section iii pac inst deliverables

PAC PROJECT INSTRUMENTATION SPECIFICATIONS

SECTION - III

Page 1 of 22

SECTION III

INSTRUMENT DELIVERABLES


SECTION - III

Page 2 of 22

INDEX

SR. NO. TOPIC PAGE

1 SCOPE 4 2 CLARIFICATIONS OF THE INSTRUMENT DELIVERABLES 4

3 INSTRUMENTATION INTERFACES WITH OTHER DESCIPLINES 13

4 INSTRUMENTS DELIVERABLES OVERVIEW LIST 18

5 SUMMARY OF DOCUMENTS IN OWNER SCOPE OF APPROVAL 21


SECTION - III

Page 3 of 22

Abbreviations used in the document BDP = Basic Design Package BDEP = Basic Design and Engineering Package DCS = Distributed Control System EBDEP = Extended Basic Design and Engineering Package EPC = Engineering, Procurement and Construction ESD = Emergency Shutdown System (Safety PLC) FAR = Instrumentation Field Auxiliary Room FAT = Factory Acceptance Test FGS = Fire, Gas and Smoke Detection System I/O = Input/Output ITB = Invitation To Bid JB = Junction Box MDF = Main Distribution Frame MIC = Main Instrument Contractor for Plant Automation Systems MOV = Motor Operated Valve MTO = Material Take-Off PCD = Process Control Diagram P&ID = Piping and Instrument Diagram PMC = Project Management Contractor RATTS = Range, Alarm, Timer and Trip Setting SAT = Site Acceptance Test SHS = Sample Handling system for analysers SIL = Safety Integrity Level SIS = Safety Instrumented System PNS = Plant Naming/Numbering Systems


SECTION - III

Page 4 of 22

1.0 SCOPE

This specification contains the minimum requirements, with respect to control, of the instrument engineering and design deliverables. This specification contains the defined scope of instrument deliverables for engineering and design to be generated for this project. All the documents/drawings specified in this section shall be in English Language and shall be either in Microsoft word, Microsoft Excel or in Auto CAD software format only in addition to required numbers of set of hard copies. PDF formats are not acceptable.

2.0 CLARIFICATION OF THE INSTRUMENT DELIVERABLES 2.1 INSTRUMENT PROJECT EXECUTION PLAN

The Instrument Project Execution Plan describes for instrumentation the objectives, goals, responsibility split, scope of work, engineering and design basis, risk and opportunities, execution strategy, HSE, design control and resources and tools. At the start of the Detailed Design Phase the BIDDER Instrumentation lead engineer will prepare a discipline execution plan.

2.2 ENGINEERING SPECIFICATIONS Engineering specifications determine the basic engineering and design procedures. These cover the criteria for the execution of the detailed engineering and design specifications applicable for the project. The instrumentation specification to be provided by the BIDDER is as a minimum but not limited to:

a. General specification for Instrumentation b. General instrument specification for package units c. Plant automation systems specification d. Fire Gas and Smoke Detection System specification e. Analyzer and analyzer systems specification f. Instrument design specification g. Instrument deliverables

2.3 BIDDER shall provide at the start of the project the design/drafting

specification applicable for the project, i.e. Instrumentation Design Basis Document. OWNER or his representative will review these specifications. The specifications are as a minimum but not limited to:

a. Instrument symbology and identification specification as per ISA b. Instrument indices and nomenclature specification as per ISA c. Instrument Tag naming philosophy as per PNS or equivalent systems

of standards d. Intools application specification and formats e. Unit of Measures f. Instrument utility specifications


SECTION - III

Page 5 of 22

g. Basis of instrument design and broad guide line of instrumentation design philosophy

h. Instrument installation requirements in line with guide line provided by OWNER

i. Instrumentation-electrical design interface specification as per guide lines provided by OWNER

j. Instrumentation-piping design interface specification k. Instrument cable specification with minimum guide lines provided by

OWNER l. Instrument drafting specification m. 3-D standard set-up n. CAD standard set-up

2.4 INSTRUMENT CALCULATIONS

BIDDER shall provide the following calculations as a minimum using process data for instruments; calculations provide the information for sizing, selection or verification of instruments or materials.

Following calculations shall be documented: a. Control valve calculation for sizing and noise b. d/p Type flow measurement calculation for sizing/selection

orifice/range. c. d/p Type level measurement calculation for selection range. d. Rota meter sizing calculation e. Analyzer sample loop calculation for determination of lead-time

between sample take-off and analysis result. f. Ex i loop calculation for determination of the capacitance and

inductance of the loop g. Voltage drop calculation for determination of the allowed voltage

drop/conductor size h. Anti surge calculations and transmitter scaling i. Level sketches for all vessels /equipments level measurement j. Instrument air consumption of all instrumentation k. Programming sheets of all micro processor based instruments l. Complex loop algorithms, all constants & Variables, with sample

calculations and all tuning parameters

Notes: 1. Preliminary calculations are by the BIDDER Process/Instrument

department. Final calculations for control valves and safety/relief devices may be replaced by seller calculations.

2. BIDDER Instrumentation shall provide BIDDER Process with the selected CV values of control valves for final relief valve load calculations.

2.5 INSTRUMENT INDEX


SECTION - III

Page 6 of 22

The instrument index lists instruments and/or functions that are required for control, monitoring and safeguarding of a process plant. As such, it functions as instrumentation "scope of plant" and is the basic document next to the P&IDs, from which the instrumentation work is executed. No instrument tag numbers (including hard and soft tags) shall exist those are not listed in the instrument index. It includes as a minimum the following, but not limited to the following

- Tag - Description - Service - Line No - P& I No - Loop Number - Location - Type of instrument - Make and model of instrument - Range of instrument - JB schedule - Cable schedule - Alarms/Trip setting - Control valve action - Interlock Number - Loop sheet no. etc There shall be a common instrument index for the whole plant/entire project, including those of any package units. All package unit vendors have to provide information in the same format in Instrument index required and approved by OWNER in a common instrument index document.

2.6 INSTRUMENT CONFIGURATION INDEX

The configuration index contains the basic information required for configuration of the monitoring, control and input/output functions of a control system. This index is used to manage and transfer the configuration information to the party responsible for the system configuration. However, if this purpose can be met with by some re-arrangement of existing instrument index, IO list, individual instrument system configuration sheets, etc. than this document is not required.

2.7 RANGE, ALARM, TIMER AND TRIP SETTING (RATTS) LIST

The range, alarm, timers (for trip on-delay and off-delays both) and trip setting (RATTS) list is a listing of all loops that interface with a control ( all types of controls i.e. continuous, sequential, on-off, etc.) and indication system, an interlock/logic system and/or with an alarm system. This listing shall contain all settings that are required for safe and reliable operation


SECTION - III

Page 7 of 22

of the plant. Data is provided by the BIDDER Process department to BIDDER Instrument department. Note: timer settings are either provided in the narratives by the BIDDER Process department by default

2.8 REQUISITION

The requisition covers the requirements for purchasing of equipment (i.e. the Indent or MR), materials and related services. The requisition shall consist of the following attachments, but not limited to the

a. Purchase specification, containing a technical description and

specification including b. Instrument data sheets c. Purchase specifications d. Technical descriptions e. Requirements for documents f. Requirements for inspection g. Related technical documents h. Inquiry requisitions i. Technical bid evaluations and recommendation j. Purchase requisitions k. Seller documents review

Requisition subjects are as a minimum but not limited to:

a. Plant automation system inclusive DCS, SIS, FGS, etc. b. Fire, Gas and Smoke (FGS) detection system c. Fire, Smoke and Gas detectors (along with above system) d. Public address system e. Beacons and sirens (along with FGS system) f. Analyzer Houses, Analyzer Systems, Gas Chromatographs and Local

Analyzers g. Field Instruments (Flow/ Level/ Pressure/ Temperature) h. Tank gauging system and product handling/storage control system i. Custody transfer flow metering j. Machine monitoring/Control/Trip system k. Control Valves (all types) l. Self-Regulating Valves m. On/Off Valves (all types) n. Instrument Cable (Single/ Multi core) o. Junction Boxes p. Push Buttons (Field) q. All erection hardware items like cables trays, ducts, instrument

tubes/fittings, and all sundry items.

Notes: 1. The data sheets will be prepared in Database. The format of the instrument data sheets shall be approved by the OWNER or his


SECTION - III

Page 8 of 22

representative. The completed instrument data sheets will be reviewed by OWNER or his representative prior to inquiry issue and prior to purchase order placement and/or call-off.

2.9 PROCESS ANALYZER SPECIFICATION

The specification for process analyzers & Gas Chromatographs details scope split, technical requirements and authority coordination. Specified are as minimum, if and when applicable:

a. Applicable standards, codes and regulations b. Environmental conditions c. Enclosure (house/shelter/shed/cabinet) d. Air handling e. Utilities (electrical power, instrument air, plant air, nitrogen, carrier

gas, potable water, effluent handling, lighting, earthing, etc) f. Sampling (probe, sample handling, tube routing, supporting, etc.) g. Interfaces with civil, piping, electrical h. Fire and gas detection i. Installation details j. Analyzer maintenance systems communication k. Certification l. Inspection (FAT, SAT, test reports) m. Documentation

BIDDER Instrumentation shall design the process analyzer systems. OWNER or his representative will review the documents prepared by Instrumentation BIDDER. Also BIDDER shall provide overall coordination with the Analyzer System Integrator.

2.10 SYSTEM FUNCTIONAL DESIGN SPECIFICATION

The system functional design specification provides the basic design specification for the plant automation & FGS systems and shall be approved by OWNER. The specification covers requirements for as minimum but not limited to:

a. System hardware inclusive interfaces with other systems b. Console design c. Displays (manufacturers standard, graphics, navigation, etc.) d. Alarm management e. Software implementation conventions (process control loop strategies,

equipment f. Control strategies, safeguarding, etc g. It is assumed that the BIDDER develops the system functional design

specification. Instrumentation will review the specification. 2.11 INSTRUMENT SYSTEM BLOCK DIAGRAM


SECTION - III

Page 9 of 22

The instrument system block diagram provides the schematic representation of the major hardware architecture of the control, safeguarding and related systems like fire and gas detection, machine monitoring, anti surge control system GPS and integration of all systems, etc. The related systems shall include all other subsystems interfaced to the instrumentation/ automation system e.g. computer/MIS (Management Information System), etc. This drawing will show the physical location and their interrelation on the signal type/carrier level of above mentioned hardware. It is assumed that the BIDDER shall develop the instrument system block diagram.

2.12 TYPICAL PROCESS CONTROL DIAGRAMS (PCD'S)

The PCD elaborates the functionality as shown on the P&ID's and gives a graphical overview of the functions of a loop or a combination of related loops, their physical location and their interrelation. It is assumed that for consistency purposes the BIDDER shall develop the loop type templates listing that are used to populate the instrument data base Intools. For all complex loops, PCD shall include control narratives for individual loop also.

2.13 INSTRUMENTATION CAUSE AND EFFECT AND LOGIC DIAGRAMS

Instrumentation cause and effect diagrams are elaborated cause and effect diagrams prepared by BIDDER Process. The information is supplemented with :

a. Study and evaluation of plant RISK as per DIN19250/AK-1 to AK6 or

SIL-1 to 4 as per IEC61508 b. Classifying interlock and safety shutdown interlock/logic c. Operational functionality (e.g. start-up overrides, maintenance

overrides, resets, Auto change- over of pumps) d. Sub-system interconnections (e.g. between safety instrumented

systems located in different buildings) e. Logic/Interlock description in narrative form with the help of process

group f. Logic/Interlock diagram in Function Block Diagram Form as per

IEC61131

The logic/sequence diagram elaborates the functionality even further than the Instrumentation cause and effect diagrams and/or sequence flow chart. BIDDER Instrumentation shall prepare the instrument logic diagram from the cause and effect diagrams, in FBD format for all interlocks and logic. It is assumed that the BIDDER together with the Plant Automation System Vendor shall prepare the final and detailed interlock/logic diagrams and sequential diagrams and implement these into the selected systems as per requirement of OWNER.


SECTION - III

Page 10 of 22

2.14 DCS GRAPHIC DISPLAY INFORMATION

DCS graphic display information shall be provided with highlighted P&ID's showing the main process equipment to be implemented in the DCS displays. Implementation shall be based on the DCS configuration and man machine interface convention by DCS supplier. It is assumed that the BIDDER together with the Plant Automation System Vendor shall develop the graphics based on the graphic design philosophy developed by the BIDDER and approved by OWNER.

2.15 INSTRUMENT INSTALLATION SCHEDULE

The instrument installation schedule shall contain all tag numbers of field-mounted instruments with relevant P&ID number, location of instrument, installation drawings and purchase requisition number, which may be extracted from the instrument index (index data base). BIDDER Instrumentation shall prepare the Instrument Installation Index.

2.16 INSTRUMENT FIELD LOCATION LAYOUT

The instrument field location layout drawing shall be based on the plot plan. The plot plan shall be divided in logical parts with preferable a scale of 1:50 and a drawing size of A1. The layouts shall show the location of instruments, local panels, cabinets, junction boxes, PA system field call station and air header systems. Each instrument will be indicated by means of a dot, instrument tag number with letter code for type of instrument and its elevation in addition to X-Y co-ordinates. A legend drawing shall show all general notes, symbols and reference drawing numbers of instrument field layouts and with a listing of all relevant installation drawings. The instruments shall be placed in the 3-D PDS model. All in-line instruments as well as off line instruments like Stanchion mounted JB, transmitters, etc. and all main cable ducts, perforated aluminum cable trays up to size 300 mm and above will be modeled by Piping using dimensional information supplied by Instrumentation.

Similarly Piping will also model displacer instruments, capacitive probes, tuning forks, servo level instruments, level gauges, thermowells, analyzer probes and orifice flanges. For all in-line instrumentation initially when the seller/manufacturer and model are not yet selected Instrumentation will provide dimensional data based on generic catalogue data and/or preliminary sizing calculations. The quality of the dimensional data will be improved by BIDDER Instrumentation once the seller/manufacturer and model are selected. Finally BIDDER Instrumentation will provide dimensional data based on the approved seller data. BIDDER Instrumentation shall provide dimensional data based on approved seller data for the other on-line instruments; BIDDER shall model these instruments in the 3-D model. BIDDER Instrumentation shall model local panels and junction boxes using an equipment model.


SECTION - III

Page 11 of 22

BIDDER Instrumentation shall prepare the Instrument Field Location Layout in AUTO CAD.

2.17 INSTRUMENT FIELD CABLING LAYOUT

The instrument field cabling layout shall be based on the plot plan. The plot plan shall be divided into logical parts, with a preferable scale of 1:100. The layout shall show the location of local panels, cabinets, junction boxes, cable main ducts/trays, sub-trays, cables, etc. Local panels, cabinets and junction boxes shall be indicated by means of an identification number. BIDDER Instrumentation shall use Intergraphs Raceway module to support PDS areas in modeling all main ducts of instrumentation cables and perforated aluminum trays of size 300 mm and above. BIDDER Instrumentation shall prepare the Instrument Field Cabling Layout in AUTO CAD. Conduit/ tray installation details and drawings are by BIDDER. Trenches are not foreseen.

2.18 INSTRUMENT PROCESS PIPING DETAILS

Instrument process piping details shall show a schematic installation of the piping between the instrument and the related process take-off point and a listing and specification of the materials required for this installation. BIDDER Instrumentation shall prepare the Instrument Process Piping Details inclusive MTO.

2.19 INSTRUMENT AIR PIPING DETAILS

Instrument air piping details shall show a schematic installation of all pneumatic instruments concerning air supply and air signals and a listing and specification of the materials required for this installation. BIDDER Instrumentation shall prepare the Instrument Air Piping Details inclusive MTO.

2.20 INSTRUMENT STEAM TRACING DETAILS

Instrument steam tracing details shall show a schematic installation of the steam tracing between the instrument and the related process take-off point and a listing and specification of the materials required for this installation. BIDDER Instrumentation shall prepare the Instrument Steam Tracing Details inclusive MTO. Instrument electrical tracing is by Electrical.

2.21 INSTRUMENT INSTALLATION DETAILS/HOOK UP DRAWINGS

In addition to instrument installation details with primary and secondary sketches for instrumentation hook up drawings, the Instrument installation details shall show a typical mechanical supporting and typical electrical installation of indoor and outdoor instruments, junction boxes, panels, cabinets, cable tray/ladders, etc. Details shall be provided for supports on the paved/unpaved ground, concrete floors, walls/concrete beams, steel


SECTION - III

Page 12 of 22

structures, etc. BIDDER Instrumentation shall prepare the Instrument Installation Details /Hook up drawings inclusive MTO.

2.22 INSTRUMENT NAMEPLATE SCHEDULE

The instrument nameplate schedule is a listing of identification numbers for instrument, cabinets, local panels, junction boxes, marshalling racks, detection equipment, etc. BIDDER Instrumentation shall prepare the Instrument Nameplate Schedule inclusive of MTO.

2.23 INSTRUMENT LOCAL PANEL LAYOUT

The instrument local panel layout shall show the arrangement of local panel mounted equipment such as push buttons, alarms, indicating, lights, gauges, including approximate sizes and location of local panels. Local panels are designed and supplied with the equipment package unit. No additional local panels are foreseen. Design documents of seller / BIDDER Instrumentation shall be approved by OWNER.

2.24 INSTRUMENT ROOMS EQUIPMENT LAYOUT

The control room and instrument field auxiliary building equipment layouts shall show the location and main dimensions of control panels and/or consoles, telecommunications equipment, and, if applicable, computer room equipment, fire alarm panel, semi graphics, etc. Consoles will show monitors, keyboards, trend recorders, radio and communication systems, etc. In case other rooms are shown on the layout, the related equipments will be shown too. The basis is the hardware, as shown on the instrument system block diagram, and the sizing, based on the hard I/O count. BIDDER shall prepare the Instrument Control Building and Instrumentation Field Auxiliary Building Layouts. BIDDER Instrumentation provides preliminary dimension information for any instrumentation in the control building. BIDDER Instrumentation shall provide approved for design AFD and approved for construction AFC data on this instrumentation items.

2.25 INSTRUMENT ROOMS CABLE LAYOUT

The cable layout for control rooms, technical/auxiliary/rack rooms shall show the route of the cables between cabinets, racks, panels, consoles, and various cable entries/exit in control room/rack room, etc. Also the route of the incoming field cables will be shown. BIDDER shall prepare the Instrument Control Building and Instrumentation Field Auxiliary Building Cable Layout.

2.26 INSTRUMENT ROOMS EARTHING LAYOUT

On the earthing layout the several earthing systems shall be shown, for safety earth, instrument earth, IS and NON-IS earth for instruments, computer earth, etc. All earthing systems will be connected to a bus bar; each system will have its own bar. The connection between the bus bar and the earthing electrode will be the responsibility of the electrical discipline. BIDDER shall prepare the Instrument Control Building and


SECTION - III

Page 13 of 22

Instrumentation Field Auxiliary Building, Analyser house, local panel, JB/Instruments Earthing Layout.

2.27 FIRE SMOKE AND GAS DETECTION LAYOUT

The fire smoke and gas detection layout is based on the plot plan. The plot plan shall be divided in logical parts with preferably a scale of 1:50 and a drawing size of A1. The layout shall show the location of detectors, manual call points installation, status lamps, alarm siren, junction boxes, panels, etc. Each instrument will be indicated by means of a symbol. Fire smoke and gas panels, cabinets and junction boxes will be indicated by means of a rectangle and an identification number. A layout with general notes, symbols and reference drawing numbers shall show all general notes and symbols of fire, smoke and gas detection layouts and further a listing of all relevant installation drawings. BIDDER Instrumentation will prepare the fire smoke and gas detection layouts.

2.28 FIRE SMOKE AND GAS DETECTION INSTALLATION DETAILS

FIRE, SMOKE and GAS detection installation detailed drawings shall show typical mounting and electrical installations, such as detector installations, horn/beacons installations, manual call points installation, wiring diagram, Junction box schedule, etc. BIDDER Instrumentation will prepare the FIRE, SMOKE and gas detection installation details.

2.29 INSTRUMENT CABLE LIST

The instrument cable list shall show all instrument cables, with the exception of the single cables between instrument and junction box, which is part of JB schedule drawings. Furthermore, the cable list shall show the cable number, type, length and size of cable, type of signal, color of outer sheathing, description of run (from - to), requisition and item number, drum number and a remarks column. BIDDER Instrumentation shall prepare the Instrument cable list.

2.30 CONNECTION LIST INSTRUMENT FIELD SIDE

Junction box connection listing shall show the termination of all instruments connected with single wiring/cabling to a junction box and the signal transmission via a multi core/pair cable to the marshalling rack/cabinet in technical (auxiliary) room. It will also indicate main cable number, type and details with destinations. BIDDER Instrumentation shall prepare the connection list instrument field side.

2.31 CONNECTION LIST INSTRUMENT ROOM SIDE

Marshalling rack/cabinet connection listings shall show the termination of all field cables at one (1) side (field side) and all control/rack room cables at the other side (control building side) and the interface connections of electrical signals. Cross wiring shall be shown on the same list. BIDDER Instrumentation shall prepare the connection list instrument control building side


SECTION - III

Page 14 of 22

2.32 ELECTRICAL INSTRUMENTATION INTERFACE The electrical-instrumentation interface describes the method of signal transmission from control and safeguarding systems to the motor control units, low and high voltage switchgear and variable speed drive systems. The signals are directly hardwired, hardwired via interposing relays or communicated via a serial link. The signals concern control, trip and status information. BIDDER provides the electrical instrumentation interface specification. BIDDER Instrumentation shall incorporate in the instrumentation database Intools external power requirements for field instruments. BIDDER Instrumentation shall prepare an Excel extract from Intools showing instruments, which require electrical supplied, external power indicating tag number, location, voltage type and voltage level. BIDDER to follow the minimum guide lines as provided in Electrical Instrument Interface specification portion of this documents.

2.33 INSTRUMENT LOOP DIAGRAMS

Instrument loop diagrams shall be prepared for each electronic loop on the project on the basis of one (1) loop per drawing sheet. A loop shall contain each component from field device to DCS and/or other system cabinet, including physical location, equipment number/location, terminal row/number and cable pair number/polarity. DCS and/or other system functions of the loop shall be shown in a simplified manner, without all configuration details. More than one drawing may be necessary for more complex loops. Intools smart loop will be used for conventional hardwired loops. BIDDER Instrumentation/System vendors shall prepare the instrument loop diagram from field instruments up to including the terminals of the field cables at the field side of the marshalling rack/cabinet (main distribution frames MDF) along with further nest loading information, software in-out blocks, etc. The field instruments include package unit supplied instrumentation. The BIDDER shall complete the instrument loop diagrams with the systems side. The format of the loop diagrams shall be approved by OWNER.

2.34 INSTRUMENT SUBCONTRACTS

The objective of the instrument subcontract is to define the instrument subcontractor's scope of work, services and supply for the instrumentation part of the installation work of a project. The instrument subcontract shall contain necessary design and engineering documents, developed during the detailed design phase of the project. OWNER or his representative shall review these documents.

The applicable specifications will be attached to the subcontract, e.g.:

a. Instrument engineering and design specification. b. Instrumentation scope split matrix multi office execution. c. Instrument installation specification.


SECTION - III

Page 15 of 22

d. Instrument cable pulling installation specification. e. Test and pre-commissioning specification. f. Instrumentation shall provide the scope descriptions for and technical

attachments to the Instrument Subcontracts.

3.0 INSTRUMENTATION INTERFACES WITH OTHER DISCIPLINES

3.1 PROCESS DESIGN 3.1.1 Process Definitions/Philosophies

a. Technology selection (Comparison of processes) b. Dynamic simulations of instrumentation of process c. Process control and operating philosophy, Instrumentation reviews

the philosophy. d. Emergency shutdown philosophy, Instrumentation reviews the

philosophy. e. Fire protection philosophy and Fire, Gas & Smoke system,

Instrumentation reviews the philosophy. 3.1.2 Process flow diagrams

Instrumentation reviews the process flow diagrams. 3.1.3 Process description

No instrument involvement 3.1.4 Safety and Environment

a. Plant effluent data: Instrumentation provides the data of the analyzer system effluents to Process during detailed engineering.

b. HAZOP & SIL study and report : Instrumentation representative is available for questions and answers during the HAZOP Meetings. Resolutions from the HAZOP / SIL study report are to be reviewed by Instrumentation wherever applicable.

c. Noise study : BIDDER Instrumentation provides predicted noise data for control valves based on Instrumentation preliminary sizing (30% probability) or on selected seller supplied data (70% probability).

3.2 PROCESS ENGINEERING

3.2.1 P & I Diagrams

a. Symbol P&IDs : BIDDER Instrumentation reviews the symbology

(legend) for P&IDs prepared by Process. b. Process P&IDs : BIDDER Instrumentation provides tag numbers for

instruments, instrument loops, safeguarding blocks, safety valves, gauges and actuated valves. An Instrumentation representative is available for questions and answers during the screening meetings.


SECTION - III

Page 16 of 22

Instrumentation shall review and comment the P&IDs. BIDDER Instrumentation shall advise BIDDER Process of the modifications due to the detailed design.

c. Fire Smoke and Gas Detection P&I Dia: See Process P&IDs. d. Utility P&IDs : See Process P&IDs.

3.2.2 Inter-connection and tie-in diagrams

No input from Instrumentation. 3.2.3 Package unit P&IDs Same as main Plants P&I Dia. 3.2.4 Process control and safety instrumented system functional specifications

(narrative) : The process control functional specification PC-FS (narrative) contains functional descriptions of complex regulatory loops, automated sequence/ batch controls, all interlocks and logic, etc.. If required, additionally sequential function charts or structured text can be provided for the sequence/ batch type controls along with control and interlock/logic narratives. The safety instrumented system functional specification SIS-FS involves all instrument actions for unscheduled process conditions and these are designed to set the process in a safe mode if it tends to move outside its operating parameters towards unsafe conditions. The reliability levels of the safeguarding functions will be classified into SIL levels (see also SIL definition). For each SIS block cause and effect diagrams and interlock / Logic diagrams will be attached, being a graphical representation of the main instrumented safeguarding functions. The documents are generated by Process. BIDDER Instrumentation will review & comment these documents. The implementation is by BIDDER with the help of automation system vendors.

3.2.5 SIL Definition Instrumentation provides input to the Safety Instrument Level as determined by Process. Instrumentation together with Process will adjust the P&IDs according the requirements set by the SIL classification.

3.2.6 Sequential re-start sequence Instrumentation reviews the sequential re-start sequence as prepared by Process in close cooperation with Electrical.

3.2.7 In-line instrument process datasheets: BIDDER Process provides process data sheets for in-line instruments, relief valves and actuated valves. BIDDER instrument ensures inclusion/reference to the latest process data in all material requisition of all instrumentation item as well as purchase requisition of all instrument items.

3.2.8 On-line and off-line instrument process datasheets: BIDDER Process provides process data sheets for instruments for on-line instruments and off-line instruments. Rest is same as above.

3.3 MECHANICAL

3.3.1 Specification for package unit instrumentation


SECTION - III

Page 17 of 22

BIDDER Instrumentation prepares a general specification for package unit instrumentation based on the general instrument specifications provided in this complete contract document. This specification covers the minimum requirements for the engineering, design, supply and installation of instrumentation equipment and commodities forming part of package units. Electrical instrument installations shall also follow the requirements set forth in the specification Electrical requirements for package units.

3.3.2 Complex packages BIDDER Instrumentation prepares for each inquiry requisition for complex package units a specific, technical description and specification including instrument data sheets. The instrument data sheets shall be completed by the selected seller later on along with selected model of instrument.

Note: scope split for filling-in the instrument datasheet shall be agreed upon in co-operation with the seller.

3.3.3 STATIC EQUIPMENT Vessel sketches Columns, reactors, vessels, tanks, shell & tube heat exchangers, air coolers, filters, heaters, boilers, indicating level, level trip/alarm points, interface level, etc.

3.3.4 ROTATING EQUIPMENT Pumps, steam turbines, air compressors & fans & blowers, turbines, process gas compressors, diesel & gas engines, extruder units, refrigeration units, vacuum units, providing various speed/vibration monitoring details on control and interlock/logic as well as complex controls like anti-surge and performance controls of the systems.

3.3.5 SPECIAL EQUIPMENT Package units, fire fighting equipments, HVAC equipment, mechanical handling equipment, solid handling equipment.

3.4 PLANT DESIGN 3.4.1 CIVIL AND STRUCTURAL

a. Control building and instrument field auxiliary room building BIDDER Instrumentation provides to BIDDER Civil the internal room dimension of control rooms, instrument rack rooms and instrument field auxiliary buildings, analyser houses, cable entry, doors/windows locations, etc. Location of rain water drains are to be indicated.

b. In addition to the building information, BIDDER Instrumentation provides to BIDDER Civil/Structural location, size and weight of instrumentation supplied, pre-fabricated structures, sheds and free-standing local panels.

c. BIDDER Instrumentation provides to Civil the routing and sizing of trenches within control room building and main cable duct route on main pipe racks in the field. However, in this complete project, no underground cable trenches, etc. are involved, except control room/cabinet room. No under ground instrument cables shall be acceptable in the field area.


SECTION - III

Page 18 of 22

3.4.2 PIPING DESIGN

a. Plot plan: The plot plan is prepared by Piping. BIDDER Instrumentation provides the routing and dimensions of main cable ducts, main and sub cable trays, and the locations and dimensions of analyser houses/sheds, local panels, local control skids, JBs, control rooms and instrument field auxiliary buildings.

b. Critical isometrics: BIDDER Instrument shall provide necessary

information on dimension of all in-line instruments, straight run requirement of all flow instruments, ground and top clearance for al in line instruments required, etc.

c. Plant model: BIDDER instrument shall review 3-D plant model

including all on-line and off-line instrument locations, approach, main cable duct lay out, cable tray layout of up to 300 mm perforated aluminum cable trays, etc. in the 3-D model.

d. Line schedule / Line List: No input from Instrumentation. The line schedule is used by Instrumentation during detailed engineering as reference document.

3.4.3 PIPING ENGINEERING

a. Valve selection: Actuated piping valves requisitioned by Instrumentation follow the valve selection as per Piping valve criteria and other guide lines /requirements given in this complete contract document. Instrumentation does not provide input to the valve selection specification.

3.5 ELECTRICAL 3.5.1 ELECTRICAL ENGINEERING

a. Electrical load list: BIDDER Instrumentation shall provide BIDDER Electrical with the required loads of Instrument Equipments.

b. Electrical Interface: BIDDER Instrumentation shall inform BIDDER Electrical of the required interface signals in line with Volume-3, Section-9, Chapter- VI and various annexure of the same.

3.6 SUBCONTRACTING

Subcontracting project execution plan : Review of instrumentation part of the subcontracting project execution plan.

3.7 OPERATIONS

Construction project execution plan: Review strategy of Seller representatives for Instrumentation and Packaged instrumentation to


SECTION - III

Page 19 of 22

support construction and (pre-) commissioning activities. Constructability review with aspects like pre-assembly, vessel pre-dressing, heavy lift requirements of valves, maximum dimensions of cabinets and analyzer houses shall be reviewed by BIDDER Instrumentation. Review of Mechanical completion procedure. Review of Strategy and Procedures for (pre-) commissioning, unit performance test, initial start-up and operation

3.8 SCHEDULES

BIDDER Instrumentation reviews the level two schedules as prepared by BIDDER Scheduling. Special focus is on the interface data with other disciplines and required-on-site dates. BIDDER Instrumentation level three schedules will be prepared based on the milestones from the level 1 and 2 schedules prepared by Project Control department. Instrumentation shall provide input to, review and maintain the schedule during the course of the project. Instrumentation shall take corrective action to meet the level 1 and 2 schedules for their own part of the work, if and when required.

4.0 INSTRUMENT DELIVERABLE OVERVIEW LIST (BY BIDDER)

In general, BIDDER to submit the following deliverables for OWNERs REVIEW/approval and incorporates OWNERs comments on the same. Also BIDDER has to prepare a schedule for progressive monitoring of the below mentioned deliverables.

4.1 Instrument project execution plan 4.2 Work schedule level 3 preparation 4.3 Status reports 4.4 Instrument Design Basis for the entire project 4.5 Instrument Sizing calculations including, but not limited to

Control valve calculation Safety/relief device calculation D/p type flow measurement calculation, incl Restriction Orifices. D/p type level measurement calculation

4.6 Analyzer sample loop calculation 4.7 Ex i loop calculation 4.8 Voltage drop calculation for all instrument signal and power cables 4.9 Segment calculation for various FF devices 4.10 Power and Heat Dissipation Calculations 4.11 Instrument air consumption 4.12 Instrument index, IO point data base for DCS/ESD and FGS 4.13 Instrument Configuration Index, programming sheets 4.14 Range, alarm, timer and trip setting (RATTS) list 4.15 Requisition (MR and PR)

Plant automation system (DCS/ESD) Fire Smoke and Gas detectors Analyzer houses, analyzer systems and local analyzers


SECTION - III

Page 20 of 22

Field instruments (flow/ level/ pressure/ temperature) Tank gauging system, Storage and product handling systems Custody transfer flow metering system Machine monitoring /control / trip system Control valves globe type / butterfly type / contoured ball type Self-regulating valves On/off valves - ball type / butterfly /globe / gate type Instrument cable (single/ multi pair) Junction boxes, Duct, Cable trays, Cable glands Push buttons (Local field mounted and control room aux console)

4.16 Process analyzer, Gas Chromatographs specification. 4.17 Control System functional design specification (DCS/ESD/FGS,

Package unit control systems, etc.) 4.18 Instrument systems block diagram and system architectures 4.19 Process control diagrams (PCDs) or Functional Loop schematics

with control narratives/explanation for all complex loops; to be given to System vendor for implementation in DCS

4.20 Instrument Interlock/logic diagrams in FBD format, which will be given to System vendor for implementation of detail logic/interlock

4.21 Instrument cause and effect diagrams with control, interlock/logic narratives

4.22 Detailed Logic diagrams in ESD systems (as built in ESD by vendor) 4.23 Sequential diagrams for any process control sequence with

narratives 4.24 DCS graphic display information and philosophy 4.25 Instrument installation/Erection schedule with bulk MTO of erection

hardware 4.26 Instrument field location layout (including all field instruments, JB,

Instrument air manifold, analyzers, PA system field call stations, etc.)

4.27 Instrument location layout for field ESD-switches in field and AUX consoles located at control room/aux room

4.28 Analyzer GA/IA drawings, panel wiring drawings and SHS drawings 4.29 Instrument field cabling layout 4.30 Instrument process piping details 4.31 Instrument air piping details 4.32 Instrument steam tracing details 4.33 Instrument installation details with primary/secondary sketches,

instrument hook up drawings 4.34 Instrument nameplate schedule 4.35 Instrument local panel/skid layout 4.36 Instrument rooms equipment layout 4.37 Instrument rooms cable layout within control room/cabinet room 4.38 Instrument rooms earthing layout 4.39 Fire, Gas and Smoke mimic layout/Graphics 4.40 Fire, Gas and Smoke detection layout along with Manual Call Point

location, lay outs 4.41 Fire, Gas and Smoke and gas detection installation details along

with Manual call point


SECTION - III

Page 21 of 22

4.42 Instrument cable list 4.43 Connection list instrument field side including JB schedule/Local

panels 4.44 Connection list instrument field auxiliary room (FAR) side for all

DCS/ESD and all third party control system ( i.e. Unit Control Panels)

4.45 Electrical instrumentation interface 4.46 Instrument loop diagrams 4.47 Instrument subcontracts 4.48 SIL/HAZOP reports (with HSE)

5.0 THE DETAILED SUMMARY OF VARIOUS INSTRUMENTAITON

DOCUMENTS WHICH REQUIRES OWNER REVIEW/APPROVAL.

The table mentioned below summarizes various categories of instrumentation related documents which are to be submitted by BIDDER for OWNER information/ review and comments / approval, etc. However, it may please be noted by BIDDER that format of all deliverables shall be approved by OWNER.

List of Instrumentation Documents requiring OWNER's review/approval Ammonia Synthesis Gas Generation (Feedstock conversion to LNG) Project

Sr. No. Document Information

Review / Comment Approval

1 DCS Documents a Enquiry Specifications Yes b Final Technical Purchase order Yes

c

System architecture, Inst. Block Diagrams for various 3rd party control systems architecture and its interface with DCS Yes

d DCS I/O List Yes

e System sizing and loading (both in terms of hardware and software load)

Yes

f Nest Loading & Channel Allocation Yes g All Panels' GA/IA and wiring details Yes

h Wiring Diagram and marshalling philosophy Yes

i Cabinet room and control room GA/IA Yes

j Power consumption and Heat Dissipation Calculation Yes

k System FAT/SAT procedure Yes

2 General Engineering Specification / Engg. Design Basis Yes

3 Instrument Index (Format and tag Yes


SECTION - III

Page 22 of 22

naming philosophy for all P&I Dia. tags and other hidden tags are to be approved by OWNER)

4 Instrument items' enquiry specifications

a

Category "A" instruments ( Which includes Control/Shutdown valves, DCS,Analyzers, servers and laptop, RADAR, PA system, all 3rd party Package unit control systems) Yes

b

Category "B" instruments and related items, i.e. all balance Instrument items, hardware, software Yes

5

All instrument items' Technical Purchase Order as mentioned above in category "A" and "B". Yes

6 Instrument Plot plan Yes

7 Instrument pneumatic and process Hook Up diagram Yes

8 Loop Sheets for DCS Yes

Yes (format only)

9 Enq. specifications of Third party / Proprietary instrumentation systems Yes

10 Control valve sizing calculation Yes

11 Orifice sizing calculation Yes

12 Instrument system grounding/earthing schematics Yes

13 Instrument air header schedule Yes 14 Instrumentation cable schedule Yes 15 Instrumentation cable route Yes

16 Electrical / Instrument Interface list Yes

17

Junction Box schedule & Foundation Field bus segment calculation and topology Yes

18

Rest all documents specified in this section, which are not covered in this table. Yes