Package Unit Instrumentation Specification_TBE and VDR

PACKAGE UNIT INSTRUMENTATION SPECIFICATION, TBE AND VDR

CHAYAPAT L.Dec 12, 2014

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Table of contents

1. Introduction

2. Instrument scope of work in the package unit

3. Guidance on option selection

4. General requirement for field instrument in package unit

5. General requirement for instrumentation system

6. General requirement for instrument installation

7. General requirement for test and inspection

8. General requirement for documentation

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1. Introduction

1. Introduction

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What is purpose of package unit instrumentation specification?

- To ensure that the instrumentation supplied as part of packaged equipment systems is consistent with the plant instrumentation requirement

- To covers the material, specifications, work, services and responsibilities that shall be provided or executed by the Vendor and by Purchaser for instrumentation associated with 'major mechanical equipment' (Compressors, boilers, fired furnaces, filters, lube oil systems, gas generators, etc.).


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General

Refer to DEP document no. DEP 32.31.09.31, there are total six (6) options A to F to define scope of supply for instrument in package unit.

2.1 Option A

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2. Instrument scope of work in the package unit 2.1 Option AScope of VendorThe Vendor shall supply the equipment package, complete with process tappings and theinstruments that are an integral part of the proprietary equipment, e.g. speed governors,overspeed trip, proximitors, vibration pickups, etc.

The Vendor's scope of supply includes the functional specification, special tools, specialtest equipment, drawings and documents. When installing instruments, allowance shall be made where necessary for any tracing, insulation and housings that may be required.

Vendor CompetenceThe Vendor's competence is limited to instrumentation that is considered an integral part ofthe proprietary equipment.

Scope of ContractorThe Contractor shall design, engineer, supply and install all remaining field instrumentationand installation materials and all cabling between the field junction box(es) and the (F)AR.The Contractor shall be responsible for the configuration of the DCS, IPS (Logic Solver) orsubsystem to perform the required control and IPF (SIF) functionality, etc. as specified bythe Vendor's functional specification.

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2. Instrument scope of work in the package unit 2.2 Option B

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2. Instrument scope of work in the package unit 2.2 Option BScope of VendorThe Vendor shall supply the equipment package, complete with process tappings and theinstruments that are an integral part of the proprietary equipment, e.g. speed governors,overspeed trip, proximitors, vibration pick-ups, etc.

In addition, the Vendor shall supply any instrument installation materials required. Theinstallation materials shall be as specified on the engineering documentation prepared bythe Contractor and issued to the Vendor. The detailed design of the installation shall be theresponsibility of the Vendor.

The Vendor's scope of supply shall include the functional specification, special tools,special test equipment, drawings and documents.

Vendor CompetenceThe Vendor's competence is limited to instrumentation that is considered an integral part ofthe proprietary equipment, and to the installation of installation materials.

Scope of ContractorThe Contractor shall design, engineer, supply and install all remaining field instrumentationand all cabling between the field junction box(es) and the (F)AR.

The Contractor shall be responsible for the configuration of the DCS, IPS (Logic Solver) or subsystem to perform the required control and IPF (SIF) functionality, etc., in accordance with the Vendor's functional specification.

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2. Instrument scope of work in the package unit 2.3 Option C

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2. Instrument scope of work in the package unit 2.3 Option CScope of VendorThe Vendor shall supply the equipment package complete with field-mounted instruments installed.

All instrumentation in the scope of supply of the Vendor shall be supplied and installedaccording to the Principal's standards.

The Vendor's scope of supply includes functional specification, special tools, special testequipment, drawings and documents.

Vendor CompetenceThe Vendor shall have been deemed competent by the Principal to meet the Principal'sstandards.

Scope of ContractorThe Contractor shall design, engineer, supply and install all cabling between the fieldjunction box(es) and the (F)AR.

The Contractor shall be responsible for the configuration of the DCS, IPS (Logic Solver) orsub-system to perform the required control and IPF (SIF) functionality, etc., in accordancewith the Vendor's functional specification.

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2. Instrument scope of work in the package unit 2.4 Option D

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2. Instrument scope of work in the package unit 2.4 Option DScope of VendorThe Vendor shall supply the equipment package complete with field-mounted instrumentsinstalled.

All instrumentation in the scope of supply of the Vendor shall be supplied and installedaccording to the Vendor's standards.

The Vendor's scope of supply shall include the functional specification, special tools,special test equipment, drawings and documents.

Vendor CompetenceThe Vendor's instrumentation standards used for the equipment package shall have beenaccepted by the Principal.

Scope of ContractorThe Contractor shall design, engineer, supply and install all cabling between the fieldjunction box(es) and the (F)AR.

The Contractor shall be responsible for the configuration of the DCS, IPS (Logic Solver) orsub-system to perform the required control and IPF (SIF) functionality, etc., in accordancewith the Vendor's functional specification.

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2. Instrument scope of work in the package unit 2.5 Option E

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2. Instrument scope of work in the package unit 2.5 Option EScope of VendorThe Vendor shall supply the equipment package complete with field instrumentation,control room instrumentation and (F)AR instrumentation. The required control and IPF (SIF) functionality, etc. are pre-configured in the (F)AR instrumentation. Field instrumentation within the equipment package boundary shall be installed by the Vendor.All instrumentation shall be supplied to the Principal's standards.The Vendor's scope of supply shall include the functional specification, special tools,special test equipment, drawings and documents.

Vendor CompetenceThe Vendor shall have been deemed competent by the Principal to meet the Principal'sstandards.The Vendor shall be competent to manage complex interfaces between other equipmentand other Vendors.

Scope of ContractorThe Contractor shall specify, route, supply and install all cabling between the field junctionbox(es) and the equipment package cabinet(s).The Contractor shall install all control room and (F)AR equipment and any instrumentssupplied as part of the package but not installed by the equipment package Vendor.The Contractor shall be responsible for the interfacing requirements of the equipmentpackage with the DCS and IPS (Logic Solver).

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2. Instrument scope of work in the package unit 2.6 Option F

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2. Instrument scope of work in the package unit 2.6 Option FScope of VendorThe Vendor shall supply the equipment package complete with field instrumentation,control room instrumentation and (F)AR instrumentation. The required control and IPF (SIF)functionality, etc. shall be pre-configured in the (F)AR instrumentation. Field instrumentationwithin the equipment package boundary shall be installed by the Vendor.Instrumentation shall be supplied to the Vendor's standards, except that each instrumentshall be given a tag number following the Principal's tagging system.The Vendor's scope of supply shall include the functional specification, special tools,special test equipment, drawings and documents.

Vendor CompetenceThe Vendor's instrumentation standards used for the equipment package shall have beenaccepted by the Principal.

Scope of ContractorThe Contractor shall specify, route, supply and install all cabling between the field junctionbox(es) and the equipment package cabinet(s).The Contractor shall install all control room and (F)AR equipment and any instrumentssupplied as part of the package but not installed by the equipment package Vendor.The Contractor shall be responsible for the interfacing requirements of the equipment withthe DCS and IPS (Logic Solver).


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3. Guidance on option selectionThe flowchart below should be used to select one of the options in item no.2. It describes how the option selection process shall be approached by the Contractor.

The Contractor shall demonstrate to the Principal that all steps in the selection process have been followed in selecting the most suitable option for the particular equipment package.

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4. General requirement for field instrument in package unit 4.1 Design Philosophy

The design philosophy of package unit shall be the same as project design philosophy or plant instrument design philosophy.

This section shall be described all general requirements for instrument design in the package unit. Details are as follows:

4.1.1 Genera Instrumentation 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

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

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

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 (EExdIIC T4) shall be used.

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

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

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4. General requirement for field instrument in package unit 4.1.1 Genera Instrumentation

Body material for all instruments and valves shall be equal to or better than the vessel/piping material. 316 SS shall be used as a minimum for pressure gauge sockets/bourdon tubes, d/p cell bodies, and for bodies of all non indicating transmitters.

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

Impulse Tubing: ½” O/D x 0.065” wall thickness /316 SS. Size/Material

( Refer to project design philosophy)

4.1.2 Code & Standard

( Refer to project design philosophy)

4.1.3 Units of measurementsFlow Liquid m3/h (Chemicals : l/hr)

Gas Nm3/hSteam kg/h

Level %, mmPressure kg/cm2g, mmHg (Vacuum)Temperature ºC

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4.1.4 Connection Details

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4. General requirement for field instrument in package unit 4.1.5 Accuracy of Instruments

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4. General requirement for field instrument in package unit 4.2 Requirement for field instrument

The procurement of all instruments shall be strictly from the manufacturers listed in Clientapproved vendor list included elsewhere in this bid package. If Client vendor list does not coversome instrument items, the package vendor shall submit the sub vendor list for such instrumentitems for Client approval.

4.2.1 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 flowmeasurement shall be mmH2O.

4.2.2 Level measurement For level measurements using DP type transmitters, flanged diaphragm seal type DP

transmitters shall be used. For all types of tanks Guided wave Radar type level gauging system (including interface

level) shall be used. Servo type level instrument (with density measurement) shall beconsidered as second level instruments on tanks.

Displacement type level Instrument shall not be used.

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4.2 Requirement for field instrument

4.2.2 Level measurement The zero elevation & zero suppression are required for DP level transmitter. Stand pipes with isolation valves shall be used for LG/LTs. Maximum length for standpipes

shall be 4600 mm. 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.

4.2.3 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 drainand vent.

Mounting bracket shall be provided c/w instrument transmitter and suitable for 2” pipeinstallation for all transmitters.

The fabricated valve manifold shall be provided for all pressure measurements ,except forclose coupled hook-ups where integral manifolds shall be used. In general transmitters forhydrocarbon service shall be installed close coupled if there is any accessibility problem, thencan be installed on grid level according to installation standards with minimum length ofimpulse tubing

2-way : Pressure measurement3-way & 5-way : D/P measurement (Level & Diff pressure & Flow measurements)

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4.2.4 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 110 mm (4.5”) 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 75º 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.

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4.2.5 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. 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 testterminals 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 theinstrument.

Dual compartment housing shall be provided for all Temperature transmitters for easytermination.

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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4.2.6 Temperature Elements Thermocouple shall generally be mineral insulated ‘Duplex’ type. Type K (Class 1) shall be

used for temperature up to 1100 oC. Thermocouple shall be Ungrounded. Resistance Temperature Detectors (RTD) shall be ‘Duplex’, 3 wire type Pt100 (Class A), used

for -200 to 600 oC

4.2.7 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.

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 fromsolid type 316 stainless steel bar-stock or better material as determined by corrosiveconditions.

The line 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 to6’ according to API 551.

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 <0.8) as a part of vendor documentations.

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4.2.8 Temperature Gauge Bimetallic type only to be used. The Dial size shall be 150 mm (6”) nominal and instruments

shall be ‘every angle’ head type for visible installation.

4.2.9 Control Valves / On-Off Valves Control valve shall generally be Globe type. For higher sizes Butterfly type may be

considered depending on the application. On-Off Valves shall be Ball type with Tight shutoff (TSO) leakage class. The valve CV selected shall be larger than the maximum calculated Cv. The valve

characteristic Selected should produce a travel of 35 to 65% at normal/operating flow rate. The Combination of valve Cv and characteristic should generally produce a valve operating

range of 10 to 90% of travel for all of the flow conditions specified. The trim material for general service shall be 416 SS or alternatively 316 SS with Stellite

sheath or solid stellite minimum. The guide bushing or bearings shall be Type 440C stainless steel. An acceptable alternate is 17-4 pH SS or 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.

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. Output gauge shall be provided.

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4.2.9 Control Valves / On-Off Valves 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, andshall be supplied complete with suppression diodes.

Wherever solenoid valves are used for control valves in modulating services, the solenoidvalve shall be installed between positioner output & actuator & de-energising of SOV shallbring control valve to failure poison by venting the actuator.

A field manual reset (FMR) shall be provided for critical trip application. 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-safeposition only.

Intrinsically safe valve Limit switches shall be actuated directly from the stem / shaft. Theyshall be adjustable and unaffected by vibration. They shall be hermetically sealed. Inductivetype limit switches shall be used.

Control Valves shall be supplied, equipped & tubed with air filter regulator (with outputgauge), electro-pneumatic positioner, boosters (if required) and solenoid valves (ifapplicable). Air tubing shall be stainless steel (SS 316).

The minimum control valve size shall be 1”. Where the line size is less than 1 inch or theselected 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 flangedgenerally, valve Face- to –Face dimension shall follow API6D.

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4.2.9 Control Valves / On-Off Valves 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 metrefrom control valve body.

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

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

5. General requirement for instrumentation system

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5. General requirement for instrumentation systemGeneral 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/O’s (i.e. RedundantCPU, Power supply & I/O cards) in general shall be provided. If Vendor has to supply aPLC to control his machinery or package unit, the PLC shall be located in a suitable panel.

The method of control shall be clearly specified in the machine or package unit requisitionas 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 serialcommunication facility (Modbus) which will be connected to the plant DCS Wherever dataof the serial link will be used for calculations or non critical control loops, the serial link shallbe redundant. Commands (start, stop), trip or critical control loop signal shall always behardwired between DCS/SIS & package Unit.

Dual communication busses shall be used simultaneously, with automatic switch over to thespare bus upon failure of the primary bus. The system shall automatically check bothbusses and alarm on the failure of either one.

The serial link shall be completely commissioned in a so called “integration test” beforeshipment of the PLC/Panel. Machines or units, which are controlled by the DCS Thepackage vendor has to supply suitable software description / specification as well as toprovide suitable descriptions / date for the programming and graphic design of the DCS.

The Graphic design of vendors control system shall be inline with purchasers Graphicdesign specification .

Safety relevant systems can be integrated in the plant SIS system.

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5. General requirement for instrumentation systemGeneral 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 overallfunction and design of the machine and / package without split of responsibilities orguarantees. All other requested tests (e.g. running test, performance test etc.) shall becarried out by Vendor fully under Vendor responsibility.

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

In general, any critical trip signal which lead to a plant trip shall be 2 out of 3 (triple fieldinstruments) and provided by vendor.

5.1 General Purpose Packages (Utilities –IA Compressor / Nitrogen plant) for exampleIn general, Packages will be controlled by their own control system and shut-down safetyprotection 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 packageinterface panel. When the package is running in a steady state the local control set point maybe 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),system processors, I/O cards (inclusive of backplanes / racks / cabling, process controllers,communication cards etc) as a minimum.

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5. General requirement for instrumentation system5.1 General Purpose Packages (Utilities –IA Compressor / Nitrogen plant) for example 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/interlockscan be carried out in plant DCS/PLC system & same may be excluded from packagevendor scope.

5.2 Intrinsically Safe System Requirements Following points must be considered while designing an intrinsically safe system:All intrinsic

safety barriers shall be active type isolating barriers. Each instrument in the Zone 0 & 1 hazardous area and the intrinsic barrier shall be certified

for intrinsic safety. Each input and output in a loop shall have separate barrier. No barrier shall be shared

between two loops or inputs / outputs. 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. All barriers shall be of MTL or P&F and shall follow AVL of the main control/shutdown

systems (DCS/SIS).

5.3 Software Design Requirements 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 DCSplatform with similar specifications, shall use the identical standards and templates used forthe main plant system. The PLC / DCS configuration shall be logically structured to allowadditions, deletions and other minor modifications without causing a major programrevision.

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5. General requirement for instrumentation system5.4 Hardware Design Requirements 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 ofmonitoring the program online for trouble-shooting purposes. It shall also be capable ofstoring the logic on magnetic, optical or flash storage media for backup purposes. Thenecessary software required for package operation shall be provided by package vendor. Inthis case, no external hardware is required.

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 & thecorresponding relays shall be supplied by package vendor in package panel .

For commands & set-points originating from Plant DCS/SIS & terminating in Packagepanel pot-free contacts with contact rating 230VAC 5A shall be provided, the relays &isolators shall be supplied by DCS vendor.

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

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.

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

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

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5. General requirement for instrumentation system5.4 Hardware Design Requirements 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.

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.

5.5 System Diagnostic Requirements The system shall include a full diagnostic facility which shall intelligently identify all system

faults and failures to ensure a fully operable system is maintained. All system faults and failures shall be alarmed in the DCS, UCPs and annunciator panel.

5.6 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 device’s 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.

5.7 Cabinet Design5.7.1 Cabinets in the control room (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 removable gland plate and front & rear lift-off opening doors.

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5. General requirement for instrumentation system5.7 Cabinet Design5.7.1 Cabinets in the control room (UCP: Unit Control Panel) Control panels, in general, shall be of free standing, totally enclosed construction,

fabricated from 3.2 mm thick steel plate. 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 others on site.

Doors shall be secured by a locking system. 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.

5.7.2 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). Allnecessary cables, cable trays, cable glands, required for the on-skid wiring shall beprovided by Vendor.

The Panel shall be standard Rittal cabinet with appropriate paint for the environmentalconditions stated.

Cable entries shall be at the bottom of the cabinet.

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5. General requirement for instrumentation system5.7 Cabinet Design5.7.2 Local Control / Operation Panel in Outdoor (LCP: Local Control Panel / LOP:Local Operation Panel) 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.

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.

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).

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5. General requirement for instrumentation system5.8 Power supplies Only a single or redundant (if applicable) 110V or 220V AC 50 Hz power supply (UPS) shall

be provided to the vendor’s 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 vendor’s equipment/instrument located in the control room or field is in the Vendor’s scope, unless indicated in the Interface sketch otherwise

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.

5.9 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 15% (free space only)

15% installed spare circuits, sub-circuits and terminals distributed throughout the system and IO channels distributed amongst the various types of inputs and outputs.

6. General requirement for instrument installation

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6. General requirement for instrument installationGeneralIn general all the package vendors to supply pre assembled, Tubed & Wired Instrumentation Systems, to minimize the site construction work.

6.1 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.

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.

6.2 Process Impulse/ Pneumatic Tubing The minimum material requirements for instrument impulse tubing after the first block valve

shall be in accordance with the following: Tubing : Seamless 316 stainless steel to suit the highest design pressure/temperature

application. Fittings : Double ferrule 316 stainless steel compression type manufactured by

Parker, Swagelok make only. Impulse line valve after the first isolation valve & drain valve shall be gate valves,

except for equalization valves in case of DP transmitters which shall be globe type.

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6. General requirement for instrument installation6.3 Instrument WiringInstrumentation cables shall comply with the following requirements: SWA cables can be installed without conduit. FRP (Fibreglass Reinforced Plastics) or SS

(Stainless Steel) cable tray shall be used. All cables shall be tagged on each side of the cable. Vendor’s standard cables/wires can be used for the internal wiring in vendor’s panels and enclosure. However all wiring shall be tagged as required in general requirement for cable tag no.

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.

All cables in plant areas and between the control room and field ,also inside package vendors Battery limit shall be run overhead FRP or SS cable tray supported on steelwork and avoiding hot surfaces. The cable support infrastructure shall be of suitable materials for the area in which it is to be installed; giving consideration to mechanical strength and corrosion resistance.

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. 110/220VAC). The safety related signal cables (SIS and F&G) can be run on the same tray of non-safety related signals (DCS).

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6. General requirement for instrument installation6.3 Instrument Wiring 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 inputsf) Non-Intrinsically safe Digital inputsg) Intrinsically safe Digital outputs & SOVf) Non-Intrinsically safe Digital outputsg) Vibration signalsh) Gas & Flame Detectors.I) Power

Intrinsically safe barriers for all such signals wherever required shall be provided by vendor. Both ends of cables shall be glanded and the cable armour is to be earthed at one end only,

always in the field. 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. 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 conductive medium.

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

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6. General requirement for instrument installation6.3 Instrument Wiring Field junction box cable entries shall be at bottom only. 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.

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

For intrinsically safe certified instruments EExe IIC T4 Zone 1, 2 certified FRP/GRP/SS Junction boxes, with a minimum ingress protection of IP 65 with certified 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 EExd 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 vendor’s shop.

7. General requirement for test and inspection

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7. General requirement for test and inspection GeneralThe equipment/systems should not leave the Vendor’s premises for shipment without an operational test witnessed by the Client/PMC representatives. The following provides guidance to normal testing requirements.

7.1 System Functional TestThe FAT at system vendor works shall be witnessed by the client & PMC. Before starts to witness the FAT, the vendor shall have performed a complete system functional test in accordance with the Vendor’s standard procedure as well as a test of all the HMI displays, I/O points, digital and analogue functions etc.

7.2 Test Equipment & Simulation FacilitiesThe Vendor shall provide all necessary test equipment and simulation facilities required for witness tests, and supply manpower in order to:

• Review acceptance test criteria• Schedule and arrange test facilities• Demonstrate the system according to acceptance test criteria• Analyse and interpret test results for client/PMC personnel• Provide assistance in case of system malfunctions during the acceptance test period.

For packaged equipment linked to the main plant DCS via a serial link it may be necessary to carry out an integration test, during the DCS FAT, to confirm the functionality of the serial link, and the correctness of the Modbus mapping via actual simulation of data on the vendor communication card.

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7. General requirement for test and inspection 7.2 Test Equipment & Simulation FacilitiesA test rack shall be provided by Vendor for the Modbus test. The complete Modbus link shall be ensured and commissioned including indication on the DCS operator screen and Vendor panel screen if applicable.

7.3 Field InstrumentsAll Inline instruments and instruments connected to package control system shall be witnessed 100% for the vendor provision. All Local mounted instruments (for e.g. gauges) to be installation according to vendor’s standard or principal's standards.Testing and calibration certificates to be provided by package vendor.

8. General requirement for documentation

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8. General requirement for documentationThe Vendor shall be prepare and submit, as a minimum, the following (if applicable)documents for instrumentation1) Instrument Index2) Instrument Data Sheets (ISA standard is preferable.)3) Package Control & Interface philosophy4) Wiring Diagrams / Junction Box Termination Detail5) Hardwire Signal List (IO List) between Vendor PLC & Purchaser Control System (DCS/SIS)6) Soft wire Signal List / Serial Interface with Purchaser’s DCS7) Hardwire Signal List (IO list) for Machine Monitoring System8) DCS Graphic Plan9) Sequence / Interlock Logic Diagram & Description10) Function Description of loops to be controlled by the Plant DCS/SIS.11) Instrument Loop Diagram (Note 1)12) Instrument Drawings (by Sub-Vendor)13) Instrument Panel General Arrangement for(equipment layout and internal wiring diagram)

i) Local control panel(s) / Local Gauge Board.ii) Unit Control Panel .

14) Sizing calculation of Safety Relief Valves & Control Valves.15) Construction Drawings (if the site work is required by EC (Contractor))16) Operation and Maintenance Manual for all instruments and control system

Note 1: Instrument Loop Diagrams supplied by Vendor shall be the loops from vendor's instrument to the package control system only. In case of package instruments and interconnection signals connected to the plant DCS/SIS/F&G etc., the respective engineering contractor shall prepare the loop drawings.

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Documents

Package Unit Instrumentation Specification_TBE and VDR