03.Job Specification Instrumentaton.pdf

JOB SPECIFICATION (INSTRUMENTATION)

C4 MIX STORAGE FACILITIES PANIPAT NAPHTHA CRACKER PROJECT

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Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved

JOB SPECIFICATION AND DATA SHEETS (INSTRUMENTATION)

C4 MIX STORAGE FACILITIES

PROJECT : PANIPAT NAPHTHA CRACKER PROJECT (PNCP) OWNER : INDIAN OIL CORPORATION LTD.

PMC : ENGINEERS INDIA LTD.

JOB NO. : A535

Tender No. : A535-000-16-43-MB-T-3001

0 03.07.14 ISSUED FOR BIDS NA RK RK

Rev. No

Date Purpose Prepared

by Checked

by Approved

by

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CONTENTS

1.0 GENERAL

2.0 ORDER OF PRECEDENCE OF VARIOUS DOCUMENTS

3.0 DESIGN REQUIREMENTS

4.0 TECHNICAL SPECIFICATIONS

5.0 CONTROL ROOM INSTRUMENTATION

6.0 CABLE TERMINATION

7.0 LOOP CHECKING

8.0 MISCELLANEOUS REQUIREMENTS

9.0 COMMISSIONING SPARES

10.0 MANDATORY SPARES

11.0 SPARES & CONSUMABLES IN WARRANTY

12.0 DRAWING/ DOCUMENT APPROVAL FOR FACTORY ACCEPTANCE

13.0 INSPECTION AND TESTING

14.0 LOGISTIC SUPPORT CERTIFICATE

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1.0 GENERAL 1.1 The C4 Mix storage facilities (broadly comprising of 1 no. Horton sphere , 1 no.

mounded bullet, associated pumps, butadiene chilling system, butadiene loading pump and associated works) shall be located in the existing offsites area (also refer overall plot plan for exact locations of various equipments attached elsewhere in the tender). These works shall utilize the control system philosophy followed for existing offsites area within existing control system (DCS/ESD/F&G PLC system racks and other hardware) located in SRR#6 with serial interfacing to operator consoles located in MCR. Modifications in existing control system/additional hardware /softwares as required to meet the functional requirement specified herein. A minor part of activities /works pertaining to butadiene loading shall be located in loading /unloading area. The signals for these be controlled & operated from loading gantry control room. The EPCC Contractors scope for C4 Mix storage facilities and butadiene chilling system includes Design, Engineering (including residual engineering), procurement, supply, shop and field-testing, installation/ erection, commissioning, supply of spares, documentation, etc. on a turnkey basis for its successful commissioning and operation for the unit with all associated works, Complete field instruments including for all packages, entire cable routing within the EPCC battery limits as defined elsewhere in the bid document. This section identifies the job requirements/ specifications pertaining to the scope of EPCC for C4 mix storage facility. This specification / document shall be read in conjunction with scope of work / supply, process packages, various specifications, standards /drawings / documents, approved P&IDs, process scheme and other documents attached elsewhere in the bid document. The requirements, which have not been explicitly identified in Scope of Work but referred in this Section, are in Contractors scope.

1.2 NCP PLANT EXECUTION: The Naphtha Cracker plant consists of NCU units (i.e. NCU, C4 Hydrogenation unit, Pyrolysis Gasoline unit, Butadiene Extraction Unit, Benzene Extraction unit, AMINE TREATMENT UNIT), Poly Propylene unit & HDPE, LLDPE/HDPE Swing, CPP unit, Cooling Water Systems, DM Water / RO Plant / Condensate Polishing unit, ETP, Offsites-1 i.e. Offsite storage tanks, Loading/ Unloading area, Instrument air system, N2/O2 metering outside battery limit, Offsites-2 i.e. Raw water System, Fire Water System, Flare, and hooking up facilities in existing Panipat Refinery and marketing terminal) , MEG unit, N2/O2 unit.

1.3. Definitions: a. Owner : IOCL b. PMC : EIL c. EPC : Contractor for C4 Mix storage facilities works. d. YIL : Existing DCS system vendor in SRR#6/MCR e. Invensys : Existing PLC system vendor in SRR#6/MCR F. GE Fanuc: Existing PLC system vendor in Loading gantry control room.

1.4 BATTERY LIMIT DEFINITIONS

The scope shall include, but not limited to the following: - All instrumentation and control for C4 mix storage facility and butadiene chilling

system. - Modifications of existing control systems including supply of necessary

hardware & software as required for meeting P&ID/Package requirements as per specifications included herein.

- Supply and laying of cables including hardwired and system cables , as applicable.

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- All types of Power Supplies, that is, 110V AC Uninterrupted Power Supply (UPS), 24V DC no break, 240 V AC Non-UPS in control Rooms and its distribution for Contractor supplied equipments/control systems and free issue items.

- Cable ducts/ trenches for complete instrumentation works. - Installation of butadiene chiller package control panels (free issue to

contractor) in field and SRR/MCR. - Coordination with other package vendors for completion of job - Coordination with existing control system vendors/TFMS

vendor/Loading/unloading system vendors (M/s YIL, Invensys, Enraf, GE )for completion of job

- Any other activity not explicitly specified in this section but required as per Bid Document are also in contractors scope.

1.5 CODES AND STANDARDS 1.5.1 Contractor shall refer various codes and standards indicated in Design philosophy, f

Standard Specifications for package units 6-52-0052 in additions to EIL standards & specifications attached along with this package. All latest codes shall be considered. All the codes referred above shall be latest and if any of the codes and standards has the change in their numbering or in heading, the latest one shall be considered.

1.5.2 In general, Contractor shall carryout engineering as per IEC/BIS standards. Any

other standard, if necessary, can also be referred by contractor during the execution of the job, without diluting the basic requirements, however with prior information to Owner/ EIL. In any case contractor must furnish a list of codes and standards other than those specified in this document, which shall be followed by them during engineering.

2.0 ORDER OF PRECEDENCE OF VARIOUS DOCUMENTS

In the event of any conflict between this specification, related standards and codes, any other attachment to this package or process packages, the contractor shall follow the following documents in the order of their priority: a) Statutory requirements b) Instrumentation Job Specification c) Drawings d) Standard specifications and Installation Standards e) Codes and standards Generally, the Job specification is made to cover the specification that is not identified elsewhere. Hence, this specification shall be considered in addition to other specifications and shall be read in conjunction. Wherever this specification categorically refers to supersede another specification, this specification takes precedence. Mandatory spare requirements given in mandatory spare section shall prevail over any other specification with respect to mandatory spares. Above-mentioned documents shall take precedence over any other specification enclosed elsewhere in the bid document, in case of contradiction. In case of contradiction between any specification, CONTRACTOR shall refer the matter to PMC for clarification. PMC's decision in this regard shall be final and binding.

3.0 DESIGN REQUIREMENTS

This design requirement is an addition to Instrumentation Design Basis (6556-01-16-51-DB-02) and Design Philosophy (6556-01-16-51-DB-01) attached elsewhere. Wherever there is a contradiction, these design requirements including various Specifications/Standards referred shall take precedence.

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3.1 Area Classification 3.1.1 All Instrumentation shall be suitable for area classification as per approved area

classification drawing. For safe areas instrumentation shall be suitable for safe area. However, irrespective of area classified as zone 1 or zone 2 all Instrumentation shall be suitable for Zone-1 or Class-I, Division-1 with Gas grouping as per approved area classification drawing. In this regard please note that minimum temperature classification of instruments shall be T3 unless approved area classification drawing requires more stringent temperature class. For Zone-0 area, Zone-0 certified equipments shall be used.

3.1.2 For classified area in general, intrinsically safe philosophy shall be followed for all

inputs/ outputs in hazardous area except for MCC/PCC inputs/outputs. Contractor must select external barriers, wherever applicable, on entity concept. All barrier shall be isolating type. Contractor shall select the barrier based on the following requirements: i) The barrier shall be of latest/ enhanced available versions of makes selected or

shall be same as that of existing. ii) The model no. selected should be well proven as per the criteria specified. iii) The barriers selected should have back-up support and representative

available locally. Typically barrier selection must be made based on the following: a) Analog Inputs (4-20 mA) - Series 5000 of MTL/ Eqv. P&F b) Analog Outputs (4-20 mA) - Series 5000 of MTL/ Eqv. P&F c) Digital Inputs - Series 5000 of MTL/ Eqv. P&F d) Thermocouple, RTD Inputs - Series 5000 of MTL/ Eqv. P&F (Temperature/Current Converter (With configuration connector )- universal type) e) Digital Output - Series 5000 of MTL/ Eqv. P&F f) Proximity Inputs - Series 5000 of MTL/ Eqv. P&F In case barrier is required for any other Input / Output, the same shall be of MTL / P&F makes only. Approval of actual model number shall be obtained from Owner / Owner representative before proceeding.

3.1.3 Instruments, which are not available as per their standard design from any reputed

manufacturer as intrinsic safe, can be supplied in flameproof design. All such instruments shall be certified for the area classification.

3.1.4 Junction boxes in hazardous area shall be certified flameproof wherever flameproof

instruments are connected to junction boxes. 3.1.5 All the hazardous area instrumentation item shall be provided with Certificate from

statutory authority as per requirement. 3.2 Instrumentation Design Philosophy

The type of instruments shall be as per the requirements of process schemes, P&IDs, Engineering Design Basis, Design selection criteria for instruments and the process requirements and various specifications, standards enclosed with this bid specification.

3.2.1 Power Supply Philosophy

CONTRACTOR shall supply / distribute all types of power supplies i.e. 110 VAC UPS, 24 V DC, 240 V AC Non-UPS for instrumentation & control system including field requirements. Further distribution to control system (modifications in hardware) and field instruments/ gauges / local panels shall also be by Contractor For intrinsically safe digital inputs, interrogation voltage shall be as per requirement of intrinsically safe circuit and provided by CONTRACTOR. 24V DC interrogation voltage shall be provided for Substations/Switchgear and non-intrinsically safe inputs/outputs.

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a) The tentative load of 18KVA is required for feeding power (110VAC UPS) to various control system/MMS in SRR#6.and instruments/panels in field. The above mentioned spare capacity is available in existing UPS. Contractor shall verify the load requirement before proceeding. Any further modification required for feeding the required loads shall be carried out by contractor. Contractor to note that 110VAC DCS/PLC/Package PLC load in SRR#6 shall be considered directly for UPS ACDB in SRR#6 without isolation transformer. One feeder for non DCS load shall be considered from UPS ACDB to DCS PDB in SRR#6 (without isolation transformer). A new PDB shall be considered for the same. Further distribution to field shall be from DCS PDB. PDB for 24VDC shall be separate for each type of power supply.

b) 24V DC for DCS/barriers, etc. shall be derived from 110VAC (UPS) using redundant power packs. However, 24V DC as required to cater to F&G PLC/ESD PLC I/Os shall be considered from existing battery charger. Spares /spare feeder (1KVA) in existing battery charger to be identified by the EPCC contractor and necessary modifications to be carried out by the contractor.

c) For 240VAC (non-UPS), existing spare feeders in power panels/lighting panels or in existing 240VAC non UPS PDB to be identified and utilized in consultation with site incharge.

3.3 Cables 3.3.1 All multicables between field / local panels / control rooms shall be flame retardant as

per 6-52-0052 and shall follow the following philosophy:

a) Signals : 12 pair individually and over all shielded (4-20 mA or (screened) and armoured, twisted, 0.5 mm2

switch contact) (min.) conductor as per 6-52-0052. b) Thermocouple : 12 pair T/C extension cable (20 AWG min.) as

per 6-52-0052, wherever required.

c) RTD : 6/8 Triad 1.5 mm2 min. conductor, as per 6-52-0052, wherever required. d) Solenoid valves : 12 pair individually and overall shielded, armoured, 1.5 mm2 conductor min. as per 6-52-0052. e) LEL gas detector : 6/8 Triad 2.5 mm2 conductor min.

3.3.2 a) 1 pair cables for fire safe ROVs. This shall be fire survival type (orange colour). For special requirements refer cable specifications attached.

b) 2 triad cables shall be used for connecting duplex RTD signals to temperature transmitters.

c) For Gas detector 2.5mm2 conductor shall be used for single pair as well as 6/8 triad cable.

3.3.3 a) System cables (serial cable from MMS display unit to MMS panel in control room)

shall be free issue to contractor . Laying shall be in EPC contractors scope. b) Supply/laying of special cable from tank level instrument in filed to TFMS shall

also be in the scope of EPC contractor. 3.3.4 All system cables /FO cables shall be routed in HDPE hard pipe. Fittings shall be

used for joining the HDPE Pipe. All system cables/FO cables shall be routed in

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the middle 150mm portion of the duct. Wherever it is absolutely necessary to route these cables underground, it shall be routed in the RCC trenches only.

3.4 Junction Box 3.4.1 In general separate junction boxes shall be used for the following:

a) 4-20 mA DC signals (IS) b) 4-20 mA DC signals (non-IS) c) Thermocouples, wherever used d) RTDs, wherever used e) Contact signals (Field switches, push buttons etc.) f) Interlock and shutdown signals (Solenoid valves) g) Power supply to various instruments h) Gas detector signals.

3.4.2 Each JB shall be provided with 2 multi-cable entries with one plugged with

weatherproof plugs. One junction box shall be connected to one multicable only. Plugs shall also be flame proof for flameproof junction boxes. Multicable entry for 12 pair/signal JB shall be 1.5 NPT(F).

3.4.4 In general, Junction boxes, cable glands and accessories shall be weather proof to IP

55. However these shall be weatherproof to IP 55 and flameproof wherever connected to flameproof instruments in hazardous area. Slipper type PVC sleeves shall be used over cable glands for all cable entries in junction boxes to avoid water entry in junction boxes. Cable glands shall be provided at instrument end and junction box end and at local panel end (as applicable). For duplex RTDs and Temperature transmitters contractor to ensure that the cable gland size /entry is suitable for 2 triad.

3.4.3 The junction boxes in the field as well as in local panel shall be provided with

sufficient number of terminals to terminate all the pairs of multi-cable (including spare pairs) and shields of individual pairs as applicable.

3.4.4 3-way junction boxes shall be used for connecting the field transmitter and field

mounted analog indicator in series with control room receiver. 3.5 Installation Standards

All process hook-ups for all the instruments shall use piping installation standard & close coupled as far as possible unless limited by process temperature in line with the sample installation standards. The instrument purging and flushing shall be carried out by CONTRACTOR as per requirement of P&IDs or as required due to process condition. CONTRACTOR shall prepare the installation standard for flushing/purging, which shall include Rotameters, DP relay, Non-return Valve, Restriction Orifice/needle valve fully piped and tubed. All diaphragm seal installation shall be provided with spacer ring and Vent/Drain connection with valves and plugs. Spacer ring material for diaphragm seal type instruments shall be same as diaphragm seal material. However for diaphragm seal instruments in butadiene service shall be without spacer ring to avoid stagnation of fluid, since stagnation can cause popcorn formation.The standards for the same shall be prepared by contractor. Piping material required for installation hook up shall be as per Piping Material Specifications. Radiography, Post Weld Heat Treatment (PWHT) and stress relieving shall be carried out, if required as per Piping Material Specification. CONTRACTOR to take precaution

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with respect to welding and PWHT of valve ends so that the valve internals are not damaged. After installation of instrument seal welding shall be provided as per instruction of PMC/Owner at site in addition to the requirement of piping material specification. Based on installation standards for each type of instruments, CONTRACTOR shall prepare Bill of Material (BOM), which shall indicate the requirement of various installation materials required for installation of each instrument. Pump discharge pressure gauges are not to be close coupled but remotely located to avoid vibrations. For impulse piping of pressure gauges full threaded coupling instead of union is to be used. Unions shall be used only in Galvanised Iron lines. All the installation standards provided in the bid document shall be considered as sample/ typical (whether written or not) and contractor shall prepare the installation standards based on the guidelines / philosophy provided here. Contractor to note that instrument connection sizes on tanks, pits, pipes shall be generally followed as per standards 7-52-0001 , 7-52-0002 & 7-52-004. All transmitters, instruments and instrument connections should generally be accessible from the ground or permanent platforms. The quantities indicated in the list of items against each installation standard are tentative only and actual quantity and items shall be worked out by Contractor based on requirement. Instrument on gas service are to be installed only above or atleast parallel to the tapping with the slope in impulse piping towards the tapping to achieve self draining.

3.6 MCT Blocks New Multicable Transit Blocks shall be provided by contractor for Cable entry to SRR#6. Existing MCT shall not be used in SRR#6. Minimum indicative size of MCT frame to be considered is furnished in the attachment to the tender. However, the same is tentative and it shall be contractors responsibility to finalize the size based on calculation of instrumentation filed cables (incoming/outgoing/spares ). This shall include all multicables pertaining to butadiene chilling system, pumps etc. a) The MCT shall be sized, supplied and installed at site by contractor. Multiple

MCT blocks of appropriate size shall be provided for cable entry. b) New MCT frame with blocks has been envisaged for C4 mix storage facility and

butadiene chilling system. The MCT frames shall be of of standard RGB type of M/s Bratberg or equivalent make and of steel construction. The supply of New MCT blocks/frame, etc shall be complete with insert blocks, spare blocks, stay plates, end packing etc..

c) Contractor shall size the MCT considering 50% spare for each cable size/O.D. In addition to installed spares, Contractor shall also provide 50% spare insert blocks in each cable size/O.D. as loose supply.

d) The power cables for instruments shall be suitably separated from the other cables and shall be routed through separate MCT blocks. In general, the MCT frame considered for instrument shall not be used for electrical cables.

e) The MCT shall be installed as per the recommended practice of supplier. No spare space shall be left uncovered in the frame.

f) The electrical power and control cables shall not be routed through instrument MCTs and if necessary separate MCTs may be used for the same.

g) Suitable cutout and structural supports for installation of MCT frames on the walls of SRR#6 shall be provided by Contractor. Contractor to note that since SRR#6 is a blastproof building, special tools like diamond cutter or any other tool, as required, shall be used for installation of MCT Frame. The supply of special tools and tackles, as necessary, is in the scope of contractor.

h) For routing the cable in loading gantry control room existing MCT shall be utilized by the contractor. This shall include removal/modification/recast of the

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concrete Pit ouside the control room to facilitate the entry of cable inside the rack room to the satisfaction of Instruction of Engineer in charge.This shall include supply of all construction material asrequired for removal/ recast/ modification of all civil works.Identification of spare blocks/Frames in the existing frame of required size for the cable entry as per instruction of Engineer in charge. Removal/Insertion of cable/refixing of MCT Frame to achieve a positive seal against entry of Gas/water as per Instruction of Engineer in charge.Removal of all debris/waste material near the SRR as per Instruction of Engineer in charge

3.7 Cabling Philosophy Cable Routing 3.7.1.1 Contractor to refer Instrument cable duct /trench layout for the cable routing from unit

to the control room attached with the bid package Contractor shall provide new cable ducts as per the drawing .Walkway shall be provided for new ducts located on pipe rack for accessibility. Contractor shall provide necessary supports for cable duct to be laid on existing pipe rack /sleepers. Wherever existing pipe rack /sleeper is not available, contractor shall provide required supporting arrangement for new cable ducts. Contractor shall ensure that this supporting arrangement does not foul with existing underground and above ground facilities.

3.7.1.2 From field junction box to overhead cable duct, the cables shall be routed through angle / perforated trays. Single pair cables from instrument to junction box shall be through perforated trays.

3.7.1.3 Wherever trenches are required, new RCC trenches shall be considered. Cables shall

be laid 100 mm above the trench bottom in order to avoid direct contact with water always. All cable trenches shall be back filled with sand after cabling is completed.

3.7.1.4 All cables inside the control rooms shall be properly dressed and routed in perforated

trays under false flooring, which will be supplied & installed by the Contractor. Separate cable route and trays shall be used for signal or alarm inputs in control room.

3.7.1.5 Separate routing of following types of cables shall be planned within control room rack

room to ensure ease of cable installation and to prevent interference among the cable:

- Analog 4-20mA cables - Thermocouple extension cables - RTD cables - Contact/alarm cables - Shutdown cables (for solenoid valves) - Power cables - System communication cables Similar segregation philosophy shall be followed by contractor for IS cables also. Separation with electrical cables (LT and HT both) shall be maintained as per API guidelines or a minimum of 1500 mm.

3.7.2 Trench 3.7.2.1 Where ever cables are to be routed underground, these shall be laid in RCC

trenches. RCC trenches shall have a minimum depth of 800 mm with angle inserts provided at 100 mm above the bottom of the trench at every 1500 mm interval. All RCC trenches shall be provided with removable RCC covers.

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3.7.2.2 Each underground cable shall be provided with identifying tags of lead securely fastened every 25m of its underground length with at least one tag at each end before the cable leaves / enters the ground.

3.7.2.3 For any crossing of cable trench (underground) with electrical trench, it must be made

at 90 only and the cross-section area of the trench must be same at the point of crossing. Instrumentation trench shall be routed above electrical.

3.7.2.4 Since all local panels shall have bottom entries for cables, the cable trench shall be

used for routing cables up to panels. The length of cable trench shall be kept minimum. The platforms where panels are installed shall be raised by 150mm above the finished level.

3.7.2.5 At road crossings, pipe sleeves shall be provided by the contractor for the cable run.

Culverts shall be used wherever necessary. 3.8 110V ACUPS & 24 V DC Power Supply

3.8.1 Spare feeders available in the existing UPS distribution board shall be used.

Contractor to verify the same at site. Any modification required in the existing feeder is included in vendors scope of work

These shall cater to: a) Distribution for any local control panel (as applicable).

b) Redundant power feeders shall be supplied from UPS distribution board. c) Redundant subsystem in control room shall have separate feeders from power

distribution cabinet in control room.

3.8.2 Bulk Power Supply (BPS)

a) Power supply distribution other than 110V AC shall be provided using dual redundant Bulk

Power supply (BPS). Separate sets of power supplies shall be used for each application.

b) Wherever bulk power supply provided by the contractor for transmitter power, input

interrogation, or for any other application, the following specifications shall be taken care of:

i) Bulk power supplies shall be redundant floating with +/- 0.5 V tolerances.

ii) Separate power supplies shall be provided for controller subsystem.

iii) Separate power supplies shall be provided for powering of system (if applicable) and for

interrogation/powering of I/Os.

iv) Status indication for each power supply at operator console.

v) Switch/ Fuse for each loop.

vi) Each Bulk power supply shall be sized for 35% of loading of its capacity on normal

time; the max loading is to be 70% of its capacity of BPS.

c) All BPS shall be provided with surge protection capabilities. BPS shall also be provided

with cooling fans and BPS failure and BPS fan failure alarm indication shall be

provided in DCS.

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3.8.3 Only Copper cables termination inside control room shall be considered for UPS ACDB to PDB.

Contractor shall also refer Electrical scope of work and job specifications for UPS.

3.9 Fire Proofing: Fire proofing of cable ducts and trays shall be done by contractor in line with fire proofing standard / drawings attached elsewhere in the tender. Contractor shall refer doc no. A535-068-16-51-JS-02 (Cable duct/tray fire protection

requirements) and drawing no. A535-068-16-51-SK-1002 attached with the tender 4.0 TECHNICAL SPECIFICATIONS

4.1 Instruments

4.1.1 Control Valves

Special considerations shall be given to the selection of valve trims and body material for resistance to erosion due to noise, cavitation and high fluid velocity. The actuator shall be selected considering instrument air supply pressure of 5.0 Kg/cm2g or minimum air pressure indicated in overall design basis whichever is lower. Direct line mounted solenoid valves shall not be considered. Welded type control valves are not to be used for any service. For all valves with temperatures above 200 C, valve bonnets shall be with radiation fins / extension bonnets. For all control valves, ball and butterfly valves shall be fire safe, where required as per piping specifications or requirement given elsewhere and as per approved P&IDs. Valves shall be fire safe as per Piping Material specification (PMS). For fire safe actuator and accessories, fire safe box shall be supplied, wherever specified / required as per approved P&ID. For all control valves, the trim characteristics shall be Equal Percentage. However for valves in open-close service, the trim inherent characteristic shall be On-Off.

Contractor to note that for the control valve actuator colouring scheme shall be as follows:- Direct Acting (Open on Air failure) valves:- Green. Reverse Acting (Close on Air failure) valves:- Red. Also all the control valve shall be tagged by fixing SS tag plate. In case multiple valves are required to be installed because of controllability or rangeability requirement, the same shall be provided by contractor irrespective of representation shown in the P&ID. Smart positioners shall be considered with all control valves. Smart positioners with HART output shall be of one of the following makes:

- Fisher - Dresser - Metso - Flowserve

In addition to operational and maintenance data provided by the positioner like actual

stem position, instrument input signal, Pneumatic pressure to the actuator etc. the positioner shall also provide the cycle counting and store accumulation data to help keep control valve stem leakage in control. The positioner shall also have build in manual stroke button for stroke open or close the valve foe quick verification. Smart positioners shall be able to communicate with Universal Hand Held communicator.

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Two numbers of HHC shall be supplied by Contractor for SMART positioner. Control valves in butadiene service shall meet the following special requirements

a) Zero Emission Valves: These valves shall be designed for zero fugitive emissions. The contractor shall furnish bellow sealed bonnet, suitable bonnet gasket and stem packing and must guarantee that the valves will have fugitive emissions of less than 100 ppmv. b) Contractor to ensure that there are no copper or copper-alloys in direct contact with the medium. Copper and copper alloys are not recommended due to the possible formation of copper-acetylene compounds which can decompose in an exothermic reaction. c) Gaskets/seals, packing and soft seats shall be fabricated of graphite or Kalrez. Teflon and other plastics shall not be used in Butadiene service since they may initiate the formation of 'popcorn' (a polymer).

All limit switches shall be proximity type with suitable hardware at control room and shall be provided in a suitable enclosure. All limit switches of the shutdown valves, which are being actuated by PLC, shall be connected to the PLC. Similarly, the pumps which are being actuated by PLC, their pump running indications shall be connected to PLC.

ROVs: Valves along with actuators and all accessories shall meet the fire safe design requirements specified in 6-52-0037. "Type test certificates" for fire safe design of supplied valves, actuators & controls shall be provided by the contractor. Special requirement of butadiene service also applicable as mentioned above. The typical sketches for "Fire proof enclosure for fire safe actuator and accessories " are attached for reference. The sketch enclosed indicates the minimum requirements. In case contractor needs to provide additional accessories (quick exhaust valve, relay etc.) or increase the pneumatic tube size to meet the requirement in terms of valve operation and opening / closing time, the same shall be provided by contractor. The actual hook up drawing for offered valves shall be prepared by contractor. Contractor to note that the fire safe box shall be of two piece construction and it shall also have opening for maintenance purpose; these shall be indicated in the dimensional drawings to be submitted.

Solenoid Valves

All solenoid valves in the electrically classified area in the field shall be certified intrinsically safe with a compatible isolating barrier in the control room. The solenoid coil design shall be suitable for working continuously with the specified voltage levels. The corresponding barrier selection should ensure proper functioning, compatibility and certification considering voltage level, current levels & the coil resistance for the selected solenoid valves. The solenoid valves in the safe area shall also operate at 24 V DC and shall be similar to intrinsically safe solenoid valves except for hazardous area certification requirements. All solenoid valves shall be certified weatherproof to IP-55 as a minimum, in addition. Contractor shall categorically analyze selection w.r.t cabling distance, type of cable, barrier selected, before finalizing make/model.

4.1.2 Pressure Relief valves and rupture discs Vendor to note that 20% overpressure shall be considered while sizing pressure relief valves when the cause of overpressure is 'External Fire'. IBR Requirements.

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a) All valves under IBR service shall be tested and test certificates in Form III C shall be furnished duly undersigned by IBR authority or its approved representative. b) For valves under IBR service, Carbon contents in steel shall not exceed 0.25% for flanges, body parts etc. or any part that may require welding. Moreover the sulphur and phosphorous shall also be limited to 0.05% each. c) All valves on steam service with overpressure requirement of 5% or specified in data sheets requiring IBR sizing shall be sized as per IBR design code. d) IBR certificate in Form III item 11 for construction certificate of manufacture and test shall be furnished for the pressure relief valves in steam service with design code as IBR. The pressure relief valves shall be of the 'full nozzle, adjustable blow-down type' design, in accordance with API RP 520 and ASME 'Boiler and Pressure Vessel Code', section VIII. The pressure relief valves shall be safety-relief type (suitable for the application and service). Minimum inlet rating of pressure relief valves shall be 300#. Pressure relief valves relieving to flare shall always have a closed bonnet. Thermal relief valves discharging to flare /variable back pressure shall be bellows type with minimum size of 1D2. The valves in Butadiene service shall be designed for zero fugitive emissions. For butadiene service, no copper or copper-alloys shall be in direct contact with the medium. Copper and copper alloys are not recommended due to the possible formation of copper-acetylene compounds which can decompose in an exothermic reaction.

Where ever required, DIERS Analysis shall be carried out by contractor. Contractor shall perform the required DIERS Analysis check and furnish sizing calculation both as per API and as per DIERS Analysis. In case increase in pressure relief valve size is warranted as per DIERS Analysis same shall be selected and supplied by contractor. Wherever rupture disc has been shown/required along with the pressure relief valve as per Process / P&ID, Contractor to note that the rupture disc shall be installed upstream of the pressure relief valve. Pressure transmitter with indication to control room shall be provided downstream of disc to indicate any rupture. Rating of rupture disc shall match with the inlet flange rating of PSV.

4.1.3 Field Transmitters 4.1.3.1 Contractor shall provide all transmitter of SMART type. 4.1.3.2 The contractor shall supply 2 nos.universal hand held communicators for field

transmitters. In addition to hand held communicators, contractor shall supply chargers for charging communicators of field transmitters.

4.1.3.3 The hand held communicators shall be universal type and suitable for all makes of transmitters.

4.1.3.4 Response time of the SMART transmitters shall be in commensurate with the process. It shall be equal or better than half of the scan time of the control loop specified else where in this package.

4.1.3.5 The square root extraction for the differential pressure based flow measurement shall be carried out in the smart transmitter if the accuracy of the transmitter as specified could be maintained throughout the range even after square root extraction.

4.1.3.6 All the transmitters should have horizontal impulse entry only for easy interchangeability without impulse modification in future.

4.1.3.7 For differential pressure transmitters with tappings at long distances, separate pressure transmitters are to be considered and difference to be made at DCS.

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4.1.3.8 For the draft range transmitters with range less than 750 mm WC instead of 500mmWC mentioned in the design philosophy, the calibrated accuracy shall be .0.15% of span within a turndown of 1:10.

4.1.4 Temperature Transmitters

The Temperature Transmitters shall not be an integral part of the temperature element but shall be a separate field mounted instrument receiving the signal from the temperature element. Temperature transmitters shall have double compartment housing. Also Transmitter shall be provided with dual sensor connectivity with hot swapping feature

4.1.5 For DP transmitter, integral valve manifold shall not be co-planer type. Conventional

type valve manifold shall be provided 4.1.6 For temperatures above 250 deg C, thermocouple with local indicator shall be

considered in place of Bimetallic gauges. 4.1.7 Loop Powered Indicators

For applications requiring indication remote from the transmitter, at both local/local panel as well as at the Control Room, the CONTRACTOR shall use intrinsically safe loop powered indicators in series with the field transmitter and the Control Room receiver instruments. Make of the loop powered indicators shall be MTL Series 600 or equivalent, for local panel mounting (for the Units which are classified as hazardous). For safe area instrumentation, weather-proof (IP-55) indicator shall be provided; however, wiring shall be same as indicated above. However for loops in control/ interlock with local indications, Analog output from DCS shall be used for providing signals/power to loop indicators. Connection in series in such cases shall not be allowed.

4.1.8 Orifice plates Orifice plates upto 12 shall be considered with flange tapping. For line size greater than 12 , D-D/2 tapping shall be considered. For orifice plates in butadiene service, padded flanged taps shall be provided at 2.5D and 8D at upstream and downstream respectively. Also note that for accommodating padded nozzle on small lines, lines shall be blown to minimum 8 for 150# rating class and 10 for 300# rating locally. Orifice plate size shall be in line with the blown up line size. Diaphragm seal FT suitable for mounting on these padded flanges shall be provided.

4.1.9 Tank level instrumentation/ TFMS Two radar s and one servo gauge shall be used on sphere and mounted bullets. LSHH shown on bullet shall also be radar type LT. One radar on sphere/bullet shall be with 4-20mA & connected to ESD PLC for interlock actuation. The other radar and servo shall be connected to existing CIU in existing TFMS system. Spares are available in existing CIU. Any modifications as required for interfacing of the same shall be in contractors scope. Modifications in software as required like building of graphics, configuration of tags, etc in existing TFMS PC , data transfer to DCS & loading/ unloading PLC in loading gantry shall be carried out by contractor by utilizing the services of specialist of existing system vendor. The field instrument shall be suitably selected so as to be compatible with existing TFMS system. The nozzle sizes for LT (Radar) shall be 8 flanged with 8 Stillwell and LT (servo) shall be 6 flanged with 12 still well. Rating of flange shall be as per vessel rating/piping class. Sizes of nozzle are indicative only. In case lower size of nozzle is required based on selected vendor, the same shall be acceptable. However, nozzle size on vessel to be suitably coordinated by the contractor. The size of nozzle for Pressure Transmitter shall be 3 flanged. The multipoint Temperature element shall be

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3 flanged with Stillwell. The Stillwell for temperature element shall not be provided with perforations. Also refer datasheets of tank level indicators attached elsewhere in the tender.

4.1.10 Gas detector Gas detector (sensor/transmitter) shall be connected to F&G PLC to be located in SRR#6. Refer gas detector datasheet and standard specification attached with tender.

5.0 CONTROL ROOM INSTRUMENTATION 5.1 Control System

Contractor shall be fully responsible for proper engineering, integration , installation, performance and operation of all equipments including I/O and marshalling racks & bought out items supplied by them as per requirement including site survey, data collection, verification and identification of all requirements. In case of conflict in any of the engineering requirements, the most strigent requirement shall be followed while engineering DCS/PLC. The operation of butadiene chilling system and C4 Mix storage facility shall be done from the existing control systems (DCS/PLC) in SRR#6/MCR/LGCR as per P&IDs. Supply of additional hardware / software including necessary modifications required in the existing control systems to cater to new I/Os shall be part of contractors scope. The existing operator consoles (DCS/PLC) shall be used for the monitoring, control, logics and shutdown of the unit. Necessary changes in graphics/ logics shall be carried out in the system. Required configuration of existing and new tags shall be in contractor /DCS vendors scope.

A sketch of the existing system configuration with the proposed modifications is enclosed for reference. Contractor to submit a revised sketch indicating the modifications proposed pertaining to C4 Mix storage facility.

Any co-ordination required with existing system for supply of additional hardware & software as well as software configuration shall be in EPCC contractor scope. The DCS/PLC system cabinets, marshalling cabinets etc. shall be located in the rack room whereas the operator console shall be located in the console room. The color, dimension (i.e. height & depth) of the new cabinets & consoles shall match with the existing system.

5.2 The drawing and documentation which are required for engineering of DCS/PLC shall be prepared by CONTRACTOR, and shall be based on general philosophy followed for the existing unit which will be furnished to CONTRACTOR at the time of detailed engineering. The correctness and completeness of these documents shall be the responsibility of the CONTRACTOR.

Schedule for the preparation and submission of drawings and documents for Control System engineering shall be as agreed mutually between CONTRACTOR and PMC/Owner, after the award of contract. Contractor shall participate in the following activities of DCS engineering of their unit and for the following major issues for the successful commissioning of the unit with field and control system fully integrated: - - Kick-off Meeting at DCS/PLC Sub-vendor's works/PMC/Owner/

CONTRACTOR'S office (at the discretion of PMC/Owner). - Engineering w.r.t DCS/PLC & furnishing DCS related engineering inputs

/documents to DCS vendor. - Review of DCS/PLC Sub-Vendor drawings/documents. - Factory Acceptance Test at DCS/PLC Sub-Vendor's works.

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- Site activity including field testing; Loop checking, test run, site acceptance and commissioning of the unit.

- Site engineering. 5.3 For preparing Hardwired Console drawing contractor shall note the following:

All the hardwired push buttons / selector switches as indicated / required (manual reset of trip, manual activation of trip, control room reset for solenoid valves etc.), auto start / stop logic for pumps and other packages shall be indicated on HWC layout drawing with appropriate tag no. and legends. Contractor to verify the space available on the existing hardware console for mounting new pushbuttons, switches, alarm annunciators.

5.4 Instrument I/O list shall be prepared by Contractor based on the P&IDs for the purpose of finalizing DCS/PLC hardware requirement. Blank format is enclosed. Contractor shall take care of the following points while preparing I/O count:

a) Operation of all ROVs & deluge valves & indications of ROVs shall be considered from F&G PLC.

b) Any cause like level high in sphere etc. which actuates pumps/ROVs/compressors, etc (except gas detector) shall be connected to ESD PLC. Interconnection (hardwired) shall be considered between ESD PLC & F&G PLC for actuating the ROV from F&G PLC. However, activation of respective interlock pumps/compressors shall be from ESD PLC.

5.5 The control system philosophy shall be in line with existing plant philosophy with regards to redundancy, scan time requirements, loading requirements & other operational/ engineering related requirements. In general 6-52-0055, standard specification for DCS/PLC shall be followed. However , wherever existing control system specification overrides 6-52-0055, the same shall override & be considered to maintain uniform plant philosophy.

5.6 HMS

In order to aid maintenance of field instruments & smart positioners, a dedicated HMS exists in SRR#6. This has connectivity to all I/Os. This system interacts with all smart transmitter and positioners to provide a) Monitoring of device (Smart Transmitters and Smart Positioners/Control Valves)

status on-line. b) All maintenance related data like diagnostics alarms, transmitter range, settings

etc. c) Trend Data for all devices. d) Facility to re-range, configure and calibrate field transmitters and smart

positioners remotely. e) An audit trail for a complete historical record of all configuration, calibration and

device alerts. f) Data on predictive maintenance such as list of transmitters experiencing drift,

control valves loosing as shipped characteristics etc. g) Advanced diagnostic features like device step response, device signature,

dynamic error band etc. h) Documentation like various trend reports, Diagnostic reports, predictive

maintenance reports, audit reports, historical data and device specification sheets in addition to those available with selected software as stand-alone.

All hardware as required like HMS MUX/Slave patch cards in line with existing cards shall be provided and the same shall be interfaced to the existing HMS PC. Contractor shall consider new cabinets for installation of hardware pertaining to HMS for all I/Os in line with existing philosophy.

5.7 Make and model no. of existing hardware used in DCS /PLC is indicated below. The same shall be followed as far as possible to maintain uniformity.

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TABLE :- MAKE & MODEL No. OF MAJOR COMPONENTS TO BE FOLLOWED INLINE WITH EXISTING SUPPLY

Sl No. Item Description Make Model

1 DCS System Hardware

i. Distributed Control System Yokogawa CS 3000

ii. Processor card for FCS Yokogawa CP451

iii. Power supply card for Nodes Yokogawa PW481

iv. Field control station Yokogawa AFV10D

v. Analog I/O Card - 8I + 8O Yokogawa AAB841

vi. Analog Input Module - 16 Channel Yokogawa AAV141

vii. Analog Output Module - 16 Channel Yokogawa AAI543

viii. Digital Input Module (32 Channel) Yokogawa ADV151

ix. Digital Output Module (32 Channel) Yokogawa ADV551

x. Serial Communication Module Yokogawa ALR121

2 PLC System Hardware

i. Enhanced Tricon Main Processor-II, 16 MB SRAM Triconex 3008

ii. Trinconex Communication Module Triconex 4351B

iii. 32Pts TMR Analog Input Module Triconex 3700A

iv. 32Pts TMR Digital Input Module Triconex 3503E

v. 32Pts TMR Digital Output Module Triconex 3625

vi. 110/120VAC/DC High density Power module Triconex 8310

vii. I/O bus expansion cables Triconex 9000

3 Cabinets Rittal

4 Barriers/Isolators & Relays

i. Analog Input isolators MTL ICC212

ii. Analog Input Barrier MTL 5042/5043

iii. Analog output Barrier MTL 5046

iv. Temp. Converter (T/C input/ RTD Input) MTL 5074

v. Digital Input/ Prox Sw Input Barrier MTL 5011B

vi. Digital Output Barrier MTL 5021

vii. Hart Mux Slave MTL 4842

viii. Hart Mux Master MTL 4841

ix. Relays for Input (MCC+others) OMRON G2R-2SND-24VDC

x. Relays for Outputs (MCC - HT motors) TELEMECHANIQUE LC1-D12BL

xi. Relays for Contact Multiplication OMRON MY-4ND2-24VDC

xii. Push Buttons/Relays/ Emergency Push buttons/Mimic

Lamps/Selector switches

IDEC

5 24VDC Power Supply Unit. TDK Lambda HWS600-24

6 Diode oring unit (suitable for above PSU) TDK Lambda D600-B-24

7 PC and Server HP

8 Network Switches Netgear

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9 Printer HP

5.8 Job methodology for carrying out modifications in control system to be decided by

the contractor. In the interest of contractor following is proposed:

- Undertake a site survey to ascertain the required hardware/software to meet functional requirements in line with existing system.

- Identification of proper hardware & software necessary for interface. - Engineer the complete system based on the requirement specified including

re-engineering or engineering modifications in the existing system where these changes are being effected.

- System configuration and generation based on the actual requirements. The generation shall also be carried out for those existing part of system, which is affected by these additions.

- Vendor shall study the impact of the new additions on the existing system and prepare a Functional Design Document with following chapters: System Description System Configuration Hardware system requirements Hardware modification on the existing system Software System requirements Software modification requirements Modified Software Graphics Functional Schematics

- Hardware modifications and / or rearrangement and / or additions / deletions required to accommodate new system hardware / software requirements.

- The loading of the new tested software after incorporating all hardware modifications. The switch over from the existing system configuration and application to new application software shall be smooth and shall not result in shutdown of the existing system

5.9 System Modification/ Change Management

- Contractor shall carry out all the modifications/ changes/ revisions necessary to be incorporated and pointed out at the time of FAT including graphic changes, wiring changes, I/O assignments, logic changes etc.

- Contractor shall carry out all changes/ modifications/ revisions which are to be carried out during installation including additional inputs for sub-package items, configuration of new tags, termination changes, incorporation of cable schedule connections, modification and addition of new graphics modification of group trend history etc.

- Contractor shall carry out any changes required during loop checking and pre-commissioning activities such as range change, graphic display changes, reassignment of I/O, termination changes etc.

- Contractor shall carry out changes/ modifications required in the system during commissioning and start up due to operational requirements like graphic changes, tag reassignment, tags new assignment, history trend and grouping, format changes, set point range changes, logic modifications etc.

- Contractor scope shall include incorporation of all such software/ hardware configuration, engineering changes that may occur for normal engineering project execution.

- Contractor to support the site till commissioning of unit and SAT without any implication to owner.

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5.10 Contractor is required to get prior approval from Owner/ EIL in case he plans to sub- contract a part of their job to any other Vendor. The handling and storage of the equipment at site shall be contractors responsibility for all equipments supplied by them. Non air conditioned ware house shall be provided for storage of system at site. Contractor shall store the equipments at their own risk and cost. Handling of material at site is Contractors responsibility.

5.11 Programmable Logic Controller (PLC) PLC shall be with TMR configuration of Triconex make with SIL3 certification as a minimum. The PLC shall be sized considering I/Os and other sizing requirements like scan time, CPU loading etc . The sizing calculations shall be reviewed during detail engineering. Contractor shall be fully responsible to supply number of PLCs as required meeting above requirements and approved sizing calculations. The main PLC processor and I/O cards replacement should be possible on line without compromising the plant safety and TUV guidelines. The PLC system shall have high availability. In case of two out of three (2oo3) inputs in PLC, the inputs shall be wired in three different cards. For 1oo2 the inputs shall be wired in two separate cards. TMR PLC I/O modules for DI,DO &AI not involved in 2oo3 configuration shall be provided with installed hot standby modules for on-line replacement. All PLC I/O signal shall be two wired, with no looping or common sharing of power supply or negative points. All MCC digital inputs/output, Field input/output (Non IS) shall be connected through interposing relay. All intrinsically safe DI shall be provided with barrier. All connectivity between Hardwired consoles (in MCR) and DCS & PLC system cabinets in SRR#6 shall be hardwired. The supplied PLC must have a provision of sequential time stamping of all alarm inputs and outputs with a resolution of at least PLC scan time. The scan time of programmable controller shall be less than 500 milliseconds. Instrumentation shutdown and interlock shall be de-energizing to trip.

5.12 Documentation Node (DON) Existing DON for SRR#6 shall be utilised. Preparation / loading of all required software documents required as per the existing philosophy already adopted along with any additional licenses shall be in Vendors scope.

5.13 Other requirements

Contractor shall provide following furniture: Furniture for two numbers of workststions and two no. of printers shall also be provided. The make/model shall be as per the existing furniture already supplied in SRR#6.

5.13.1 Contractors scope of work includes but not limited to the following a) Installation of all new DCS/ PLC cabinets/items and free issued package vibration

monitoring system cabinets and other system cabinets (marshalling cabinets, relay cabinets, operator consoles, PDBs etc.) in MCR and SRR#6. Base frame of cabinets shall be provided by the contractor. The structural frame where ever required shall be fabricated out of minimum ISMC 100x50x6mm channels and 50x50x6mm angles of MS.

b) Any civil work necessary with respect to fixing and finishing for new cable entry, any fixing & finishing required for structural fixing, floor finishing, etc shall be taken care of by the contractor.

c) Removal, modification and refixing of existing false floor tiles & existing chequered plates as applicable. Any addition structural support, if required, for false flooring shall also be provided.

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d) Installation of all owner supplied equipment and free issued equipments/items including cabinets, panels etc

e) Contractor shall provide necessary cable tray/duct inside the SRR#6/MCR/loading gantry control room for laying of cables below the false flooring.

f) All engineering /software modifications for configuring inputs in existing UHN/ AIMS/ DON as per the existing philosophy.

g) FAT/ SAT procedures shall be such that all functionalities specified in tender document are included.

5.13.2 The following shall be considered for all bought-out items: All bought-out items/sub-systems shall be fully tested at manufacturers shop prior to shipment by manufacturer to vendor works for integration. All such test reports shall be submitted to owner/consultant/TPI for review.All the bought out items shall be commissioned and site accepted in the presence of manufacturer representative. P&IDs will be given elsewhere in the bid package, which will be used for preparing functional schematics, graphic diagrams, Logic diagram, etc. Cause & effect chart/ diagram have been indicated in the P&ID For preparing/implementing logic diagram. The system and documentation and instruction manual CD/DVD shall be submitted with proper labelling with CD storage/carry case and not loosely. Contractor shall carry out tuning of controller, complex control scheme simulation, and interlock simulation at site during field testing. Procurement and Engineering done by Contractor on third party procurement if any shall be certified by original equipment manufacturer. Contractor to ensure the accessories/ peripherals of PC shall be as per the existing configuration. Graphic, control Groups, Trends, logs and reports shall be approved by purchaser prior to start of engineering/ implementation. General cleaning of system and daily housekeeping in the existing SRR#6 will be done by Contractor till the mechanical completion of the facilities. Necessary civil works for the package cabinets which will be free issued to Contractor for installation shall also be in contractors scope.

5.13.3 All cable trays shall be Pre-fabricated galvanised Iron perforated trays. The cable trays shall be made out of Mild Steel sheets of 2.5 mm thickness in standard lengths (section) of 3000mm and clear width of trays shall be 60, 100, 150mm, 200mm, 300 mm. Cable trays shall have horizontal array of holes of 10mm diameter at every 300mm of tray length for cable clamping purpose. Gaps between holes shall be less than 40mm. hot dip galvanising for the cable trays shall be carried out as per IS-4759 after fabrication of trays. The amount of galvanizing shall be 66 m / 460 g/m2. All surfaces shall be free from defects such as burrs, sharp edges, projections etc. Each section of tray shall be supplied with required accessories such as connector plates, nuts, bolts, washers etc. required for connecting ends of each tray section. Connector plates, nuts, bolts, washers etc. shall be hot dip galvanized.

The construction of cable trays shall be such as to facilitate easy handling, assembly and installation at site. The workmanship shall be such as to ensure easy laying of cables without causing damage of cables. The connections between two sections of cable trays shall be done by bolting only. Connector plates shall be designed with sufficient strength without derating the load carrying capacity of the tray. The side rails for each section of trays shall have holes on each end for fixing the connector plates.

5.13.4 Cable glands for all types of cables inside SRR#6 for field cables shall be in contractor scope. All cable glands shall be Ni plated Brass, double compression type.

5.13.5 Cabling Philosophy inside SRR#6

All cables inside the SRR#6/UPS Room/loading gantry control room /MCR shall be properly dressed and routed in perforated trays under false flooring which will be supplied & installed by the contractor. Separate cable route and trays shall be used

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for signal or alarm inputs. Similar segregation philosophy shall be followed by contractor for IS cables also. System cables shall be routed on perforated trays below false flooring and shall be provided with conduit after the system cable emerges from false floor so as to ensure protection from rodents and also have mechanical protection. The segregated cables shall be routed in separate cable trays in rack room below false flooring immediately after entry into control room. Separate routing of following type of cables shall be planned within control room/rack room to ensure ease of cable installation and to prevent the interference among the cables:- - Analog 4-20mA cables - Thermocouple extension cables - RTD cables - Contact/alarm cables - Shutdown cables (for solenoid valves) - Power cables - System communication cables Separation with electrical cables shall be maintained as per API guidelines.

5.13.6 Free Issue Instrument/ Equipment Details

Some of the items shall be free issued by owner to the contractor. Installation of these in SRR#6 shall be in contractors scope under supervision of respective instrument, equipment supplier/ package vendor. contractors scope shall also include; - Supply of all interconnecting cables between free issue items & DCS/ PLC

including serial cables, supply, laying, glanding, feruling and termination at both ends.

- Glanding, feruling and termination of all field cables in respective cabinets in SRR#6 Glanding (if required), feruling and termination of all serial cables,with DCS systems. Hardware installation and provision of power supply (if any) required for interfaces.

- Powering up of these items including providing power feeders for each of these individually with switch fuse unit in power supply distribution cabinet, supply and laying of power cable between (PDB) and each of these items including glanding, ferruling and termination at both ends.

- Proving of the links including necessary co-ordination with the Package/ System vendor of these equipments.

- The serial links, in general are MODBUS protocol. However if any other protocol is provided, Vendor shall consider necessary hardware/ software for connectivity and integration in contractor scope.

- For the sub package vendor cabinets, installation of the cabinets is in Contractors scope. Details of cabinets and location shall be furnished during detail engineering. Consider approx. 8 nos of cabinets.

5.13.7 Field switches (Ex Proof), wherever used, shall be connected through interposing relay.

5.13.8 For bypassing the field inputs for operational and maintenance requirements from MOS soft switch from existing PLC console, existing MOS enable selector switch already available in Hardwired console shall be utilised. All PLC interlock graphics shall also be replicated on DCS operator consoles. Bypassing shall be event recorded and logged with date and time stamping.

5.13.9 Non-IS potential free contact inputs shall be interfaced through interposing relays.

5.13.10 Outputs to MCC, other non-IS devices shall be interfaced through interposing

relays.

5.13.11 For control systems where the architecture necessitates that the transmitter power supply be segregated from controller power supply and the input/output power

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supply, the system shall be designed with capability to discriminate between transmitter failure and zero signal value. The detection of the transmitter failure shall be alarmed and shall cause the controller output to be held at the prior valid signal output value until the operator takes action by transferring the control to manual.

5.13.12 All the system provided by Vendor shall be upward compatible i.e. new enhancements can be incorporated in the system for future up gradation. Any updation in software of existing system due to new version used during addition of new system shall be suitably taken up by Contractor

5.13.13 Application software shall be designed in a manner that requires no modification to the system operating software. Software design shall be such that future revisions or updates of the system operating software will not affect the successful operation of the system.

5.13.14 All software, exclusive of application software, shall be the most recent revision that is applicable to the system hardware at the time of the hardware freezes date. The system shall allow for upgrading of system operating software on all redundant modules of the system without the necessity of shutting down the process, without losing the operator interface and without the loss of access to any control function.

5.13.15 Application software shall not require modifications in order to be able to run under new releases of the system operating software. Any new release of system software shall be backward compatible with files created using the previous software releases.

5.13.16 Contractor shall provide Vendors principle recommended antivirus software. 5.13.17 For proximity probe input to PLC/DCS shall be provided with IS barrier cum pre-

amplifier. 5.13.18 Type of report generation shall be finalized during detail engineering by

operation/process department of client. 5.13.19 In case of cascade control, minimum scan time of tags as applicable is to be

considered for both the controllers. 5.13.20 For all split range applications, the controller shall provide two independent output

signals one for each control valve. 5.13.21 For DCS /PLC inputs, the repeat indication in field shall either be in series with

transmitter (if in open loop) or through DCS/ PLC (if used in interlock/ control loop). 6.0. CABLE TERMINATIONS 6.1 Panels / Cabinet Wiring / Termination

a) All interconnection between field and rack room shall be from Marshalling racks only. All interconnection between marshalling racks and system cabinets within the rack room shall be through prefabricated cables with plug-in connectors at both ends.

b) Contractor to provide separate marshalling cabinets for field cables and cables from MCC, if spare space in the existing cabinets is not sufficient. For all intrinsically safe signals marshalling shall be done in the barrier cabinet. Separate cabinets shall be used for digital and analog barriers.

c) All interconnecting cables between cabinets/printer/console etc. shall be armoured or run through conduits to protect from rodents.

d) Contractor shall be fully responsible for sizing of each cabinet/ rack/ panel to ensure sufficient maintenance space. A cabinet/ rack/ panel found congested at any stage of project execution shall be replaced by the contractor without any implications.

e) All the panels and cards of the systems shall have corrosive environment protection coating as per G1 of ISA S 71.04 .

f) For all cabinets, the circulation of air must be through suitably designed fans with failure alarms to PLC (diagnostics) and the sizing of the fans shall be to meet the maximum heat load of the cabinet.

g) All the cable entry/wiring entry/exit shall be through bottom plate only with suitable glands.

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h) The ferruling philosophy / type shall be decided during detail engineering based on overall philosophy for the existing Panipat refinery.

i) Cabinet lighting shall be 230 V AC non-UPS only and the lamps shall be white threaded type. One no. additional socket shall be provided in each cabinet for use of other testing devices.

6.2 Isolating Barrier

All signals of classified hazardous area i.e. analog input, digital input, thermocouple /RTD input, pulse input, proximity switches are intrinsically safe. Similarly analog output & digital output to solenoid valves shall be intrinsically safe. Exceptions are analog inputs from explosion proof/flameproof instruments or safe area and digital input from Substation/Switchgear or explosion proof/flameproof instrument or safe area. Digital inputs / outputs to Substation/Switchgear/MCC shall be without barrier, but shall be provided with relay isolation by Contractor. The field transmitters shall be smart type with HART protocol. The isolating barriers considered by EPCC contractor for the control systems to be supplied by EPCC shall meet the above requirements. For cases where signals are from safe area, contractor shall consider appropriate termination panel, series resistance etc. as required to meet the functionality. Similarly for explosion / flameproof instruments, contractor shall provide suitable external isolators. For intrinsically safe input, DI interrogation voltage shall be as per barrier requirement supplied from the barrier or control system. Isolating barrier shall be provided for all analog inputs if it is required for input isolation. For Units classified as safe area, intrinsically safe isolating barriers are not required for inputs as well as outputs connected to the Control System as identified above. For such cases, external isolator for analog input/output, T/C, RTD, pulse input and relay isolation for DI/DO shall be considered. In case PLC analog and other inputs have in built galvanic isolation, external isolators are not required. Similarly for DI, if PLC has opto isolation, no external relay isolation is required, for DO relay interface shall be provided. However, hardware as required for connecting PLC shall be supplied. CONTRACTOR shall supply suitable cable based on the distance for connecting to these barriers. Output barrier selected for SOV circuit shall be decided based on SOV coil specification, distance, cable parameters etc. to arrive at compatible SOV, cable and barrier combination. Barrier for SOV shall be so selected that maximum output voltage is available to SOV.

7.0 LOOP CHECKING

EPCC CONTRACTOR is totally responsible for all the work related to loop checking including cable laying, dressing, identification, ferruling & tagging, termination, calibration, loop testing. The detailed procedure is as outlined in standard specification for instrumentation works 6-52-0052 and other Standard specifications. Contractor shall follow the same for all control systems being supplied by EPCC contractor. For loop checking: Contractors scope is to lay all single, multipair cables upto control room from the field location of Instruments/Junction Boxes/Local Panels/Local Cabinets, including the installation of Multi Cable Transit (MCT) Blocks as per MCT Vendors recommendation, laying of all cables through MCT till the Cabinets in control room , tagging of all field cables, performing continuity/insulation test of cables, identification of all cables and core and dressing of cables inside the control room, the glanding of cables to DCS/PLC system cabinets including the supply of cable glands. Loop checking pertaining to butadiene chilling system and free issue pumps is also included in the scope of EPCC Contractor.

8.0 MISCELLANEOUS REQUIREMENTS 8.1 Proven Track Record (PTR)

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The instrumentation selected for the units shall be rugged in design and must be well proven in the hydrocarbon industry. Prototype design or equipment of experimental nature or design undergoing testing etc. shall not be selected and supplied. Following criteria must be applied before selecting a particular instrument item:

a) For Instrument Items (Other than Systems)

The instruments as being offered / supplied should have been operating satisfactorily in hydrocarbon industry like Refinery, Petrochemical and Gas Processing Plant under similar process conditions for at least 4000 hrs.

8.2 Vendor List

Vendor List for Instrumentation items is provided elsewhere in the Bid package. CONTRACTOR shall consider the instrument supplier as identified in the Vendor List. Vendor list provided in the package is for the Make only, and not for any specific Model. For any instrumentation item, the offered model for the same must meet the specification and proven track record (PTR) requirement.

8.3 Electrical-Control & Instrumentation Interface Electrical-Instrumentation interface is the connectivity with respect to substation with

the Control Room and field. The interface required is in the following areas:- 6 Substation to Control Room / rack room / local control panel for power cable

to UPS and DC system and non-UPS load for cabinet lighting, receptacles etc. 7 Control signals between Substation/Switchgear etc. and control system.

No signal from field related to electrical system shall enter through Rack Room. Similarly, no power cable from Sub-station shall enter through Rack Room. Only Control signals directly connected to the Control System of Instrumentation & Control shall enter through the Rack Room. Separate entries shall be provided for the same.

8.4 Factory Acceptance Testing of DCS/PLC and any other critical System shall be witnessed by OWNER/PMC at their discretion. The factory testing of system shall be carried out with all auxiliaries, marshalling rack etc, fully wired.

8.5 Cable Duct (Wherever required on the proposed new route)

The ducts & RCC trenches as indicated in instrument duct/trench layout is in CONTRACTORS scope. Instrument cable duct shall be fabricated using galvanised sheets and other galvanised structural members. Perforated trays used shall be galvanised iron. Galvanizing for instrument cable duct shall be as per IS 4759/1984. a) For thickness less than 5mm, thickness of galvanizing shall be 66 micron /460

g/m2. b) For thickness 5mm and above, thickness of galvanizing shall be 86 micron

/610 g/m2. Ducts shall be fabricated as per EIL standard 7-52-254. Cable ducts shall be supported at the bottom longitudinally on both edges, throughout its length by means of MS channels (minimum 100 mm) to avoid sagging due to cable weight. The cable ducts running on the pipe rack shall not have hot line above or below or on any side. No steam line should run near to the cable duct. The same is applicable for any other cable trays.

8.6 Heat Tracing And Insulation

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8.6.1 Heat tracing and insulation of line mounted instrument, instrument impulse lines shall be carried out as per line specifications. Similar philosophy shall also be followed for equipment mounted instruments.

8.6.2 For all steam traced lines, a suitable type of steam trap must be provided for proper

and efficient tracing. Separate dedicated steam trap shall be used for each instrument. Steam trap shall preferably be located on ground level with its outlet connected to drain funnel or as advised elsewhere in the package.

8.6.3 Wherever electric tracing is shown in the approved P&ID and selected for instruments

and instrument lines, this must be suitable for the line temperature rating. 8.6.4 Steam tracing shall be avoided inside any room / or shelter. Typically, heat tracing

required within analyzer shelter shall be carried out using electric tracing. 8.6.5 Insulation of all in-line instruments like control valves, safety valves etc. shall be done

as per the line requirements. Also all direct equipment mounted instruments like level gauge, displacer/float type instruments etc. shall be properly insulated as per insulation requirements of the equipment on which these are installed.

8.7 Painting Requirement

Painting of mild steel installation material, instrument supports and structural supports shall be as per the technical specification of shop and field painting attached else where in the bid package.

8.8 Instrument process data may or may not be available in full or part in the Package.

CONTRACTOR shall prepare Process datasheets for all instrumentation in extreme case where no data is available for any instrument, and complete instrument process data sheets where data is partially available. Based on the same, instrument data sheet/specification shall be prepared. Sizes for Control Valves and Pressure Relief Valves if provided in the P&IDs are indicative only. CONTRACTOR to verify all Sizes and procure or carry out detailed engineering based on the same. Contractor shall size where these are not provided. For all Flow Instruments, particularly Orifices, if any change in line size is required, the same shall be carried out by CONTRACTOR after approval from PMC/Owner. The increase/decrease of line size/instrument is in contractors scope. Contractor shall execute the project based on various specifications/Standards, etc. in this bid documents. In carrying out so there will be some differences from the P&ID. As a part of residual engineering, CONTRACTOR shall correct/update the P&IDs as procured/engineered. Wherever there is a change in the P&IDs due to various specifications, the same shall be incorporated in the as-built P&ID by CONTRACTOR.

8.9 Wherever interface level measurement is there in the vessels, level sketches for the

same shall be submitted for PMC/Owner review. 8.10 All electronic field instruments shall be provided with a canopy. Canopy shall be

prefabricated and metallic with a suitable coating. 8.11 Spare Instrument air tapping points, if available, on the main air header can be

considered for instrument air supply to the new control valves. For the existing valves, which are being replaced by the new ones, the existing valve shall be dismantles and kept in the store. Care shall be taken while dismantling so that the existing air connections (from I/P converter/ air filter regulator) shall be used. Any tubing, fittings, glands required for the same shall be in the scope of the contractor.

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9.0 COMMISSIONING SPARES

Commissioning spares shall be supplied as required for commissioning the plant. The same shall be included in CONTRACTORs Bid. CONTRACTOR shall procure these spares as per recommendation of Vendors/Suppliers and these shall be available at the time of commissioning. These shall include all instrumentation and control items including for sub-package items.

10.0 MANDATORY SPARES REVIEW Mandatory spares shall be dealt separately. Purchase Specifications (PS)/ Purchase

Requisitions (PR) approved/reviewed shall not be considered as acceptance of mandatory spares if it is part of PS/PR. All the mandatory spares shall be addressed for each item separately after all procurement is over. CONTRACTOR shall prepare separate transmittals for mandatory spares, which shall identify list and tag number (where applicable) with the basis. CONTRACTOR shall prepare format for such submission for PMCs approval for each item. The mandatory spares already reached site shall have receipt note from Owner/PMC or its representative and same shall be attached with the transmittal.

11.0 During warranty period, CONTRACTOR shall supply all spares and consumables for Instrumentation and Control items. CONTRACTOR shall provide warranty maintenance services and supply of spares for maintaining an uptime of 98% for each system. i.e. PLC, local control panel etc.

Any fault shall be attended within 72 hrs. 12.0 DRAWING/DOCUMENT APPROVAL FOR FACTORY ACCEPTANCE

All the drawing/document submitted by CONTRACTOR shall be for approval or review or for record as detailed elsewhere in Drawings / Documents requirement section. For system and an individual item when inspected at shop shall be based on drawing/documents marked with approval/review code or for record by PMC and approved by CONTRACTOR. CONTRACTOR approval can be provided on Code-1 document/drawing or record marked by PMC only.

13.0 INSPECTION AND TESTING 13.1 All instruments and system oriented items shall undergo factory testing and inspection

by third party inspection as defined elsewhere in the tender document. 13.2 The inspection and testing for complete instrumentation & control system shall be

carried out as per related standard specifications, international codes and practices/standards, approved documents and/or any other document attached along with specifically suggesting testing to be carried out at manufacturers works.

13.3 No system or system oriented item shall be dispatched without integrated factory

testing witnessed by TPI / Owner. The testing procedures shall be detailed out by contractor based on testing requirements indicated in individual system specifications and shall be approved by TPIA.

13.4 Inspection and testing requirements as per 6-52-0052 shall be referred. 13.5 Contractor shall submit all test records / test results for records to purchaser as bound

volume along with the test procedure for each test carried out. 13.6 Acceptable criteria for Radiography and other NDT requirements for all the

instruments / instrument castings shall be inline with those specified in valve / piping

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specifications for the similar service. Valve specifications/piping specifications have been attached elsewhere in this package.

13.7 IBR Certifications shall be provided by contractor in the appropriate for