FS ( 0.5 %)

- Tank gauge 1.0% FS

- Servo type tank gauge 2 mm (up to 20 m height)

- Radar type tank gauge 1 mm or better for custody transfer

5 mm or better for normal application

- Draft range Pressure transmitter - SMART 0.15% of span within TD ratio of 1: 30

- Diaphragm seal transmitter - SMART 0.2% of span within TD ratio of 1: 100

- Pressure gauge 1.6% FS

- Temperature Transmitter 0.2% of calibrated span for RTD

0.5% of calibrated span for Thermocouples

- Bimetallic 1.0% FS

- Small size pressure gauge 3.0% FS

- Draft gauge 3.0% FS

- Receiver gauge 1.5% FS

- Thermocouple & Resistance Bulb Applicable Codes/Standards

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2. FS: Full scale. 3. Overall rangeability of transmitter except for draft range shall be 1: 100.

Draft range transmitter rangeability shall be 1: 30 for the accuracy indicated above.

4. In few cases (draft range), body pressure / static pressure rating of

100 bar as specified below (for DP transmitters) is not available, then

static pressure limit shall be minimum 1.5 times of the Design

pressure

5 . INSTRUMENTS

5.1 Transmitters

The SMART type transmitters supported by HART or Foundation Fieldbus protocol, based on 4-20mA 24VDC, shall be used for all electronic transmitters. The SMART transmitters shall be capable of communicating with Hand-Held Communicators. Separate transmitters shall be used for shutdown & control loops. Considering the site under lightning prone area, all field transmitters shall be

provided with surge Protection devices. For Pressure & Differential pressure

type transmitters the Process connections shall be 1/2 (NPTF) and from the

side/horizontal to the transmitter Range calibration units for flow measurement shall be mmH2O.

The accuracy for special transmitters shall be as below: - Draft Range Transmitters : Accuracy of 0.15% of span within a turndown

ratio of 1:10 30. - Diaphragm seal Transmitters : Accuracy of 0.2% of span within a turndown

ratio of 1:100. - Anti-surge loop : All transmitters used for shall have faster response & high accuracy. - SIL(Safety integrity level) loop : Min. SIL 2 certified transmitter shall be offered. 5.2 Level measurement For level measurements using DP type transmitters, flanged diaphragm seal type

DP transmitters shall be used. For all types of tanks only Guided wave Radar type level gauging system

(including interface level) shall be used. Servo type level instrument (with density measurement) shall be considered as second level instruments on tanks. Displacement type level Instrument shall not be used.

Stand pipes with isolation valves shall be used for LG/LTs. Maximum length for

standpipes shall be 4600mm.Standpipe(if required) shall be used for Level measurements only. Separate nozzle shall be provided for pressure instruments.

Stand pipes shall not be used for shutdown applications.

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5.3 Valve Manifold

As far as possible all transmitters shall have traditional flange design for easy interchangeability without impulse line modifications in future and shall have integral drain and vent. Mounting bracket shall be 2 pipe mounting for all transmitters.The fabricated valve manifold shall be provided for all pressure measurements ,except for close coupled hook-ups where integral manifolds shall be used. In general transmitters for hydrocarbon service shall be installed close coupled if there is any accessibility problem, then can be installed on grid level according to installation standards provided by PMC with minimum length of impulse tubing

2-way : Pressure measurement 3-way : D/P measurement (Level & Diff pressure measurements) 5-way : D/P measurement (Flow measurement)

5.4 Pressure Gauge

Bourdon type pressure gauges shall be used. However for pressure less than or equal to 1kg/cm2-g Diaphragm type or Capsule type shall be provided. Dial size shall generally be 150 mm (6) minimum and cases shall be screw on or bayonet bezel with stainless steel , blow-out protection shall be provided at the backside. The gauge shall be oil filled type. Pulsation damps shall be fitted at the input connection, or liquid filled gauges shall be used on pulsation service applications.

Siphons shall be provided for pressure gauges on steam, or hot condensable gas service (above 75 C). Excess flow check valves shall be provided for gauges operating on pressure > 70 kg/cm2.Gauge saver shall be provided wherever design pressure exceeds 130% of selected range. Diaphragm seal type to be used for corrosive service. Solid front type gauges shall be used for ranges 60 kg/cm2 & above.

5.5 Temperature Transmitter

Temperature transmitters shall be field mounted HART compatible OR

Foundation Fieldbus Type. Head mount transmitter shall not be used. The temperature transmitter should be installed as close to the measuring element as practical. Individual temperature elements shall have head mounted terminal connections.

For all open loops on Fieldbus , a multiplexer shall be supplied by vendor.

All transmitters shall be capable of communicating with Hand-Held Communicators All Transmitters shall have integral LCD indicator in engineering units and be furnished with test terminals and bypass diode to facilitate field testing without disconnection of integral indicator. The transmitters shall have over-range protection to 1.3 times the maximum range of the instrument.

Dual compartment housing shall be provided for all Temperature

transmitters for easy termination. Display shall be rotable. Conventional transmitter shall have universal input for thermocouple / RTD and output 4-20mA DC for 2-wire system. Transmitter output signal shall be linear and directly proportional to the measured temperature. Transmitter shall have automatic cold junction compensation for thermocouples. Burnout protection (selectable Up Scale / Down Scale) must be provided for temperature transmitters.

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5.6 Temperature Elements

1) Thermocouple

Thermocouple shall generally be mineral insulated Duplex type. Type K (Class 1) shall be used for temperature upto 1100

oC. Thermocouple shall be

Ungrounded.

2) Resistance Temperature Detectors (RTD)

RTD shall be Duplex, 3 wire type Pt100 (Class A), used for -200 to 600oC

5.7 Thermowell

The thermowells shall have 1.1/2 flanged connection generally. Screwed connection shall not be used. For thermowell mounted on equipment/vessel, the flange rating shall be 300 # as a minimum or higher as per equipment rating. And the Thermowell connection shall be 1 1/2" NB for uncladed vessel & minimum 3" NB for claded vessel. Flange material shall be SS 316 as a minimum or better as per piping /equipment class. However for thermowell mounted on pipe line the flange rating shall be as per pipe class.

The thermowell rods can be welded to the flange if the application permits it or drilled from solid type 316 stainless steel bar-stock or better material as determined by corrosive conditions. The immersion length for thermowells installed perpendicular or at 45-degree angle to pipe wall shall generally have a minimum 2 inches and a maximum 5 inches from wall of pipe according to API PR 551.

For 6 & smaller line if thermowell is installed in Elbow, then the line size shall be 3 minimum. And for line installation, the line size at thermowell installation shall be expanded to 6.

The nozzle standout for thermowells shall be 150 mm minimum.

The vendor shall consider and issue the resonant wake frequency calculation (as per ASME, PTC 19.3, fw/fn



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Stellite. The trim material for general service containing H2S or for Caustic service

shall be 316 SS. An acceptable alternate is 316 SS with Stellite sheath or solid Stellite.

Vendor to however ensure the suitability of the trim material as per given process conditions & select appropriate material for trim.

f) The SMART type positioner supported by HART protocol shall be used for the modulating control valves. The SMART positioner shall be capable of communicating with Hand-Held Communicators. (Exception: Anti-Surge control valves in Compressor Unit will be depending on vendors standard.).Output gauge shall be provided.

g) Solenoid valves shall be 24VDC, certified EEx-ia IIC T4, class H, three-way universal type as a minimum. The solenoid valve shall be powered from the associated control system, and shall be supplied complete with suppression diodes.

Solenoid valves shall be sized CV, so as not to impede control valve stroking times. The solenoid shall be with 1/2 NPT cable entry and internal connection terminals. Flying leads are not acceptable.

Wherever solenoid valves are used for control valves in modulating services, the solenoid valve shall be installed between positioner output & actuator & de-energising of SOV shall bring control valve to failure poison by venting the actuator. A field manual reset (FMR) shall be provided for critical trip application. Integral Reset with SOV shall not be provided.

h) Limit switches : On-Off valves / Shutdown valves shall be equipped with both open & close limit switches. And control valve shall be provided with limit switch for indicating the fail-safe position only. Intrinsically safe valve Limit switches shall be actuated directly from the stem / shaft. They shall be adjustable and unaffected by vibration. They shall be hermetically sealed.

Inductive type limit switches shall be used. i) Control Valves shall be supplied, equipped & tubed with air filter regulator

(with output gauge), electro-pneumatic positioner, boosters (if required)and solenoid valves (if applicable). Air tubing shall be stainless steel (SS 316).

j) The minimum control valve size shall be 1. Where the line size is less than 1 inch or the selected valve size could be used a 1 valve body with a reduced trim shall be used. Standard valve body sizes shall be used. Control valves 1 and larger shall be flanged generally, suitable for insertion between pipeline flanges.

k) The minimum permissible instrument air pressure 4.0 kg/cm2g shall be taken into account for design of all Pneumatic actuators.

l) Control valves shall be specified to provide an acceptable noise level when continuously operating to meet local area requirements but shall generally be less than 85 dBA at 1 metre from control valve body.

m) Packing material : For Fluid Temperatures up to (232C) packing shall be a TFE material either of the molded Teflon V-ring or braided type. For temperature above 232 C, Grafoil, graphite ribbon / filament, or Kevlar packing shall be used.



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n) Control valves to be provided with upstream and downstream 3/4'' drain valves, which are to be blind flanged. Control valves not having block and bypass provision shall have hand wheel.

o) Motor operated Valve : i) Open & Close indication required in field on Actuator & PLC. ii) Open & close command from PLC in addition to local push button in field on

Actuator. iii)Monitor relay (electrical availability of MOV) indication to be sent from MOV

actuator to PLC. iv)Remote / local selector switch feedback shall be provided to the PLC. While

switch is in local, Operation of MOV from PLC shall be inhibited. 5.10 Mandatory Spares : Package vendor to supply the required quantity for respective Instruments being

supplied ,as specified in the Mandatory spare part list Instrument attached (Attachment-1)

6. CONTROL SYSTEM

6.1. General

Machines or Package Units shall be equipped with a PLC based control system (no relay technique).

The PLC with dual processor, dual power supply, dual I/Os (i.e. Redundant CPU, Power supply & I/Ocards) in general shall be provided. If Vendor has to supply a PLC to control his machinery or package unit, the PLC shall be located in a suitable panel. The requirements for the panels can be found under Cabinet Design in this specification. The method of control shall be clearly specified in the machine or package unit requisition as well as be indicated on the interface sketches as part of the requisitions.

If the system is controlled by a Vendor PLC, the PLC shall be equipped with a serial communication facility (Modbus) which will be connected to the plant DCS Wherever data of the serial link will be used for calculations or non critical control loops, the serial link shall be redundant. Commands (start, stop), trip or critical control loop signal shall always be hardwired between DCS/SIS & package Unit. The serial link shall be completely commissioned in a so called integration test before shipment of the PLC/Panel. Machines or units, which are controlled by the DCS The package vendor has to supply suitable software description / specification as well as to provide suitable descriptions / date for the programming and graphic design of the DCS. The Graphic design of vendors control system shall be inline with purchasers Graphic design specification .Safety relevant systems can be integrated in the plant SIS system. For DCS/SIS controlled machines or units, the Vendor shall execute functional test for the control system to ensure that vendor can provide the requested guarantee for the overall function and design of the machine and / package without split of responsibilities or guarantees. All other requested tests (e.g. running test, performance test etc.) shall be carried out by Vendor fully under Vendor responsibility.

In case a machine or unit requires special electronic devise (e.g. special burner management system for package boiler, speed governor for steam turbines, anti-surge controller for compressors, etc.) the electronic units are in the scope of



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the Vendor and shall always be housed in a suitable panel (refer to section 8 Cabinet Design).

In general, any critical trip signal which lead to a plant trip shall be 2 out of 3 (triple field instruments).

The Plant Machines/Packages will be controlled as described below, but control and control requirements will be described / specified with the requisition as well as be reflected in the requisition Interface Block Diagram

6.2. Special Purpose Machines (Recycle gas Compressor / Make-up gas Compressor ) Special Purpose Machines are process critical machines that are not provided with a (spare) standby facility and are to be supplied complete with their own control & safety protection systems. The system cabinets shall be installed in the RR ( Rack Room).The PLC shall be provided with a Engineering PC (Server- grade) along-with the interconnecting cables & laser printer located near the UCP. A separate 19 TFT HMI with SOE recorder shall be provided which shall be located in Control Room for operation /monitoring of the Package by the operator. The PLC shall apply fail-safe logic.

A dedicated & redundant Anti-Surge Control system with switching unit shall be provided in the Unit control panel (control room) for the Centrifugal Compressor(Recycle gas compressor). It shall be preferably of CCC make and of latest model.

The Special Purpose Machines control and safety protection systems shall be designed to maximise the system availability in order to minimise downtime or loss of production that could result from component failure within the Package control equipment. These control and safety protection systems shall be afforded the same level of integrity as that of the Plant PLC. The package PLC shall be with DMR TUV AK5 SIL3 certification for Compressors, and with TMR/QMR AK5 SIL3 certification for Boiler.

The Control Systems for Special Purpose Machines shall be fully redundant with respect to power feeders, internal power supplies (and power conditioning) , processors (inclusive of backplanes/racks/cabling, process controllers, etc.) ,and input/output cards as a minimum. On critical applications, shutdown trip initiators shall be triplicated (2 out of 3 voting), thereby permitting online maintenance of instrumentation without interruption to the machine/package operation reference a typical example as given in API 614, chapter 2, paragraph 3.1.5, Arrangement 3.

6.3. General Purpose Machines (Charge Pump)

General Purpose Machines are categorised as those provided with a spare/standby machine.

Typically the general purpose machines control is integrated in the plant DCS and PLC. A dedicate PLC system is not required.

Note 1 : For steam turbine driven machine, the electronic governor, Overspeed Shutdown system(2oo3) shall be supplied/programmed and located in a purged panel on-skid.

Over speed Shutdown System: Any of the devices shall be replaceable online. And each device shall be powered from a separate source.

Note 2 : The Fire Water Pumps are not categorized in the above strategies. The pumps shall be provided with a dedicated local control panel as per NFPA-20.

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Note 3 : If local operation is required, a LCP shall be preinstalled on the skid with all critical lamps and indicators .

6.4. General Purpose Packages(Utilities IA Compressor /DM Plant/Nitrogen plant/ETP) In general, Packages will be controlled by their own control system and shut-down safety protection instrumentation. These shall allow for stand alone operation i.e. package start up, shut down and continuous control. Packages shall be started (and stopped) from the package interface panel. When the package is running in a steady state the local control set point may be switched to remote and the main plant DCS will then take control. The package control system can be in accordance with the following

Packages shall be provided with fully redundant control and safety protection systems (PLC) with respect to power feeders, internal power supplies (and power conditioning), processors,I/O cards (inclusive of backplanes / racks / cabling, process controllers, communication cards etc) as a minimum. Shutdown signals and common fault/alarm signals to/from the machine control panels and main plant DCS/ SIS shall be hardwired. However for smaller packages, control/interlocks can be carried out in plant DCS/PLC system & same may be excluded from package vendor scope.

6.5 Intrinsically safe system Requirements

Following points must be considered while designing an intrinsically safe system:

a) All intrinsic safety barriers shall be active type isolating barriers only.

b) Barriers must be selected based on entity concept. Cable parameters shall also be considered while matching entity parameters.

c) Each instrument in the Zone 0 & 1 hazardous area and the intrinsic barrier shall be certified for intrinsic safety by any statutory authority.

d) Each input and output in a loop shall have separate barrier. No barrier shall be shared between two loops or inputs / outputs.

e) Any intrinsically safe loop requiring any device to be connected in the hazardous

side (Zone 0 & 1) permanently or temporarily shall also be intrinsically safe.

f) Configuration tools whenever required for any intrinsically safe item which forms

part of the intrinsically safe item shall also be certified intrinsically safe.

g) All barriers shall be of MTL 5500/5000 or equivalent P&F make only.

6.6 Software Design

PLC based systems shall be programmed using either ladder diagram logic or symbolic function block logic diagram as per IEC 1131. DCS systems, based on the main plant DCS platform with similar specifications, shall use the identical standards and templates used for the main plant system.. The PLC / DCS configuration shall be logically structured to allow additions, deletions and other minor modifications without causing a major program revision.

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The PLC / DCS shall have self diagnostics to aid in determining and correcting a malfunction.

6.7 Hardware Design

1) The PLC / DCS shall have the capability of being easily field programmed and reprogrammed through a portable terminal. This device shall also have the capability of monitoring the program online for trouble-shooting purposes. It shall also be capable of storing the logic on magnetic, optical or flash storage media for backup purposes. The necessary software required for package operation shall be provided by package vendor. In this case, no external hardware is required.

2) The hardwire interface signals between the plant DCS / PLC / F&G (Fire and Gas System) and Package control system shall be as follows,

For commands originating from Package control system (panel) & terminating in Plant DCS/SIS, pot-free contacts with contact rating 230VAC 5A shall be provided & the corresponding relays shall be supplied by package vendor in package panel . And for commands & set-points originating from Plant DCS/SIS & terminating in Package panel pot-free contacts with contact rating 230VAC 5A shall be provided, the relays & isolators shall be supplied by DCS vendor. In case when the Vendor can not comply with this requirement and have any exception, Vendor shall formally identify for HPCL/PMCs notice.

3) Each input and output point shall have a status indicating light mounted on the module. This light shall indicate the powered state.

4) Input and output points on a module shall be grouped for specific areas or pieces of equipment to minimize the number of operating functions affected when a module has failed, and must be replaced.

5) No more than one Rack, IO backplane or PLC I/O module shall be powered by one circuit breaker or fuse.

6) Circuits shall not be split between I/O racks or channels. All connected outputs shall be individually fused.

7) All PLC / DCS controlled DC devices which are inductive shall have an energy suppression diode or equivalent installed on the output cards.

8) All memory modules shall have battery backup unless the type of nonvolatile memory used is guaranteed to maintain its contents indefinitely without power.

9) The serial ports shall have diagnostics to check the health of the communication with the DCS and switch automatically to the back up (if Redundant link is applicable) in case of communication failure and also generate a system alarm.

10) All panels / cabinets and other parts of the system shall have nameplates to identify their function and area of service. These nameplates will be used for construction and maintenance reference.

11) If the distance between the vendor PLC & plant DCS is above 500mtrs,then Fiber optic link shall be used for data transfer from PLC to DCS. Necessary hardware i,e Interface unit , patch cords ,media converter etc. inside PLC cabinet shall be supplied by vendor.

12) Junction box color shall be as follows: For all IS & Field Bus Junction Boxes: Blue (Epoxy shade) inside Epoxy Yellow For Non IS & Power Junction Boxes: Gray (Epoxy shade) inside Epoxy Yellow

Alternatively Black color is also acceptable.

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6.8. Hardware Installation

The PLC/DCS processor shall be identified with an instrument application number. All I/O racks shall be identified by rack or channel number. All wires and terminal strips shall be clearly marked with a permanent tag. Each point on the I/O modules (cards) shall be tagged with the field devices instrument tag number where possible or alternatively the channel number shall be on the wiring tag. The I/O wiring shall be tagged with the PLC/DCS address to which it is terminated.

6.9. Alarm Philosophy

a) Adequate alarms shall be provided to give audible and visual warning of any process and machinemalfunction in the package.

b) All trips shall have pre-trip warning alarm in addition to alarm at the trip condition. c) All rotating equipment shall have the status indication provided on the local

control panel. d) All package alarms including pre-trip warning alarms and trip alarms (shutdown

alarms) shall be annunciated on the local control panel. First out alarm sequence shall be provided for all shutdown systems.

e) As a minimum common pre-warning alarm and common trip alarm contacts for the packages shall be provided for remote indication in control room. Additional alarm contacts shall be provided as required.

f) Alarm annunciator system shall include color coded and back lighted windows, logic units, flasher unit, buzzer, acknowledge, Test and Reset push button.

Alarm Annunciator system shall be of the solid state design and intrinsically safe type.

g) The design of the alarm annunciator system shall be such that transient alarm time of less than 330-millisecond duration shall be automatically rejected.

h) Alarm Annunciator design shall in general be in accordance with ISA S 18.1.

i) Fault contacts actuating alarms shall be normally closed, energized and shall open on the abnormal Condition. Each annunciator cabinet shall have 20% spare windows minimum, for future use and these spare Windows shall be wired up to the terminal block.

j)Alarm inscriptions shall be on a transparent white acrylic/Perspex for pre-warning

alarms & shall be on a transparent red acrylic/Perspex for trip alarms (shutdown

alarms). The lettering shall be in black on white / Red background.

6.10 Cabinet Design

1) Cabinets in the RR (UCP: Unit Control Panel)

All equipment shall be housed within free-standing steel cabinets. The cabinets shall be a standard Rittal cabinet, Cabinet Colour RAL7035) complete with a 100mm plinth, removable gland plate and front & rear lift-off opening doors. Control panels, in general, shall be of free standing, totally enclosed construction, fabricated from 3.2 mm thick CRCA steel plate. Removable side panels shall be provided as appropriate. Cable entry shall be at the bottom of the cabinet. Vendor is to allow sufficient space below removable gland plate to accommodate the bending radius of the cables and to facilitate the installation of the cable glands. Cable glands will be provided by others. Punch of holes by

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others on site. Doors shall be secured by a three point locking system actuated by cam-operated keylocks. A single key shall fit all door locks. Cabinet ventilation shall be arranged so as to avoid Hot-Spots. Forced ventilation, shall consist of twin parallel units each rated for 100% duty. All air entry and exits shall have removable, cleanable filter elements. Fan failure alarm shall be provided. Vendor to generate a common trouble alarm & provide it on the Annunciator, through a relay. The common trouble alarm shall comprise of Bulk power supply failure, Cabinet temperature high, System Failure & Common trouble alarm from MMS.

The number of cabinets to be optimised by machine vendor based on the requirements of PLC, MMS, ASC etc.

2) Local Control / Operation Panel in Outdoor (LCP: Local Control Panel / LOP: Local Operation Panel)

LCP / LOP shall be skid-mounted on the Machine or installed near the Package, if applicable. All on-skid instrumentation shall be wired into the LCP / LOP(if applicable). All necessary cables, cable trays, cable glands (304 SS), required for the on-skid wiring shall be provided by Vendor.

The Panel shall be standard Rittal cabinet with appropriate paint for the environmental conditions stated. Cable entries shall be at the bottom of the cabinet. Cable glands for field run cable will be provided by others.

The countermeasure against the environmental condition such as the sun shade and the anti-condensate heater shall be provided, if required.

The critical push button (Start, ESD switch(pull to enable type),Remote /Local with locking arrangement etc.) & lamps (ready to start etc.) shall be provided for start up which shall be clearly identified in vendor P&ID during detail engineering. Each switch, lamp & control device shall have a nameplate on the panel exterior.

An Annunciator shall be provided on Local Control Panel. The Annunciator window associated with any trip input shall flash on initiation, go steady when the alarm is acknowledged, change to a different steady color when initiating device has reverted to process normal condition (i.e. available for logic reset), and extinguish when logic reset has been activated.

Additionally Common trouble alarm & Package Control panel (system) failure alarm shall be provided on Annunciator.

When the control panel is installed in hazardous area, it shall be of an air purge type. And then these switches & lamps shall be of Flame proof type.

For machines having vibration measurement a local display unit for vibration & temperature monitoring (certified) shall be provided/located in a purged enclosure at LCP.

Local panel shall be equipped with a electronic speed indicator. It shall receive a 4-20 mA signal from VVVF drive. Speed indication signal shall also be provided in DCS/PLC.

3) Layout

The internal layout shall be designed to provide unimpeded access to all electronic modules, power distribution, switches, protective devices, terminals and termination areas.

The internal framework shall be designed to provide rigid and secure mountings for module card frames, power distribution and field termination areas.

4) Terminations and Wiring

a) Cable core markers shall be Raychem (or equal) heat-shrinkable cable marking system. Both ends of all cables and their used cores shall clearly identify both source and destination, using individual ferrule cable marker rings.



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Core indents will be adjacent to the terminal.

b) Connection to field cabling shall be via PHOENIX screw-less, clamp type terminals and shall be arranged grouped into banks field cable wise. (Note that field analogue instrument will be SMART Fieldbus or HART type protocol devices, and the field terminals for these devices are to incorporate facilities to allow a SMART hand-held communicator to be connected at the field terminals within the cubicle without disturbing the wiring.)

c) For interface signals with the main plant control systems, the terminal blocks (TBs) shall also be grouped based on the system it is connected (e.g. separate TBs for DCS, SIS, etc) and segregated based on the signal type (e.g separate TBs for Analogue, Digital & Serial Interface Communication signals).

d) Terminals shall accommodate only one conductor each side. Any looping requirements shall be achieved by using purpose designed links. Field termination side of terminal blocks shall be reserved for field cabling only.

e) Protective covers shall be provided for all power distribution terminals (greater than 48V AC or DC) to reduce the likelihood of accidental short circuits and contact by maintenance personnel. Appropriate and clearly defined warning labels shall be provided.

f) The cable armouring will be cut back and glanded-off on the removable gland plate in the base of the cabinet.

g) Each incoming multi-core cable screen entering the cabinet shall be individually connected to the relevant instrument earth bar.

h) Spare terminals shall be clearly marked with multi-core cable number and type of signal (i.e. digital or analogue).

i) Cable trays, trunking and tie bars shall be supplied to separately support the field and panel wiring. Dedicated trays and trunking shall be allocated to Field cabling and segregated by their respective services. Blue trunking shall be

used for IS cables on the hazardous side of the barriers. Up to 200 mm

width,FRP trays shall be perforated type and above 200 mm width, FRP trays shall be Ladder type .The thickness for all cable trays shall be 5mm

(min). Supports for cable tray shall be provided at every 1500 mm

distance. Only SS 316 nuts & bolts shall be used for FRP trays joining

plates. j) All stranded Cable connections shall be provided with insulated pin or blade

type cable crimp connectors suitable for screwless clamp type connection .

k) Segregation of Power cables from Instrument cables shall be provided.

l) All cables & conductors shall be sized to carry the continuous rated current of the protective device. Minimum 600V / 1100V, PVC insulation grade shall be used.

m) Instruments. equipment and junction boxes which are part of the skid or package shall be preinstalled by vendor. The cables for instruments shall also be appropriately glanded (and terminated) at both ends.

n) If the control room is in package vendors scope ,then all the required MCT frame & MCT Blocks at Rack room end & Control room end shall be supplied by package vendor. MCT sizing shall be done to provide 30% (minimum) to 50% (maximum) spare capacity for future cable additions. While designing / assigning MCT spare holes, all spares assignments should be at the top of the MCT blocks only. MCT frame for instrument cables & Electrical cables shall be separate. No spare space shall be left uncovered in the frame.

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6.11 Power supplies

Only a single or redundant (if applicable) 110V AC 50 Hz power supply (UPS) shall be provided to the vendors control system panel at one point (located in Control room, Satellite rack room, any switch house/building or Field) by the EC (Contractor) Further distribution of this power or any derived power (e.g. 24V DC etc) required for any of the vendors equipment/instrument located in the control room or field is in the Vendors scope, unless indicated in the Interface sketch otherwise.

In case a package vendor is supplying a separate Local control panel or MMS panel alongwith with Unit Control panel .All power required for local control panel / MMS panel shall be sourced from package vendors Unit control panel.

All equipment must be able to function correctly, and shall not instigate unsafe faults due to any normal switched-mode upset by the UPS system. The Bulk power supplies inside vendors panel shall have a individual power supply failure contact, which shall be wired to indicate the individual supply failure.

The cabinet shall be provided with isolators for each UPS feeder, suitably sized to allow direct termination of the feeder cable(s).

Vendor shall provide all necessary internal power supply units for System components and these shall be sized for the total possible complement of I/O that could be accommodated with the Cabinet.

Vendor shall be responsible for all power supply distribution within the cabinet and to external system components.

All power supply bus-bars shall be adequately segregated and be provided with removable insulated covers.

6.12. Susceptibility to Interference

The system as supplied shall be unaffected by the operation and dimming of fluorescent lighting, and by the use of hand-held radio transceivers up to 5 watt output power using the frequency range 27 MHz to 470 MHz. System RF immunity shall be based on the case where the equipment cabinet doors are open.

6.13 Spare capacity

Generally, automated control systems shall be kept the following spare capacity at final:

Spare cabinet /rack space for a potential increase in I/O hardware by 1015% (free space only)

2015% installed spare circuits, sub-circuits and terminals distributed throughout the system and IO channels distributed amongst the various types of inputs and outputs.

Additionally Mandatory spares shall be supplied as per Mandatory Spare part List-Instrument(Attachment-1).

6.14 Fault Protection

Each circuit, sub-circuit and peripheral equipment shall be individually protected. Common fault alarms shall be provided. Miniature circuit breakers (two pole)shall preferably be used throughout the power distribution system.

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6.15 Earthing

The complete earthing requirements for control system, field instruments, JBs, Panels etc. shall be provided by vendor in line with the governing local electrical code.

Vendor to provide 2 separate bus bars (one for signal & another for body earth) in control room. The earth pits (one for signal earth & another for dirty / body earth) outside the control room shall be provided by others. Connection from common Bus bars to earthing pit shall be by vendor. Proper earthing cable & size shall be vendors responsibility.

6.16 Electrical / Instrument Interface

The local start/stop shall be wired to MCC. Feedbacks shall be wired to Local from MCC. If required at any other location i.e vendor PLC, then feedbacks shall be duplicated with requisite hardware by vendor.

In case that the Machines and Packages are supplied with a dedicated PLC, the commands to MCC E/I interface may also be sent to MCC from the PLC directly. Appropriate relays to be considered in package PLC.

Commands to MCC- Drives (up to 55 KW): All commands to MCC shall be

hardwired. The pot free contact shall be provided from vendor PLC. The relay

contact shall be suitable for 240 V AC.

Commands to MCC- For Drives (above 55 KW): All commands to MCC shall be hardwired. The pot free contact shall be provided from vendor PLC. The relay contact shall be suitable for 110V DC.

Feedbacks from MCC to package PLC shall be provided through potential free

contacts..

In cases where the Machines and Packages do not have a dedicated PLC, the commands to the MCC shall be initiated from the Plant DCS/PLC. All signals related to the E/I interface (interlocks & commands only) shall be hardwired.

In case if the MCC is supplied by package vendor , then all MCC related

cables (status & commands) shall be wired to interface panel. The Interface

panel shall be supplied by package vendor.

6.17 Vibration Monitoring System

Machinery vibration monitoring will be applied to the machinery specified in the requisition. Package vendor to supply the Bentley Nevada (B/N) 3500 vibration monitoring system along-with the field probes and proximitors. All wiring & components shall be pre-wired & brought upto the certified junction box mounted on the edge of the package skid. Package vendor shall be responsible for the MMS Engineering. And shall supply the MMS in accordance with the specification supplied by PMC.

BN System1 software & MMS PC shall be provided by others .However package vendor shall provide System 1 configuration data (i.e. compressor / coupling /bearing / general data & required & desired associations etc.) to System 1 vendor. Format for the same shall be supplied by PMC after award of contract. Also package vendors shall co-ordinate with the System-1 vendor for all the activities.(i.e.

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system configuration , programming, system generation, machine diagnostics, historical data trending) required for complete integration of supplied MMS Rack(s) with System 1.

Package vendor shall confirm the cable specification to be followed for interfacing the Machine monitoring probes with the MMS system supplied by vendor, based on distance informed by Client/PMC. When multiple Racks are supplied by Package vendor, then package vendor shall provide all interconnecting cables between the Racks.

7.0 Analyzer General : If On-line gas analyzers expected or envisaged in package units the below shall be followed as minimum.

Analyzer system shall generally consist of several of the following items:-

7.1. Complete analyzing system with sample conditioning units with required hardware & software to be provided. 7.2 Analyzers enclosure shall be weather proof to NEMA 4X and explosion proof suitable to the hazardous area in which they are to be installed. 7.3 Where appropriate, the analyzer may be installed in a purged cabinet or enclosure in order to comply with required area classification. In this case, the power supply shall be automatically switched off on loss of purged air flow or pressure inside the enclosure.(Type X) 7.4 Analyzers installed locally shall be protected by means of a shed, which shall protect the analyzer from rainwater and direct sunlight. 7.5 All components in contact with the sample shall be stainless steel minimum. 7.6 The Analyzers shall meet Environmental Protection Agency (EPA) USA regulations or shall be TUV approved. 7.7 All the Analyzers supply voltage shall be of 110 V AC UPS. All Analyzers shall have 4~20 mA output and signals shall be brought to DCS. 7.8. In case of any serial port connectivity of the analyzer system with DCS, necessary coordination with the DCS vendor for implementation of the mapping, demonstration to client/ consultant is to be given and documented.

7.9. All Analyzers shall be microprocessor based and shall have automatic calibration facility, self-diagnostic facility with local indication.

7.10 Vendor shall provide spare calibration gas cylinders sufficient for 6-months operation after Site Acceptance Test.



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8. CONSTRUCTION

In general all the package vendors to supply pre assembled, Tubed & Wired Instrumentation Systems, to minimise the site construction work.

8.1. Instrument Air Supply Air supplies for field mounted instruments and the local control panels shall be

provided from a single main air header connection (provided by EC (Contractor) at one location). The Vendor shall provide all necessary sub-headers and branches required to feed each instrument or machine internal to the packaged equipment

skid. Individual instrument take off isolation valves shall be provided. GI

Pipe(3) shall be provided from Isolation valve of Air Header up to the Air

manifold. Further distribution shall be done through the Air manifolds (6

Way Or 10 Way).Instrument air manifolds made out of 2 inch Seamless SS

pipe. Each valve, or other user device, shall be identified by the instrument tag number. Air tubing shall be minimum 316 stainless steel, and only imperial tubing shall be used.

8.2. Process Impulse/ Pneumatic Tubing

The minimum material requirements for instrument impulse tubing after the first block valve shall be in accordance with the following:

1) Tubing : Seamless 316 stainless steel to suit the highest design

pressure/temperature application.

2) Fittings : Double ferrule 316 stainless steel compression type manufactured by Parker, Swagelok Fittings make only.

3) Impulse line valve after the first isolation valve & drain valve shall be gate valves, except for equalisation valves in case of DP transmitters which shall be globe type. 8.3. Instrument Wiring

Instrumentation cables shall comply with the following requirements:

1) SWA cables do not require sun protection and can be installed without conduit. FRP Cable tray shall be used. All cables shall be tagged on each side of the cable.

Vendors standard cables/wires can be used for the internal wiring in vendors panels and enclosure. However all wiring shall be tagged as required in section 7.4. And Panel internal wiring shall be done with 1mm2 (min) dia conductor cables.

2) Multicore cables shall have a minimum of 20% spare pairs. Spare pairs of multicore cables shall be connected to terminals both in field junction boxes and at the control cabinet end.

3) All cables in plant areas and between the control room and field ,also inside package vendors Battery limit shall be run overhead FRP cable tray supported on steelwork and avoiding hot surfaces. The cable support infrastructure shall

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be of suitable materials for the area in which it is to be installed; giving consideration to mechanical strength and corrosion resistance.

4) Instrument signal cables shall be run separated from power supply cables and on different trays. Intrinsically safe (IS) signal cables are to be run on different trays and have separate junction boxes from those used for non-IS signals (if any). The cable tray shall be segregated upon the voltage level (24VDC v.s. 110VAC). The safety related signal cables (SIS and F&G) can be run on the same tray of non-safety related signals (DCS).

5) Separate junction boxes shall be used for signals connected to different systems like Main ESD PLC, DCS , Package PLC, Machine Monitoring system ,Fire & Gas System etc.Further it shall be segregated based on signal type as given below

a) Intrinsically safe Analogue inputs/outputs (4-20 mA).

b) Flameproof Analogue inputs/Analogue outputs (4-20mA).

c) Thermocouple inputs.

d) RTD inputs.

e) Intrinsically safe Digital inputs

f) Non-Intrinsically safe Digital inputs

g) Intrinsically safe Digital outputs & SOV

f) Non-Intrinsically safe Digital outputs

g) Vibration signals

h) Gas & Flame Detectors.

i) Power

6) For hardwired signals from Local panel, segregation shall be as per above point 7.3 no. 5

Intrinsically safe barriers for all such signals wherever required shall be provided by vendor.

7) All instrumentation cables shall be FRLS as per IEC332 part III Cat A.

8) No multi-core cables shall contain both intrinsically safe and non-intrinsically safe circuits. Care shall be taken that the selected cables length (i.e. overall loop resistance) capacitance and inductance do not invalidate the certificate for intrinsic safety.

9) Both ends of cables shall be glanded and the cable armour is to be earthed at one end only, always in the field

10) All junction box gland plates are to be pre-drilled .The cable entries to be provided for the holes sizes and quantities specified during detail Engineering.

11) Terminals shall be screwless ,clamp type of PHOENIX / WAGO make .

12) Both ends of all stranded cores shall be provided with insulated pin or blade type cable crimp connectors. The head of the crimp is to be large enough to retain any conductor identification marker or tags.

13) Both ends of all cables and their used cores shall clearly identify both source and destination, using individual ferrule cable marker rings. Core indents will be adjacent to the terminal.

14) Terminals shall accommodate only one conductor, any looping requirements being achieved by using purpose designed links.

15) To achieve insulation and continuity of the screen, the drain wires shall be accommodated using terminals within the box, which are to be mounted on insulators to avoid making contact with the junction box or any other electrically



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conductive medium. Each junction box (as applicable) shall be provided with external earthing lugs suitable for 4 mm2 earthing connection.

16) Field junction box cable entries shall be bottom. Top entry is not allowed. All junction boxes shall have pre-drilled and tapped entries according to the selected cable glands (by Engineering Contractors). Spare holes shall be provided and fitted with certified plugs.

17) Breathers shall be installed on all junction boxes to avoid condensation within the enclosure.

18) Field junction boxes shall normally be positioned for accessibility from grade, walkways or platforms.

19) Cable glands (304 SS) are to be suitable for both the cable type, size, earthing SWA and for the degree of protection chosen to comply with the hazardous area classification. Glands are to be complete with earthing rings and shroud. The earthing ring is to be connected to the plant `dirty' earth system by a suitably sized conductor, minimum 2.5 mm2. Only in the case of non-conductive JBs, Instruments and other devices, will earthing rings be necessary.

20) The selection of cables should take into account the possible elevated ambient temperature due to installation close to equipment operating at high process temperature.

21) Instrument signal and power wires shall be colour coded as per below table. The color code for outer sheath shall be as follows: IS cable Light Blue, F&G Red, Others-Black. This colour coding applies to wiring from the field side of marshalling terminals in system cabinets & packages, field junction boxes and all field mounted instrumentation as minimum.

22) For intrinsically safe certified instruments EExe IIC T4 Zone 1, 2 certified FRP/GRP Junction boxes, with a minimum ingress protection of IP 65 with certified double compression EExd SS304 gland (ET) suitable for area classification shall be provided. For non-IS signals EEx d IIC T4 Zone 2 certified Die cast Aluminum(LM-6) min. 5 mm thick junction box with double compression EEx-d certified SS304 gland (NPT) shall be provided. Junction boxes shall be sized to accommodate the incoming cables. All spare threaded entries shall be fitted with the appropriately certified plugs. All on-skid wiring shall be completed at vendors shop. Pre-installed junction boxes on e.g. skids are to be supplied with drillings for the plant multicore cables based on the engineering contractor information.

8.4. Marking

1) Each cable shall be clearly and permanently marked by using a stainless steel nameplate on which the cable number shall be punched in 8 mm letter height. The plates shall be fastened to the cable with heavy duty cable ties or stainless steel wire at both ends.

2) Each terminated wire shall be clearly and permanently marked by using Raychem (or equal) heat-shrinkable cable marking. The wire number shall be stamped on the tube outer sheath using a hot marker or equivalent method.

3) All field junction boxes shall be identified by permanently fixed labels on the outer surface of the door.

4) All instrumentation and equipment Tag Number shall be clearly labelled using additional stainless steel labels supplied by Instrument Sub-vendor. Labels shall be 50mm x 20 mm in size and attached to the instrument. The characters shall be at least 6 mm in height and marked as per the manufacturers standard, e.g.

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black laser burnt is preferred. Glued or stick-on types are not acceptable.

8.5 Cable details

Colour of

Outer Sheath Type

No of

Cores

/Pairs

Brief Specification Wire Colour

Coding Non -IS

IS Remarks

S1 6, 12 pairs

Main signals runs (Analogue / Digital signals except SOV) between RR and field junction boxes shall be FRLS as per IEC 332 Part III Cat A, twisted pair (as per IS std.), multi-stranded 1 mm2 (17 AWG) pair electrolytic annealed copper conductors, 85C PVC insulated as per IS-5831 type C, an individually shielded with aluminum-mylar/polyster screen,and an overall aluminum-mylar/polyster screen over a 0.5 mm2 (20 AWG) (minimum) tinned copper drain wire, 90C PVC bedding to IS 5831 type ST-2, galvanised steel wire armoured, 90C PVC sheathed overall to IS-5831 type ST-2, an overall shield, 600V/1100 V grade insulation as per BS-5308 Part-II.

Black(-), White(+) (Each pair within a cable shall be identified with a unique number.)

Black Light Blue

S2 1 pair Individual analogue/digital signal runs between field junction boxes and instruments, shall be FRLS as per IEC 332 Part III Cat A ,twisted pair (as per IS std.), multi-stranded 1.5 mm2 (15 AWG) pair electrolytic annealed copper conductors, 85C PVC insulated as per IS-5831 type C, overall aluminum-mylar/polyster tape over a 0.5 mm2 (20 AWG) (minimum) tinned copper drain wire, 90C PVC bedding to IS 5831 type ST-2,galvanised steel wire armoured, 90C PVC sheathed overall to IS-5831 type ST-2, 600V/1100 V grade insulation as per BS-5308 Part-II.

Black(-), White(+)

Black Light Blue

D1 6, 12 , 24 cores

Main runs between RR and field junction boxes for digital output signals for solenoid valve (24V DC) output, etc., shall be FRLS as per IEC 332 Part III Cat A, multi-stranded 2.5 mm2 (13 AWG) core electrolytic annealed copper

Red(hot), Black(neutral) (Each pair within a cable shall be

- Light Blue

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Colour of

Outer Sheath Type

No of

Cores

/Pairs


Coding Non -IS

IS Remarks

conductors, 85C PVC insulated as per IS-5831 type C, 90C PVC bedding to IS 5831 type ST-2,galvanised steel wire armoured, 90C PVC sheathed overall to IS-5831 type ST-2, 600V/1100 V grade insulation as per BS-5308 Part-II.

identified with a unique number.)

D2 2 core

Single outputs for solenoid valve (24V DC) output from the RR or field junction boxes to field devices, , etc. shall be FRLS as per IEC 332 Part III Cat A via single core cables which shall be, multi-stranded 2.5 mm2 (13 AWG) core electrolytic annealed copper conductors, 85C PVC insulated as per IS-5831 type C, 90C PVC bedding to IS 5831 type ST-2, galvanised steel wire armoured, 90C PVC sheathed overall to IS-5831 type ST-2, 600V/1100 V grade insulation as per BS-5308 Part-II.

Red(hot), Black(neutral)

- Light Blue

T1 6, 8 Triad (typical)

Main runs between RR and field junction boxes for three wire devices, shall be FRLS as per IEC 332 Part III Cat A ,twisted Triads (Triple) (as per IS std.), multi-stranded 1 mm2 (17 AWG) electrolytic annealed copper conductors, an individually shielded ,85C PVC insulated as per IS-5831 type C with aluminum-mylar/polyster screen and one overall aluminium-polyester screen over a 0.5 mm2 (20 AWG) (minimum) tinned copper drain wire, , 90C PVC bedding to IS 5831 type ST-2, galvanised steel wire armoured, 90C PVC sheathed overall to IS-5831 type ST-2, an overall shield, 600V/1100 V grade insulation as per BS-5308 Part-II.

Blue, Brown, Black (Each pair within a cable shall be identified with a unique number.)

Black - RTD signal, Vibration measurement ,Axial Displacement measurement. This cable specification shall be applied for distances less than or equal to 300mtrs.For distances exceeding 300 mtrs , follow cable specification listed below.

T2 1 Triad

Three (3) wire devices which have individual signal cable runs to field junction boxes or direct to the RR , twisted Triads (Triple) (as per IS std.), multi-stranded 1.5 mm2 (15 AWG) copper conductors, 85C PVC insulated as per IS-5831

Blue, Brown, Black

Black -

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PACKAGE UNITS




Colour of

Outer Sheath Type

No of

Cores

/Pairs


Coding Non -IS

IS Remarks

aluminium-polyester screen over a 0.5 mm2 (20 AWG) (minimum) tinned copper drain wire, type-C 90C PVC bedding to IS-5831 type-ST2 , galvanized steel wire armoured, 90C PVC sheathed overall to IS-5831 type-ST2 600/1100 V grade insulation.

T3 1 pair Individual signal runs between elements & transmitters, shall be FRLS as per IEC 332 Part III Cat A 1.3 mm2 (16 AWG) pair solid conductor, provided with overall aluminum-mylar / polyster tape over a 0.5 mm2 (20 AWG) (minimum) tinned copper drain wire. The Thermocouple extension wire shall be in accordance with ISA (ANSI) MC96.1.

Yellow / Red (K-type)

Black Type of thermocouple extension cable shall be compatible with thermocouple used. JX type shall not be used

P1 3 cores

Power feeder for instruments / Local Panel - 110V AC 50 Hz, shall be FRLS type. The power supplies shall be 2.5mm2 (13 AWG) minimum, copper conductors, PVC insulated ,galvanised steel wire armoured, covered by an outer sheath of PVC ,1100V grade min. The power cables shall be designed as per IS-1554 Part-I.

- for 3 core Red (hot), Black (neutral) and Green (earth)

Black -

E1 1 core Earthing, minimum 2.5 mm2 stranded copper conductor

Green with single yellow

strip

For the distance of more than 300 mtrs & upto a distance of 550 mtrs special cable shall be considered as per the cable specifications indicated below,

1 Cable Type 4 Triad Individual& Overall Aluminum Mylar Shielded FRLS, Armored cable

2 Applicable standards :

Generally confirming to BS-5308(2), BS-6360, BS-6746, ASTMD-2843, ASTMD-2863, IEC-754 I, IEC-332-I, III-383 And technical particulars.

3 Conductor

Material Stranded Annealed Bare Copper

Grade Electrolytic

No. of strands/Dia. of each strand

7/0.30 mm

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PACKAGE UNITS


ISSUED : 13 July 2009 JOB NO. : 6261 Sheet Shee

engineering specification for control & instrumentation...

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