Tender-document-6LNG-992fa0.pdf - Bharat Petroleum

TECHNICAL SPECIFICATIONFOR INSTRUMENTATION

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Rev. 0 LNG Unloading, Storage & Dispensing Stations in the State of Tamil Nadu & Kerala 1 of 33

9.2 SAFETY SYSTEM

PLC based ESD System shall be considered for safe shutdown of plant. The ESD system will perform thefollowing functions regardless of the availability of the SCADA.

a) Monitor emergency conditions and take appropriate automatic shutdown action.

b) Respond to manual requests for shutdown from the operator consoles.

1. ESD system shall be designed in accordance with IEC 61508 & IEC 6151 and shall be fail safe in such away that:

a) PLC shall be configured in fail-safe manner considering Processor/ I/O module/ Power supply failure.

b) Failures in the ESD system will de-energize the relevant system components causing actuators tomove to the tripped (safe) position.

c) All wiring and relays shall be designed in a fail-safe manner such that all relays are normallyenergised, and all contacts normally closed (normally means here process normal condition and not nopower condition).

d) For outputs which require no power normally but energise to shutdown (e.g. Breaker operated motors,Dual coil solenoid valves etc.) the contacts to shut down must close on emergency or on powerfailure. Alternatively, contractor to select normally close philosophy for signal transfer from ESDsystem to MCC.

2. Various safety interlocks and measures will be configured in the system.

a) Gas detectors shall be mounted at strategic locations to detect any form of gas leakage. Trip at 40% ofLEL and alarm at 20%LEL.

b) Low and high-temperature sensors shall be mounted at specific locations (such as near vaporiser inletflanges, near pump skids etc) which can monitor the ambient temperatures. In case of spillage, theyshall detect the low temperature (-75 Deg C) and actuate alarms/trips.

c) In case of any fire, the Flame detector shall also detect high temperatures and PLC shall take actionaccordingly.

d) In addition, switches shall be provided which can be actuated manually in case the operator/mechanicsees any emergency condition. ESD push button will be installed in the entrance/exit of process area,offloading area, at refuelling area.

e) Failure of main power, instrument power or air/nitrogen.

f) Control & Monitor the process and carry out relevant automatic operations. All the fieldinstruments/Equipment’s such as pressure/level/temperature/flow shall be connected to PLC.

g) SCADA system shall be connected to PLC so the operation and status of all valves, Processparameters, Alarms etc are visible on the PC screen provided. The SCADA system shall be reliable,field proven.

9.3 SURGE PROTECTION DEVICE

Surge protection devices (SPD’s) shall be provided on the system to limit the surge voltages reaching beyondthe safe limits, under normal, abnormal or lightning strike condition. Additional SPDs shall be providedapart from inbuilt surge protection devices.

a) Unless otherwise specified, SPD's shall be provided at least at the following locations:

b) All serial signal connections (UTP / STP / coaxial and not fibre optical), Ethernet signal connectionsgoing from or to control system for each port. Including spares serial and ethernet port.

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Rev. 0 LNG Unloading, Storage & Dispensing Stations in the State of Tamil Nadu & Kerala Page 12 of 33

c) All power incoming cable (110V AC, 110V DC, 230V AC, 24V DC etc), UPS and non-UPS, at thepower supply distribution cabinet.

d) All links to the telecommunication system (including WAN Routers, Ethernet Links etc)

Note – Surge protection device shall have;

a) KEMA/VDE certification

b) Test certificate/test report for confirming for rating (Voltage, nominal discharge current, surgehandling capacity etc) from NABL accredited lab.

9.4 SCADA

The SCADA will be the central information and control centre for all the devices and equipment’s in theplant.

SCADA server shall have two dedicated LAN port A & B for redundant communication. PLC shall havetwo dedicated ethernet communication ports for communicating with SCADA system. Redundancy willbe switched over to standby automatically for maintaining the uninterrupted data flow. For SCADAsizing supplier to refer I/O list.

Communication protocols between SCADA server and PLC shall be on Ethernet TCP/IP.

SCADA Server shall be OPC Compliant. The necessary software license for both OPC server and OPCClient mode shall be provided for future use.

1. SCADA server shall consist of following, as a minimum. Suitable High-performance Intel Xeon quadcore, 3.0 GHz with hyperthreading each core.

· Shall include features such as redundant power, redundant fans, mirrored memory or online sparememory, embedded RAID capability.

· Min. 16 GB RAM

· High-performance floating-point co-processor / functionality integrated with the main processors

· Min.21” flat screen TFT LCD monitor with alphanumeric & functional keyboards mouse.

· Built-in high-performance graphics accelerator co-processor providing features like text scrollingacceleration and window performance enhancement

· Min. 200 GB SAS disc drive.

· DVD (R/W) drive.

· Real time clock.

· Network Controller: 2 Fast embedded redundant Ethernet ports Multifunction Gigabit ServerAdapters.

2. As a minimum requirement, SCADA software shall have the following facilities:

a) System and Database configuration.

b) Data Acquisition from the PLCs generation and management of real time database over ethernet.Generation and management of historic data for trending and archival.

c) Alarm handling, including storage, display and printout.

d) Generation, storage, presentation of mimic diagrams with dynamic information on MMI monitor.

e) Display Management for Alarm, Alerts, Mimic diagrams, Analog and digital values, Trend graphs,Bar charts in high-resolution color graphic modes.

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f) Free format report generation, storage and printout.

g) Data logging at periodic intervals, on operator request and automatically on occurrence of an event.

h) Transmission of control commands and configuration parameters to outstations.

3. Display Requirements

a) The SCADA MMI shall support a comprehensive range of displays to enable maximum operational,engineering, maintenance and planning benefit to be obtained from the system.

b) The Operator / Engineering Workstation displays to be split in such a manner to ensure proper viewability and legibility covering all the facilities and covering all the signals & controls as per SCADAtelemetry database document.

c) The soft keys/buttons for accessing P&ID diagrams, station schematic displays, SCADA systemstatus displays, SCADA reports shall be available at all the time for direct access. Further displaysshall have navigation built-in covering Page forward, Page backward, Page up, Page down facilitiesindicating the corresponding names of the displays for navigation.

d) The following types of graphics shall, as a minimum, be made available as applicable.

· Master and Sub Index Displays

· stations/Field overall status display

· Station Displays

· Alarm and Event List Displays

· Data Trending

· Bar Graph Displays

· Electrical parameters

· Configuration Management Displays

· Database Review Displays

· PLC status display

· Communications status Displays & Communication statistics displays

· SCADA System Utility, Support & Diagnostic Displays

· System Resource [CPU, Memory, Disk loading]

· SCADA reports

Contractor shall size both the servers and MMI capability considering as per I/O count as per P&ID.

4. Control room SCADA shall be equipped with following facility

a) Data Servers (real time server), SQL Server for Historization along with one number of 21” monitorsas OWS (Operator Workstation) on latest Windows (Operating system) for “monitor and Control”with client application, Microsoft office with supporting hardware.

b) 16 port LAN switches (L3)

c) A3 Size color laser printer

d) PLC system

e) Emergency shut down push to lock type buttons

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f) Operator console with revolving chair as per control room equipment layout and console drawings,printer drawings.

Control room consoles shall be designed and constructed as integrated assemblies, comprisingoperator station, shut-down push buttons, lamps, etc.

g) Printer Desk

9.5 PLC

The PLC shall be microprocessor based programmable units with both erasable ROM and RAM.Memory.. System shall have its own processor, memory, power supply unit & communication processorsand I/O cards complete in all respects. The complete system shall be supplied with all its componentsincluding the cabinets and additional memory card slot.

1. Redundancy will be provided such that in case of failure of main processor the standby processor shalltake over automatically without any bumps. No single mode failure shall affect the system. In case offailure of complete processor system, output shall take fail safe state automatically. System will haveFollowing Redundancy considered:

a) Redundant CPU

b) Redundant CPU power supply units

c) Redundant communication port LAN A and LAN B with SCADA system

2. PLC shall have dual Ethernet ports (configurable independently) for TCP/IP communication withSCADA system

3. Configurator software licenses shall be preferred in software (software key) form instead of hardware(dongle).

4. PLC configuration and diagnostic tool should preferably have provision to warm restart of PLC.

5. The PLC shall comprise the following subsystems:

a) Central processor with system software.

b) Analogue input

c) Contact (digital) input

d) Contact (digital) output

e) Modbus Serial ports configurable (RS 232/485)

f) Ethernet port (Redundant)

g) Diagnostic port

6. It shall have a self-diagnostic feature and software watchdog timer devices to monitor & report thehealthiness of CPU, memory, power supply, comm. interfaces and Input/ Output modules at the localLevel.

7. It shall be capable of updating process parameters data and configuration data in its own built-in memory.Time stamping of all field values at PLC level. In the event of failure or break of communication linkbetween and PLC It will continue to scan all parameters and update its database.

8. It shall support communication protocol supporting report by exception to prevent unnecessary datacommunication when the data is not changing.

9. PLC shall have following Min. scan

Maximum Scan Time (Digital signal) 250ms

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Maximum Scan Time (Analog signal) 500ms

Maximum Scan Time (Close loop) 500ms

Maximum Scan Time (Open loop) 1 Sec

9.6 ENCLOSURES

1. Field mounted panels / cabinets will have a minimum degree of protection IP 65 as specified in IEC60529 and will have extended shelter/canopy for operator maintenance in the event of rain or direct sunradiation. Material of construction for ‘Ex d’ local panel will be Die-Cast Aluminium. The panels will besuitably certified for the zone of installation.

2. Control room mounted cabinet will have minimum IP 42 for control room mounted panel as specified inIEC 60529. Control cabinet or marshalling cabinets will be standard with RAL 7035 color. Ventilationslots will be provided with screens to prevent the ingress of dust, vermin, insects and water. Ventilationfans will be provided on door for air circulation with door filters.

3. All these panels and cabinet will have bottom cable entry and all wires/cores of the incoming multi-pair/multi-core cables will be terminated with proper segregation between IS, Non-IS and power cables.Terminals inside the panel/cabinet will be suitable for cable termination up to 2.5 m² or as required,disconnect type terminals as a minimum.

4. Cable entry into field mounted cabinets/local panels will be through certified cable glands of SS withPVC Hood grounding ring. Cable glands will be dual certified for Ex’e’ and Ex’d’. Irrespective of JBcertification.

5. Only Active barriers/isolators will be employed for IS signals. Zener barrier will not be used. There willbe minimum 20% free space available in the cabinets. Local panels will be provided with enough lightingfor maintenance & operational reasons, by means of fluorescent lamps.

6. Internal panel wiring will be flexible single core (stranded copper), PVC insulation, 600 V grade with aminimum cross section of 1.0 mm2. Power wiring associated with the panel lighting will be a minimumcross-sectional area of 2.5 mm2. Wiring colors will be as follows:

a) Blue: 24Vdc (-ve), White: 24Vdc (+ve) (IS signal wiring)

b) Black: 24Vdc (-ve), White: 24Vdc (+ve) (Non-IS signal wiring)

c) Brown: 240Vac live, Yellow: 240Vac Neutral

d) Black: 24Vdc (-ve), Red: 24Vdc (+ve) (Power wiring)

e) Green/Yellow: Earthing, Safety Earth

f) Green: Instrument Earth.

7. Panel shall be provided with indication tentatively

a) Power On

b) Control On

c) Alarm

d) Alarm Acknowledgement

e) Unloading Operation

f) LNG Regasification Operation

g) LNG Dispensing in operation

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9.7 SPARES PHILOSOPHY:

This philosophy applies to all sub-systems, accessories, barriers, relays, terminals, lamps, pushbuttons etc.Seller shall include following mandatory spares in their scope of supply:

1. MANDATORY SPARES

Installed Engineering Spares to the tune of 20 percent for each sub-system and for each type of module.The basis is explained below:

a) 20 percent spare input/output of each type shall be considered for calculating the I/O modules andrelated accessories.

b) For all serial input/outputs, 20 percent serial I/O ports of each type shall be provided.

c) 20 percent spares for relays, switches, lamps, fuses, circuit breakers, barriers, isolators, terminalsetc.

d) Spare pairs of the incoming cables shall be terminated on spare terminals in the cabinets.

Engineering shall take into account 20 percent installed engineering spares including processorloading.

2. SPARE SPACE REQUIREMENT

a) 10 percent usable spare space for installing additional I/O modules in future, Internal wiring for thesame shall be completed up to I/O terminals.

b) Each operator console shall include 20 percent usable spare group and related display capability.

c) I/O racks of PLC shall be provided with 10 percent usable spare space for installing additional I/Ocards of each type in future. Internal wiring for the same shall be connected upto I/O terminals.

d) Usable spare space in panels and cabinets to install 10 percent hardwired items like relays, switches,lamps, terminals etc.

3. SPARE MODULE

Seller shall supply mandatory spare module such as CPU Module, Power supply module, I/O Module,Communications Module as per SOR for future use.

4. COMMISSIONING SPARES

Seller shall supply all spares required to replace failed modules, subsystems or faulty/corrupted softwareduring the commissioning period.

5. RECOMMENDED SPARES

Seller shall recommend and supply all spares required for two years smooth operation

6. EARTHING AND SHIELDING

All metal parts (e.g. doors, swing-out racks, etc.), enclosures, etc., shall be earthed to safety groundingsystem.

Seller's documentation shall include specification for the overall grounding and signal cable shieldingarrangements required for equipment in the control room.

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7. TESTING

Testing of system shall consist of:

a) Pre-Factory Acceptance Test (Pre-FAT)

b) Factory Acceptance Testing (FAT)

c) Pre SAT & Site Acceptance Testing (SAT)

d) Test Run

8. PRE-FAT

Pre-FAT shall be conducted based on the approved FAT document and the same shall be duly witnessed& cleared by the system engineering group of the Contractor.

During the Pre-FAT testing phase, the Contractor shall ensure that the system performs according to therequirements of tender, FDS & other finalised engineering documents and furnishes the writtenundertaking to the CLIENT in this regard, prior to offering the system for FAT to CLIENT.

Contractor shall submit pre-FAT report for our review before FAT call. Pre-FAT shall be conducted asper the approved FAT procedure and on real or project specific component with observed results. Pre-FAT test shall cover minimum aspect as specified in FAT clause. Pre-FAT result shall be verified duringFAT.

All subsystems shall undergo a minimum of 72 hours burn-in period.

System shall undergo functional testing as part of powerup testing., which shall include the

following:

a) System hardware functional testing including redundancy

b) System software testing

c) Application software testing - Database verification, loop configuration check, display

verification, trending, logging reports, security functionalities, verification of logics, verification ofsystem diagnostics etc.

9. FACTORY ACCEPTANCE TESTING (FAT)

The FAT document shall be prepared covering all hardware, software and system functionalities includingsystem expansion requirements of tender & FDS. Factory acceptance test will be done based on thestipulations in the approved FAT document, which shall completely fulfill the contract requirements andapproved FDS documents.

FAT shall be carried out in Contractor’s premises.

The system testing shall cover the following aspects as a minimum:

a) Visual and mechanical testing to ensure correct, proper, good and neat workmanship.

b) Demonstration of the complete system functionalities, hardware & software compliances wrt allthe equipment’s including PLCs.

c) Checking of complete database definitions for the proper system configuration.

d) Testing of system passwords and security features.

e) Checking of various log formats, reports, archiving functions.

f) Checking of system loading w.r.t PLC, memory, disk, as per the requirements.

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g) Checking of system diagnostics for all the equipment’s as per the requirements, power failure andsystem restarts.

h) Redundancy check for dual communication channel.

i) IO & Serial communication checking by simulation

j) System building procedures and verifications.

k) On/Off Control and various sequences and interlocks as per Operation and Control Philosophy ifany

10. SITE ACCEPTANCE TESTING (SAT)

a) The SAT document shall be prepared for PLC & SCADA system and Contractor to submit it onemonth in advance to CLIENT’S/CLIENT’S REPRESENTATIVE for review and approval.

b) SAT shall involve integrated testing of complete system including third party devices withexisting SCADA system. Site Acceptance Testing will be done based on the stipulations in theapproved SAT document. Once the test is successfully performed, then the system would beready for commencement of test run.

c) SAT shall be conducted by the experienced system-engineering group of the Contractor (earlierinvolved in system design, engineering, integration & FAT).

d) Checking of hot standby functions, switchover of data channels to meet the system functionalrequirements without any loss of data and operation.

11. DOCUMENTATION

Seller shall furnish all documents for the supplied system including the following:

· System Architecture/Configuration diagram· Functional Design Specification· FAT Procedure· SAT Procedure· Test certificates· Specifications of hardware including supplier name (sub vendors also shall be indicated.)· Specification of all subsystems· Bill of Material listing all hardware including model number, part/serial number, weight etc.· Instruction and Installation manuals· Documents and drawings such as:

a) General Arrangement drawings for all the panels, cabinets, hardwired consoles indicatingdimensions internal construction and weight.

b) Channel base frame drawing

c) Input / Output assignment

d) Graphics

e) System grounding details

f) Panel wiring diagrams

g) Power supply distribution diagrams

h) UPS load details

i) Heat dissipation details

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j) Logic Diagram

k) Loop wiring drawings for all the loops, which will show all details including field junctionterminal number, cable number, bus address, device address, power supply connections etc.

l) Hardware design manual, software design manual and software specifications Start up andpower-on Procedures

12. WARRANTIES:

Vendor shall provide warranty for the performance of ESD & SCADA SYSTEM for 18 months from dateof dispatch or 12 months from date of installation, whichever is later.

In addition, vendor shall also include comprehensive extended warranty of 3 years commencing from thedate of expiry of warranty

During the entire warranty period as, above vendor shall carry out the preventive checks (half yearlyvisits) besides attending to break downs within a period of 72 hours. The scope of the vendor shall alsoinclude the spares, tools & tackles etc., visit of service personnel and other travelling/boarding expensesreplacement of defective parts free of cost, if any. However, suitable assistance (unskilled labor andlifting tools) if any, required for attending the service/repairs will be provided by the owner.

9.8 FIELD DETECTOR

All Gas detectors shall be suitable for outdoor installation, certified for use in electrically hazardous areaunless otherwise specified, all gas detectors shall be provided with dust guard, splash guard and shunshield / canopy. The pre-dominant wind direction should be considered with respect to the potentialsource of leakage to ensure positioning of the detector on the downstream side of the wind direction.

1. Flame detector

Features Requirements

Sensor : UV /IRRange : 25 M/80 Ft (Uv/Ir)Response : < 10 SecVison Cone : 90 Deg Horizontal & VerticalPower : 10-28 Vdc (12-24 Vdc Nominal)Output : 4 -20 mA , Alarm output (Connect 2A)Local Indication : Yes, for normal operation and faultHousing : Glass Reinforced Polyester, UV Resistant,Sensor Testing : AutomaticEnclosure Class : IP65Accessories : Mounting Bracket, Nut & Bolt

Note: Detector shall have Good resistance against the influences of:

- Direct and reflected sunlight

- Artificial light

- Electric discharges (static or from e.g. electric motors)

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- The radiation from electric welding

2. Methane Gas Detectors

Features RequirementsDetection Principle : Catalytic CombustionSampling : DiffusionRange : 0-100% LELOut Put Signal : 4- 20maPower Supply : 10-30VDCLoad Impedance : 600 OhmAccuracy : +/- 2% F. S. (Calibration Point)Response Time T90 : <15sEnclosure Class : IP65Installation : 2” Pipe-Holding/Wall-MountingOther Output Signals : Alarm 30VDC/2A, Normally Open/ClosedHousing Material : Aluminum AlloyAccessories : Mounting Bracket, Nut & BoltNote: -a) Set of fully equipped calibration gas kit consisting of at least 2 (two) cylinders / bottles of

calibration gas (of known mixture of air and gas), a pressure regulator with gauge, flexible tube /hose, adapter cap (to fit sensing head) shall be supplied to enable online calibration of Gas detectors.

b) The Bidder shall indicate distance limitation if any between Sensor and Monitor.

3. Portable Gas Detector

Hand-held type Portable Gas Detectors shall be supplied for measuring hydrocarbon gas from 0% to100% by Volume, 0% to 100% LEL and 0% to 25% by volume of Oxygen as well. Portable GasDetectors shall be supplied complete with its controller, audio visual alarm and shall be suitable(preferably intrinsically safe) for use in hazardous area specified.

Such units shall be certified by PESO, BASEEFA, CENELEC, FM, PTB, CMRI etc. These units shall besupplied with rechargeable batteries (240V, 50 Hz AC battery). Sufficient number of batterycharger/number of points per charge shall be provided based on quantity of such portable units. Theseunits shall be supplied complete with all accessories like carrying case, maintenance kit, calibration kitetc.

4. Beacon Cum Sounder

The Beacon color shall be 'ORANGE' for flammable gas detection.

The beacon shall be of stroboscopic type and shall be of sufficient intensity to provide visibility and clearcontrast during full daylight.

The hooter shall be electronic type with different tones shall be provided gas releases. Both Beacon andhooter units shall operate at 24 V DC and shall be certified explosion proof (flame proof) when installedin hazardous area.

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Beacon light shall follow the following sequence:

Gas leakage detected - Flashing beacon light Hooter continues

Control room acknowledge - Flashing beacon light Hooter stop

Gas leakage stops - Flashing beacon light Hooter off

Control room reset - Beacon Off & Hooter Off

Beacon

Flashing color - Orange

Ingress Protection - IP 65

Material of Construction - CAST Aluminum Alloy LM6

Finish - Inside & Outside light grey Epoxy Powder coating

Terminals - 2 nos. 3/16" Stud type terminals

Cable Entry - Two. Entries, spare entry to be plugged with suitable plug

Supply Voltage - 24 V DC or 48 VDC

Note: Beacon flashing frequency shall be 1 flash/sec

HOOTER (Indoor)

Ingress Protection - IP 65

Material of Construction - CAST Aluminums Alloy LM6

Finish - Inside & Outside light grey Epoxy Powder coating

Terminals - CLIP - ON Type Terminals

Sound Level - 90 to 110 db @ 3 Mtr.

Supply Voltage - 24 V DC or 48 VDC

Cable Entry - Two. Entries, spare entry to be plugged with suitable plug

Field Mounted Reset - Push Button

Temperature Range - 0-49 Deg C

Relative Humidity - 10-93%

9.9 Installation Material Specification

1. The impulse tube shall be SS316, Compressed type ferrule fitting such as ½” / ¼” NPT (M), NPT (F)fittings (male/female connectors), ½” / ¼” tee, ½” / ¼” union including ½” / ¼” isolation needle/ballvalves & other accessories shall be SS316.

2. Instrument Impulse tubing

a) 1/2" OD x 0.065" and 1/4" OD x 0.065" (if applicable) wall thickness, seamless, fully annealed 316stainless steel tubing shall be used.

b) Tubes shall be cold drawn as per ASTM A 269.

c) Hardness of the tubes shall be Rockwell RB 70 – 79.

d) Maximum working pressure shall be 153.0 kg/cm2 at 38DegC. for 1/2" OD Tube,

e) unless otherwise specified and 80.0 kg/cm2 at 38Deg C for ¼ “OD tube.

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3. Compression fittings

a) Compression fittings shall be of the two-ferrule type in 316 stainless steel.

b) Fittings shall be of flareless compression type and four-piece (for double compression type)construction consisting of two ferrules, nut and body suitable for use on SS tubes conforming toASTM A 269 TP 316 with hardness in the range of RB 70 to 79.

c) Hardness of the ferrules shall be in the range of RB 85-90 so as to ensure a hardness difference ofthe order of 5 to 10 between tubes and fittings for better sealing.

d) Nuts and ferrules of a particular size shall be interchangeable for each type.

e) Spanner hold shall be metric.

f) Threaded ends of fittings shall be NPT as per ANSI B 1.20.1

g) Specific techniques like silver plating shall be used over threading in order to avoid jamming andgalling.

h) It shall be ensured by the contractor that all fittings shall match the seamless ½” / ¼” OD SS 316instrument tube with wall thickness of 0.065” conforming to ASTM A 269.

4. Instrument valves and manifolds

a) Vendor shall supply instrument valves (miniature type) and valve manifolds wherever required.

b) Body rating shall be as per piping class or higher.

c) Valve body and trim material shall be 316 SS unless otherwise specified. Superior trim materialshall be selected as required by process conditions. Packing material in general shall be of PTF

d) The isolation valves for instrument service shall be 316 stainless steel, unless process conditionsrequire another material.

5. Cable Ties

All cable ties shall be constructed from black PVC and have a breaking load greater than 20 kg. Theyshall be of a self-locking style and non-slip but shall be releasable for the addition of extra cables. Cableties for use on trays shall fix into the tray slots (two-piece ties).

6. Nameplates Tags labels

The nameplates, tags and labels for identifying junction boxes, instruments, panels, cabinets, etc shall be

made from engraved trifoliate

10.0 INSTRUMENT CABLES

10.1 Design & Construction

1) Cables shall be Flame retardant low smoke (FRLS) type and fire resistance type for Fire & Gasdetection, Valves for ESD service.

2) Fire resistance cable will be multi core copper conductor, Mica tape with overlap as fire resistancelayer Extruded XLPE insulated per IEC 60092-351, Braid of copper wires designed to act ascollective screen, SHF1 sheath as per 60092-359.

3) fire resistance cable shall be tested for fire resistant properties 750 Deg C for 3 hours as per IEC60331-31.

4) Voltage Grade of cables shall be 650/1100 V.

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5) Cable shall be supplied in drum and negative tolerance in cable length for each drum shall not beacceptable.

6) 1T x 1.5mm² shall be used for gas detection system. Quad cable shall be used for RTD. Single pairor two pair cable shall be used from field instruments to junction box.

7) Multi pair cable individual and over all shielded shall be used for all the along signals from junctionbox to control room and panel to panel inside the control room as applicable

8) Multi core over all shielded cable shall be used for all the digital input /output signals from junctionbox to control room and panel to panel inside the control room as applicable.

10.2 Single Pair and quad Shielded Cable

1) Each core shall be 1.5 mm2 made of 7 stranded annealed electrolytic copper conductor. Each strandshall be 0.53 mm dia.

2) A pair shall have twisted cores and number of twists shall be not less than 10 per metre. Colour ofcore insulation shall be black blue in pair and black, blue and brown in triad.

3) Individual pair shall be shielded. Shield shall be Aluminium backed by Mylar/polyester tape withthe metallic side down helically applied with either side 25% overlap and 100% coverage. Minimum shieldthickness shall be 0.05 mm. Drain wire shall be 0.5 mm2 multi-strand bare tinned annealed copper conductor. Thedrain wire shall be in continuous contact with Aluminium side of the shield.

4) Inner and outer jacket shall be made of extruded flame retardant 90oC PVC to IS 5831-Type ST2.Oxygen index of PVC shall be over 30%. Temperature Index shall be over 250°C. The thickness of the jacket shallbe as per IS-1554 Part 1.

5) Inner jacket colour shall be black. Outer jacket colour shall be black except, for cables to be used inintrinsically safe systems it shall be light blue. A rip cord shall be provided for inner jacket.

6) Armour over inner jacket shall be galvanized steel wire as per IS-1554 Part 1.

10.3 Multipair Cable with Individual Pair Shield and Overall Shield:

1) Generally, the cable shall be same as single pair shielded cable except conductor sizes shall be 0.5mm2 made of 7 strands of annealed electrolytic copper conductor. Each strand shall be of 0.3 mm dia.

2) Overall shield shall be of Aluminium backed up by Mylar/polyester tape helically applied with themetallic side down with either side 25% overlap and 100% coverage. Minimum shield thickness shall be 0.05 mm.Drain wire shall be similar to individual pair drain wire and shall be of the overall shield.

3) A pair of communication wire shall be provided for multipair cables. Each wire shall be 0.5 mm2 ofplain annealed single or multi-strand copper conductor with 0.4 mm thick 85°C PVC insulation. Insulation shall begreen and red colour coded.

4) Pair identification shall be with numbers at interval of not more than 250 mm as per vendor’sstandard.

10.4 Multipair Cable with only Overall Shield

These cables shall be same as above except that the individual pair shall not have shielding.

10.5 Electrical Characteristics

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Resistance:

Maximum DC resistance of the conductor of the completed cable shall not exceed 12.3 Ω / km at 20oCfor cables with 1.5 mm2 conductors and 39.7 Ω / km at 20oC for cables with 0.5 mm2 conductors.

1. Capacitance:

Mutual Capacitance:

The mutual capacitance of the pairs or adjacent cores shall not exceed a maximum of 250 pF / m at afrequency of 1 kHz.

Capacitance between any core or screen:

The capacitance between any core or screen shall not exceed a maximum of 400 pF / m at a frequency of1kHz.

L/R ratio of adjacent core shall not exceed 40 μH / Ω for cables with 1.5 mm2 conductors and 25 μH / Ωfor cables with 0.5 mm2 conductors.

The drain wire resistance including shield shall not exceed 30 Ω / km.

Electrostatic noise rejection ratio shall be over 76 dB.

10.6 Control Cable

Control cables will be of single core copper conductor, PVC insulated (Type A), Extruded XLPEinsulated per IEC 60092-351. Braid of copper wiers designed to act as collective screen, overall Fireresistance, UV resistance Extruded orange halogen free polyolefine, SHF1 Sheath as per 60092-359 core.

Core identification of multi-core cables is by coloured strip applied on the core as per IS 694 /IEC 60227.

The cable shall be tested for fire resistance properties 750 Deg C for 3 hours tested as per IEC 60331-31.

10.7 Inspection and Testing

OWNER reserves the right to test and inspect all the items at the manufacture’s works.

Manufacturer shall furnish documents such as test certificates to prove the quality and composition of thematerials used for manufacturing the cable to the satisfaction of OWNER/OWNER’s Representativeduring expediting and inspection.

1) Type Test:

a) Type Certificates shall be furnished.

b) Cable shall be flame retardant to IEC 332-3 Part 3 Cat A.

2) Routine Tests:

a) These tests shall be carried out by manufacturer during various stages of manufacturing.OWNER shall review the related documents.

b) Insulation and Sheaths: All tests as per IS-5831 except insulation resistance, voltage and sparktest shall be as per BS-5308 Part 2.

c) Armour test as per IS-3975.

d) Conductor resistance.

e) Cable capacitance, L/R ratio.

3) Acceptance Test:

These tests shall be carried out in the presence of OWNER / OWNER’s Representative.

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4) Continuity test:

a) Voltage test as per BS-5308 Part 2.

b) Conductor resistance and drain wire resistance.

c) Cable capacitance and L/R ratio test.

d) Electrostatic noise rejection test type wise for each lot.

e) Tests for uniformity of galvanization of armour as per IS-2633.

f) Oxygen index test as per ASTM D 2863, temp. index test, smoke density rating test, acid gasgeneration test and flammability test.

g) Dimensional check for overall diameter and under armour/over armour diameter.

h) Overall finish check. In case of any lump purchaser shall have the right to cut outer sheath forlump portion and reject the cable.

i) Check of Drum length and overall length tolerances.

Immediately after completion of electrical tests, the ends of the cable shall be sealed to preventingress of moisture with suitable PVC/Rubber caps.

10.8 Cable Glands

1) Cable gland shall be provided for all the above mentioned cables both at field instrument, junctionboxes and local control panel.

2) Instrument cable gland shall be ½” NPTM insulating glands double compression type, weather proof(WP) IP 65 in field instrument side only for underground instruments tapping to protect the CP current drainage.

3) Except that, all other shall be standard metallic gland. All cables glands shall be of nickel-platedbrass WP IP65 and they shall be double compression type suitable for armoured cables.

4) Flame proof Ex (d) glands in hazardous area shall be supplied and along with Ex (d) certification.

5) Cable gland shall have PVC shroud.

6) Reducer/adapter & plug shall be supplied as per requirement. These shall be Nickel plated brass,Weatherproof and Flame proof as require.

10.9 Cable Trays and Cable Ducts

All branch cables/trench cable shall run on cable trays.

Cable trays will be of galvanized iron-perforated type of 2.5 mm thickness. These trays are supportedwith suitable clamps for binding the cables/tubes at every one meter (1 Mtr) interval. All the cable/tubeswill be laid in trench, false flooring/ ceiling trays, instrument support structures and supported with 50mm x 50 mm angles as a minimum.

Cable trays width of 300mm and below shall be perforated type and for above 300mm width, trays shallbe of ladder type. Cable Tray segregation shall be based on below criteria:

· AI/AO (IS & Non-IS can be on the same tray with 100mm partition)· DI/DO-24VDC· 240VAC signals

Cable trays spacing shall be followed as below:

· Spacing between Signal and control cables – 300mm· Spacing between Signal and power cables – 450mm

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Cable trays for Hydrocarbon detectors cabling etc as per site requirement.

10.10 Junction Boxes

1) Junction boxes shall be provided for intrinsically safe and non-intrinsically safe instruments also asrequired for packages such as gas detection system, fire detection system etc.

2) For non-intrinsic safe signals, junction box shall be explosion proof to Exd. IIA/IIB, T3 andweatherproof to IP 65 and made up of dia cast aluminium.

3) For intrinsic safe signals, junction box shall be weatherproof to IP 65 made up of di-cast aluminium.

4) Enclosure: Cast in corrosion resistant light aluminium alloy (LM-6) suitable for Group C & D gases.The construction shall comply to IS: 2148 - 1981 and relevant international standard (IEC - 79.1), BS: 229 - 1957).The enclosure shall have ample space for proper termination of cables as per summary of requirement attached andas mentioned in these specifications.

5) In addition, the enclosure shall be totally dust, vermin and weather proof suitable for outdoorinstallation without any canopy. Degree of protection should be minimum IP-65 as per IS/IEC: 60529 – 2001.

6) Terminals: Junction boxes shall be provided with vibration proof terminals (as per vendor list) clipon type 2.5 sq.mm suitable for 500 VAC working voltage. Arrangement of fixing terminals strip shall be made suchthat cable connections can be made easily.

7) Earthing: External and internal earthing terminals complete with set of washers shall be provided.

8) Mounting: The junction boxes shall be suitable for field mounting on M.S supporting structures.

9) Painting: Junction boxes shall be pre-treated by first coat of epoxy zinc chromate primer followedby anti-corrosive industrial epoxy grey paint shade IS 631.

10) Cable entries: The junction boxes shall have bottom entry and should be of NPT threads only.

11.0 INSTRUMENT INSTALLATION

11.1 Accessibility

1) The installation of instrumentation shall be such as to minimise the effects of fire, solar radiation,vibration, heat from process equipment, condensation, spillage, rain, and maintenance activities, etc.

2) Instruments and their connections shall always be accessible from ground level, floors, platforms,walkways (2 m above or 1 m either side of).

3) Pressure Gauges and Temperature Indicator shall normally be mounted directly online. Howeverdirect online mounting shall be avoided where vibrations are likely to be present.

4) Blind transmitters shall be mounted at 130mm above graded platform. Local controllers, indicatingtransmitters and indicating instruments shall be mounted at approximately 1500 mm.

11.2 Instrument Process Piping

1) The run of instrument impulse lines shall be such as to avoid both gas pockets in lines containingliquid and liquid pockets in lines containing gas

2) The instrument impulse lines shall include facilities for Isolation, Drain/Vent, Maintenance,Protection, Testing and Calibration.

3) Slopes of instrument impulse lines shall be as specified on the engineering drawings to be developedby CONTRACTOR and submit for review to OWNER/ENGINEER. If not specified, they shall be at

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least 10 cm/meter to the tapping point when the instrument is mounted above the tapping point and tothe instrument when the instrument is mounted below the tapping point.

4) Vertical instrument impulse lines for differential pressure transmitters shall run as close as possible toeach other.

5) For Cryogenic Service, Impulse line must be provided with a minimum of two Elbows and sufficientstraight length in the three planes in order to allow for line contractions.

6) As far as possible the process impulse line shall run in vertical plane, all horizontal tubing shall havea slope of 3 %. Tubing for gas and vapour shall have a slope downward toward the equipment/pipe toensure self-draining. For liquid the slope shall be downward toward the instrument to be sure thatvapour shall be vented to the equipment.

11.3 Erection Works

Supervision of installation/erection, calibration, checking, testing and commissioning of skids,equipment’s, instrumentation at site shall be in the contractor’s scope.

11.4 Installation Material

Instrument Process Piping

Stainless steel tubing, compression fittings, manifolds and valves shall be used for instrument processpiping connected to the isolating valves on process lines and equipment, unless process conditions requireanother material. All tube fittings shall be Swagelok / Parker. However, the supply of fittings shall befrom single Contractor throughout the plant.

11.5 Instrument Supports

The supports for instruments and junction boxes shall be in accordance with the enclosed standarddrawings.

11.6 Instrument Protection

Weather protection (Canopy to be provided for all transmitters for protection from direct sunlight andrain), hazardous area protection and, when applicable, mechanical protection shall be provided.

The method of protection shall be carefully selected in function of the fluid properties, toxicity andhazard.

Fragile instruments shall be supported independently of equipment which may generate nuisances (e.g.possible damage by mechanical vibrations).

12.0 INSTRUMENTATION WIRING

12.1 GENERAL

1) All field mounted electrical and electronic instruments shall be connected by means of individualcables to field mounted junction boxes. All the field cables and cables from field to control room shallbe intrinsically safe type.

2) The field mounted junction boxes shall be provided for the connection of multicore cables and ofindividual cables to local instruments.

Different types of signals shall be segregated into separate junction boxes :

analogue signals,

RTD signals,

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thermocouple signals,

frequency signals,

logic signals,

solenoid valves,

power supply.

A further segregation shall be made between intrinsically safe and non-intrinsically safe signals.

3) Multipair cables shall be used between each field mounted instrument junction box to controlpanel/metering panel.

4) All field cable runs shall be designed to prevent ingress of moisture. Side or bottom entries toinstruments or junction boxes should be used to ensure this. Cables shall have drip loops.

5) The cables shall be installed above ground on cable trays and/or ladders made of heavy dutygalvanised steel. Cable runs shall be designed to avoid all possible fire hazards. Where this is notpractical, cable runs shall be fireproofed using metal trunking, mineral wool and galvanised cladding.

6) The numbering system for cables, junction boxes, cross boards, panels, cabinets, consoles, shall bespecified by the ENGINEER.

7) All cables and wires shall be numbered. All cables shall be marked at each end. Each wire shall belabelled (terminal strip reference).

8) Where field cables are run in areas with little available means of support (e.g. structural steelwork),cables shall be laid in trenches.

9) All cables shall pass through a compression type cable gland before being terminated.

10) Glands shall meet the requirements of the area in which they are installed and certification shall berequired where applicable.

12.2 Cables

The instrumentation cables shall be selected in function of the application on basis of theENGINEERING specification.

12.3 Terminations

1. Screw / Clamp type terminals shall be used. Conductor ends shall be lugged with crimped end-sleeves.

Only one wire shall be connected to each terminal side.

Terminal straps shall be used for bridges between terminals.

2. Sufficient slack cable shall be left neatly coiled or looped at terminals to allow for the re-making ofterminations, additions and testing.

3. Attention shall be given to the location of terminal rails in junction boxes, etc., in order to providesufficient space to install field cables without bunching or congestion. All cable and terminal numbersshall be clearly visible.

4. All spare wires of instrument cables shall be terminated to terminals in junction boxes, control roompanels, etc.

12.4 Segregation of Cables

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Instrumentation cables (4-20 mA, mV signals, etc.) shall be adequately separated from power wiring andelectrical equipment to minimize interferences. The physical distance between instrumentation cables andpower cables in parallel routing shall be as follows:

Voltage (V) Min. distance (mm)

110 400

230 400

400 600

690 600

6000 1200

If required, the instrumentation cables shall cross the power cables at right angle and with a minimumdistance of 300 mm.

12.5 INSTRUMENTATION EARTHING SYSTEM

General

1. The earthing for electrical earth and electronic earth shall be arranged to provide safe installations, andto prevent electrical interference with their operation.

2. All earthing and shielding shall comply with the requirements of all standards applicable to the areaclassification in which the equipment is installed.

3. Instrument cases, panels. etc.

a) All parts of field installations, e.g. Cable trays, junction boxes, local panels, instrumenthousings, conduits, cable armour, etc.., shall be effectively grounded via the general plantearthing system.

b) Earthing of cable trays shall be in accordance with the IEC requirements as a minimum.

4. Each supplied instrument, local control panel, fire detection panel, gas detection panel system shall haveearthing lugs with their frames. All these lugs/ strips shall properly secure to the electrical earthing bus.

5. All system grounds of various cards and equipment shields of signals (instrument) cables shall connect tosystem ground bus, which is electrically isolated from the AC mains earthing bus. The equipment shallprovide separate earthing strip for the same. The system ground bus will have independent ground busesthrough insulated wires.

a) System grounding (earth resistance less than 1 ohm)

b) Frame and AC mains grounding (earth resistance less than 5 ohms)

6. Lightning protection

Where connections between control systems and/or distant equipment may be affected by lightning surgesor by other inducted high voltages, the connection cables shall be equipped with over-voltage arresters.

12.6 Screening

Page 879 of 921


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Screens on instrument cables carrying 4-20 mA and on-off signals (low level, low impedance signals)shall be interconnected and earthed at one point (preferably in the instrument room).

Exception shall be done for cables carrying digital (serial) signals, high frequencies, etc. In those cases,the screens shall be earthed at both ends to prevent against electromagnetic interferences caused by HFradiations.

13.0 MANDATORY SPARE

All Field Instruments Gauges (PG, TG, LI), Field Indicators, Thermowell, RTD / Thermocouple &Transmitters (PT, TT, LT) 10% subject to minimum 1 no. of each type & Size.

Mass flow meter, Transmitter unit 10% subject to minimum 1 no. of each type & Size.

Gas /Flame detector Sensors: 10 % or minimum 1 sets of each type, whichever is higher

In-line instruments

3Way manifold - 10% (subject to minimum of 1) each size and material to construction; whichever ishigher.

Valves/Tube fittings - 10% subject to minimum one no. for each type, size whichever is higher.

14.0 ERECTION WORK

1. Contractor shall facilitate activities in supply installation, testing and commissioning of I&C scope of work asdetailed below.

2. Contractor shall be responsible for complete activities involving all Sub-Contractors including Instrumentsub-Contractor (as applicable) working under him for the complete I&C works as part of his scope.

3. Scope of Work shall be read in conjunction with the specifications, datasheets, drawings and otherdocuments forming a part of the Contract document. Wherever there is a contradiction between the above,stringent conditions shall take precedence.

4. Every month, the Contractor shall submit an account for all the materials issued to him by the Company(as applicable) in the standard Performa prescribed for this purpose by the Engineer-in-Charge.

5. On completion of the work, the Contractor shall submit `Material Appropriation' statements for allmaterials issued by the Company in the Performa prescribed by the Engineer-in-Charge.

6. Contractor shall be responsible for co-ordination during installation, pre commissioning andcommissioning with Mechanical and other Sub-Contractors for proper installation of line mountedinstruments such as actuated valves, and skids as applicable.

7. Bidder shall inform at least 15 days before to owner for mobilization of special vendor engineer to site.

8. Contractor shall be responsible for installation, field testing, calibration and providing assistance for pre-commissioning and commissioning of all instrumentation items.

9. Contractor shall be responsible for all kind of works inside the terminal building i.e. installation of cablelaying, Branch cable tray / conduit erection / installation and for proper cable terminations and loopchecking, pre commissioning and commissioning.

10. Instrument items such as gauges, temperature elements, thermowells, transmitters, valves, barriers, tubes,manifolds & tube fitting, junction boxes, I&C cables and related items, cable glands, plugs, adapters,panels/cabinets etc., as required, shall be supplied from approved Vendor’s only and the same needs to beinstalled, commissioned and tested. Contractor shall take prior approval of make and specification of suchitems before placement of order.

11. During trial run/startup/commissioning, Contractor shall provide skilled personnel and supervision roundthe clock at Contractor’s cost. Any defect or changes of setting, recalibration, etc., if any during the above

Page 880 of 921


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activity shall be rectified / done immediately to the satisfaction of Engineer-in-Charge or hisrepresentative. The number and category of the personnel shall be as decided by the Engineer-in-Charge.The cost of the above is deemed to be included by the Contractor in the rate quoted.

12. Contractor's scope shall include making holes in the RCC for fixing up of supports for instrumentationitems, branch trays etc.

13. Contractor shall note that elbows (if required) shall be installed on the impulse line wherever required asper instructions of the Engineer-in-Charge, even if it is not indicated in the installation standards.

14. All Vendor supplied equipment’s/Instrument, JBs, I&C cables, cable glands branch cable trays and otherassociated items (suitable power supply, barrier, isolator, selector switch, push buttons, LED etc. alongwith their installation) along with the cable laying up to the terminal building shall be in Vendor’s scope.

15. The fieldwork shall be carried out under strict safety regulations and work permits as laid down by theClient. The Contractor shall take extreme care regarding safety and all safety gear like helmets; handgloves, safety belts, spectacles etc. shall have to be provided by the Contractor.

16. The ferruling for cables shall be done with tag no. of instruments for individual pair. Cross ferruling shallbe done for cable ferruling in field and in the terminal building as per instruction of the Engineer-in-Charge.

17. Contractor shall have to assess the actual site conditions/requirements before placement of order for cable/ trays as per the actual site condition. Contractor has to prepare a cable routing layout as per actual siterequirements from field to terminal building and get the approval from the Engineer-in-Charge, beforeplacement of procurement.

18. Allowable minimum bending radius of multi-pair / multi-core cable shall be 6 times the outside diameterfor unshielded cables and 8 times the outside diameter for shielded cables unless otherwise recommendedby the supplier.

19. Location and flow direction of on-line instruments shall be checked by the Contractor and to be rectifiedin case of any discrepancy as per the instruction of Engineer-in-Charge.

20. Contractor shall run all cables from field to Control Room. The cables shall run through tray / trench /IRC (instrument road crossings) from field to the terminal building as per instrument layout drawings (tobe furnished by the Contractor during execution).

21. Welding / NDT, Charpy V-notch, QA/QC requirement etc. shall be as per Piping Material Specification(PMS).

22. Contractor to note that 100% MPI (Magnetic Particle Inspection) shall be carried out in the entire socketweld joints used in the installation of instruments.

23. Welding shall be as per welding standard attached elsewhere in the tender document.

24. I&C scope of work shall include, but not limited to the following for successful completion of the Project:

a) Installation of all field instruments and Gas, Flame Detectors & Temperature Detectors.

b) Calibration & testing of field instruments and detectors;

c) Installation of branch cable trays;

d) Laying including termination of all interconnecting I&C cabling (single pair & multi-pair signal,single triad & multi-triad, alarm, control, power cables, system cables, etc.) between instruments,junction boxes and cabinets in Control Room.

e) Installation of canopies and junction boxes for instruments;

f) Installation of instrument valves & manifolds, mounting accessories, impulse piping/ tubing,pipe/tube fittings, cable glands, identification tags, conduits, structural material required forinstrument and junction box supports, branch trays and painting etc.;

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g) Installation and connection to lines and equipment of instrument process piping including, wherespecified, seal welding of threaded connections

h) Installation and connection of air sub-headers and of air supply lines for instruments includingconnection to the main air header or sub-header in each unit.

i) Painting of the supports, frameworks and locally manufactured panels.

j) Installation and connection at both end of electrical cables and conductors.

k) Installation and connection at both end of pneumatic cables and transmission lines.

l) Installation of nameplates and /or labels for identification and numbering of instruments, ancillaryequipment, cables, wires, junction boxes, connection boxes, cross boards, terminals, cabinets,panels, desks, pneumatic transmission lines, air supply lines, lines or cables for tracing, etc

m) Laying of earthing cables / strips for instrument enclosures, junction boxes and cable branch trays toearth grid. Installation of GI / copper strips for grounding of racks / cabinets / panels in the ControlRoom with earth pit;

n) Complete loop checking and megger testing of cables;

o) Hydraulic testing of instrument impulse lines (piping/tubing);

p) Arrangement of special tools and tackles as required.

q) Required equipment for the calibration and the pre-commissioning of the Instrumentation.

r) To perform all changes and repairs, as required, resulting from CONTRACTOR’s failure to complywith specifications, standards and/or drawings or from incorrect installation.

25. Supply and materials

a) The instruments and their ancillary equipment.

b) The material for the instrument process piping, including tubing (quality shall be approved by theOWNER/ENGINEER) and fittings. Fittings shall be compression double ferrule type. Make shall beapproved by OWNER/ENGINEER.

c) The material for the pneumatic transmission lines and for the air supply lines and sub-headersincluding, if required, the air filter/regulators.

d) The junction boxes, cross boards including terminals and accessories.

e) The protection boxes / Canopy for the instruments and ancillary equipment, including all requiredaccessories.

f) All types of cables, Cable Glands (As applicable) such as signal, alarm, control and power, datacables such as fiber optic and serial link cables including all necessary accessories.

g) Branch cable trays, conduits.

h) The accessories for fixing the cables on branch cable tray.

i) All the supports for the installation of instruments, accessories, branch cable trays, ducts, conduits,instrument process lines, pneumatic transmission lines, cabinets, panels, desks, consoles, junctionboxes, connection boxes, cross boards, steam tracing lines, etc.

j) The nameplates and labels for identification and numbering of instruments, ancillary equipment,cables, wires, junction boxes, cross boards, terminals, cabinets, panels, desks, consoles, pneumatictransmission lines, air supply lines, lines or cables for the tracing, etc.

k) All the required accessories for an installation in accordance with the prescriptions, drawings andtechnical specifications and for the verifications, checks and tests of the Instrumentation.

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l) The consumables (electrodes and welding rods, primer, lubricants, sealants, soldering flux, paint,screws, bolts, expansion bolts, nuts, washers, etc.).

S S S

Page 883 of 921

1 : :2 : Armour Flexible : --

3 : Armour Flexible Material : --

4 : Capillary length : --5 : :

6 : 20

7 :8 : 21 :

10 : 22 :

11 :23

:

12 : 24 :13 :14 :

25 :26 :

16 : a) :

17 : b) :

a : c) :

b : d) :

18 :

: 27 : *

19 : 28 : *

: : *::::

a,c,d

NOTES:

*: Vendor to furnish

1 Accuracy includes the combined effect of repeatability, linearity,hysteresis etc.

2 For Process parameters refer P&ID andInstrument Index

3 Contractor shall develop detailed data sheet with all required information like span, make/model etc during detail engineering

ATHR CHKD APPD

0 24.05.2021 ASU MKR KNS

PROJECT:

LNG UNLOADING, STORAGE

AND DISPENSING STATIONS AT

AVINASHI (TAMIL NADU) &

PANANCHERY (KERALA)

VENDOR:

Annexure 1Data Sheets:

P.017398/P.017399-G-11077-I001

REV. DATE

Sheet No.1 of 8 CLIENT: BPCL

* * *Natural Gas

* * * * * *

OPTIONSOP. MAX. DES. OP. MAX. DES. SPAN SET

SL.

NO.TAG NO.

PRESSURE TEMPERATURE RANGE

SERVICE

Size & Rating --Facing and Finish --

Wetted Parts Material -- Quantity Other Material --Process Conn --

Process Conn. Location Bottom MakeDiaphragm Seal -- Model

Element Material SS316L 2 valve manifold Yes

Process Connection 1/2" NPT(M)

Element Diaphragm Air Filter Regulator --

Body Material SS316 Mounting accessories

suitable for 2" NB pipeYes

YesOptions

Service Natural Gas/Crude oilIntrinsically safe output

meter Yes (LCD in Engg. Unit)

Rangeability 40:1 or betterTransmitter Output 4-20 mA DC MISCELLANEOUS

15 Load driving capability : 600 ohms at 24 V DCOver Range Protection

Cable Entry1/2" NPT(F) with SS plug

(Ex proff cable Gland shall be supplied)Adapter "O" Ring PTFE

Accuracy +/- 0.075% of span (Note1) Body Rating *

Intrinsically Safe Yes Zero Suppression & Elevation 100% of span

Power Supply 24 V DC Zero & Span adjustmentContinuously adjustable externally,

non-interactive type

Elec. Area Class IEC Zone 2, Gr. IIA/IIB, temp. class T3 SIL SIL 2 for ESD Services

Enclosure WP to IP 65 as per IEC 60529 / IS 2147

Case MFR. Std.Mounting Yoke Flushing/Filling Conn. with --

Operating Principle Capacitance / Peizo-resistance

Type2 Wire, Electronic smart transmitter with

HART

PRESSURE TRANSMITTERS

UNITS: Flow<-> Liquid- m*3/hr Gas- Sm*3/hr Steam- kg/hr Pressure-> BAR G Temperature<-> ºC Level/Length<-> mm

Function Transmission & Indication Capillary Material --

Page 884 of 921

1 :

2 :

3 :4 :

5 :

6 Protection class : Int7 Elec. Area Class : IEC Zone 2, Gr. IIA/IIB, temp. class T38 Power Supply : 24 V DC9 Cable Entry : 1/2" NPT(F) (Ex proff cable Gland shall be supplied)10 Accuracy : +/- 0.2% of Span11 Self Diagnostic Facility : Yes12 Cold Junction compensation : --13 Transmitter Output : 4-20 mA DC14 Load Capability : 600 ohms at 24V DC15 Sensor Element : Pt10016 Calibration : As per IEC 60751

17a) :b) :

18 :19 :20 :21 : SIL 2 for ESD Services22 : From RTD

a,b

NOTES:

* : Vendor to furnish

1 Contractor shall develop detailed data sheet with all required information like span, make/model etc during detail engineering 0 24.05.2021 ASU

2 For Process parameters refer P&ID andInstrument Index

3

TEMPERATURE TRANSMITTERS


Function Transmission & Indication (Note-3)

TypeDual compartment,2 Wire, Electronic Smart with

HART protocol of latest versionCase MFR. Std.Transmitter Head SS316

Mounting Yoke

Options:-Mount. Acc. For 2" pipe Yes

Intrinsically safe output meter (LCD) :- Yes (In Engg. Unit)

Make *Model *Quantity *SILInput

SL.

NO.TAG No. RANGE

TEMP.

SERVICE OPTIONOPT MAX. DES.

* * * * *


P.017398/P.017399-G-11077-I001

REV. DATE

Sheet No. 2 of 8 CLIENT: BPCL

ASU MKR KNS

PROJECT:

LNG UNLOADING,

STORAGE AND

DISPENSING STATIONS AT


PANANCHERY (KERALA)

VENDOR:

Transmitter wired to RTD's used for leak/spillage detection shal be supplied without local Indicator

ATHR CHKD APPD

0 24.05.21

Page 885 of 921

1 20

2 21 Over Range Protection:-

3 22 Blow Out Protection:-

4

5

6 23 Options :- a) Snubber

7 b) Syphon c) Gauge Saver

8 d) Liquid Filled casing e) Vaccum Protection

9 f) Solid front g) Two valve manifold

10 h) Block & bleed Valve Yes i) Mounting Stand

11

12

13 24

14

15

16

17

18

19


1 For Process parameters refer P&ID andInstrument Index2 Contractor shall develop detailed data sheet with all required information like span, make/model etc during detail engineering

NA

150% of FSD

Yes

Model No.

Manufacturer

Local

150 mm

APPD

PROJECT:


AND DISPENSING STATIONS

AT AVINASHI (TAMIL NADU)

& PANANCHERY (KERALA)

VENDOR: REV. DATE ATHR CHKD

0 24.05.21 ASU MKR KNS

Connection:-

Pressure Element:-

Element Material:-

Socket Material

Accuracy:-

SS316

Connection Location:-

Movement:-

PRESSURE GAUGE

Type:-

Mounting:-

Window Material:-

Enclosure:-

Dial Size:-

Colour:-

Case Material:-

Bezel Ring:-

+/-1% of FSD

Micropointer

1/2" NPT(M)

Zero adjustment:-

Beyonet type SS316

Case fill fluid

Diaphargm Seal:-

TAG NO. RANGE

TEMP.

*

*

Direct

Shatterproof glass

WP to IP 65 as per IEC 60529 / IS 2147

Bourdon

SS316

SS316

Bottom

Snubber for Pulsating services shall be provided

WELL DIM. FLANGE

SL. NO.

White background with black inscriptions

Glycerine

SS316

LINE NO. / VESSEL NO.

/ PIPING CLASSNOR MAX DES U T MATERIAL RATING, FACING, FINISH

* * *

Data Sheets:

P.017398/P.017399-G-11077-I001Annexure 1

* Vendor to furnishNOTES:

** ** * *

Page 886 of 921

1 Element : 4 Wire RTD 12 :

2 No. of Elements : Simplex 13 :

3 Calibration : 14 :

4 Element Material : Pt100

5 Resistance at 0°C : 100 Ohm 15 :

6 Leads : Hermatically Sealed 16 :

7 Sheath : 18 :

8 O.D. 8 mm 19 :

Matl. : SS316 20 : *

Nipple & Union Matl. : SS316 21

9 No. of Wires : Four Wires

Head : a) :

10 :

:

22 : *

23 Make : *

* *

"*" : Vendor to furnish

NOTES:

1 Element length shall be suitable for thermowell.

2 U-length shall be selected in such a way that the thermowell tip shall be preferably at the centre of pipe to sense the temperature accurately.

3 All welded joints shall be 100% radiographed.

4 Accuracy shall be Class A.

5 RTD/Thermocouple head shall be SS 316 painted suitably with marine painting.

6 For process data Refer P&ID & Instrument Index

0 24.05.2021 ASU

As per DIN 43760

KNS0 24.05.21 ASU MKR

protection class Intrinsically safe EEx'ia' and Weather proof to IP-65

RESISTANCE TEMPERATURE DETECTORS


Cable Entry 1/2" NPT (F)

No. of Entries Single (One SS plugged)

Thermowell

Material SS316

Construction Drilled bar stock up to immersion length 500mm ,

otherwise fabricated

Process Conn Welded

Inst. Conn. 1/2" NPT (F)

Thermowell Dwg

Options

Extra Nipple Extens150 mm (Requirmed as per wake

frequency Calulation by vendor)

Head Cover TypeScrew Cap of Die Cast Aluminium of SS

Chain

Quantity

SL.

NO.TAG NO.

TEMP. WELL DIM. FLANGELINE NO. / VESSEL

NO. / PIPING CLASSOPTION

OP MAX. DES. U T MATERIALRATING,

FACING, FINISH

* * As per Piping

Specification

As per Piping

Specification


P.017398/P.017399-G-11077-I001


ATHRREV. DATE CHKD APPD

PROJECT:

LNG UNLOADING,

STORAGE AND



PANANCHERY (KERALA)

VENDOR:

Page 887 of 921

1 Element : 4 Wire RTD 12 :

2 No. of Elements : Simplex 13 :

3 Calibration : 14 :

4 Element Material : Pt100

5 Resistance at 0°C : 100 Ohm 15 :

6 Leads : Hermatically Sealed 16 :

7 Sheath : 18 :

8 O.D. 8 mm 19 :

Matl. : SS316 20 :

Nipple & Union Matl. : SS316 21

9 No. of Wires : Four Wires

Head : a) :

10 : b) All mounting accessories Yes( Weld Pad, L bracket ect )

:

22 : *

23 Make : *

* *

"*" : Vendor to furnish

NOTES:

1 Element length shall be suitable for sensing LNG Leakage at ground and mounting to instrument stand.

2 Vendor can use RTD with head mounted transmitter in this case RTD element shall be firmly supported.

3 All welded joints shall be 100% radiographed.

4 Accuracy shall be Class A.

5 RTD/Thermocouple head shall be SS 316 painted suitably with marine painting.

6 For process data Refer P&ID & Instrument index

As per DIN 43760

Material

Construction

RESISTANCE TEMPERATURE DETECTORS (SKIN TYPE)


Cable Entry 1/2" NPT (F)

No. of Entries Single (One SS plugged)

protection classIntrinsically safe EEx'ia' and Weather proof to IP-

65

Thermowell

Process Conn

Inst. Conn.

Thermowell Dwg

Options

Extra Nipple Extens NA

Head Cover TypeScrew Cap of Die Cast Aluminium of SS

Chain

Quantity

SL.

NO.TAG NO.

TEMP. WELL DIM. FLANGELINE NO. / VESSEL

NO. / PIPING CLASSOPTION

OP MAX. DES. U T MATERIALRATING, FACING,

FINISH


P.017398/P.017399-G-11077-I001

* * As per Piping

Specification

As per Piping

Specification

Sheet No.5 of 8 CLIENT: BPCL

PROJECT:





VENDOR: REV. DATE

0 24.05.21 ASU MKR

ATHR CHKD APPD

KNS

Page 888 of 921

1 Fluid LNG

2 Measuring principle Coriolis Principle

3 Sensor /Internal Tubes Material/ Flange SS316

4 Operating pressure Later

5 Molecular weight Later

6 Ambient temperature Later

7 Hazardous area classification IEC Zone 2, Gr. IIA/IIB, temp. class T3

8 Range Note-1

9 ±0.25 % FS

10 Rangeability for specified accuracy

11 Nominal calculated size Refer Note.1

12 Zero stability ~ 0.68 Kg/hr. preferred, Better than 7kg/hr acceptable

13 Pressure drop at max. Flow < 0.6 Kg/cm2g

14 Material Transmitter : Polyurethane-painted aluminum housing (EX proof , IP65)

15 End connection To suit the line size, rating ANSI 300 class

16 Power supply (nominal) Cabal Entry 24 VDC , 230±10% V, 50±2 Hz, 1 Φ 1/2 " NPT (F) , (Ex proff cable Gland shall be supplied)

17 Outputs (active)

18 4 – 20 ma dc

19 Frequency

20 Rs 485

21 Mass flow rate

22 Mass totalizer, non-resettable

23 Mass totalizer, resettable

24 Periodic mass & totalizer, non-resettable

25 Date, time

26 Temperature

27 Pressure

28 Density

29 Volume flow rate

30 Volume flow totalizer

31 Display Display with specified accuracy, programmable and sequential with password protection

32 Communication Modbus & Hart

33 Custody transfer No

34 Mounting Vertically (flag type) mounted

35 Programmer

36 Certification

37 Documentation

Notes

1. Contractor to specify.

2. As per piping specification.

3. As per attached P&IDs.

4. For Process Data Refer P&ID

5. The design of Mass flow meter shall be as per AGA 11 /API

6. At the time of approval of DS, supplier shall furnish DS with catalogues and sizing calculation of Mass flow meter

CONTRACTOR:

KNS

REV. DATE ATHR CHKD APPD

CONTRACTOR: 0 24.05.21 ASU MKR





CLIENT: BPCL

PROJECT:

Vendor shall calculate and choose the size of the meter on the basis of process data and confirming to code AGA11/API. Bidder shall submit the sizing calculations including the

flow, velocity, pressure drop, noise etc. in the bid document.

Mounting: 2” dia yoke mounting for transmitter (if not integral to flow computer), transmitter to be replaceable separately in the field, brackets (SS) and other accessories (SS) to

be supplied. Inter connecting cable upt to 5 Mtr between Transmitter and sensor shall be supplied.

Vendor shall supply one set of Calibration Software for Meter & Flow Validation Software along with flow meter. confirmation etc.

Data Sheets: P.017398/P.017399-G-11077-I001Annexure 1

Sheet No. 6 of 8

MASS FLOW METER

UNITS: Flow<-> Liquid- m*3/hr Gas- Sm*3/hr Steam- kg/hr Pressure-> barg Temperature<-> oC Level/Length<-> mm

Accuracy (with zero stability, repeatability, hysterisis etc.)

Calibration Software, Perpetual licence.

Hazardous area compatibility, Material Test, Manufacturer’s certification, Calibration Certificate ,Test labs

with traceability acceptable internationally e.g. GTI_MRF/ GRI/ SWRI/ CEESI/ NMI/FCRI etc.

O&M manual with exploded view and part number, Compatibility to use in hazardous area, Calibration

Certification.

20:01

Page 889 of 921

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

Hardware

Required

Neoprene Rubber

MS Zinc passivated

Mounting

Make

Telephone Socket & Plugs

Plug

Ground Busbar

Rail(s) for terminals

Size

Type

Quantity

No. of Rows

Numbering System

Size

Bottom Side

Other

Type

Size

Entry

Type

Overall Dimension

Cover

Painting

Left Side

Right Side

Top Side

Manufacturer

Model

Application

Area Classification

Enclosure

Material of Construction

*

For Instrumentation IS cables

Zone 2, Gr.IIA/IIB, T3

WP to IP 65 as per IEC 60529 / IS 2147

Die cast aluminium (LM6 alloy)

Spring loaded, antiloosening & vibration-proof, screwless clamp type

2 nos, 1 1/2" NPT, Bottom

Double compression type, Nickel plated Brass & WP to IP 65 as per IEC 60529 / IS 2147

1 1/2" NPT(M)

*

3

* Vendor to furnish

-

-

-

Double compression type, Nickel plated Brass & WP to IP 65 as per IEC 60529 / IS 2147

1/2" NPT(M)

Suitable for mounting wall, column, steel structure

Required

1

*

Not required

1/2" NPT(M) & 11/2" NPT(M)

Required

2

Required

Required

PVC hood alongwith Cable gland

Hinges

VENDOR: REV. DATE

12 Nos. , 24 Nos.

2 Nos.

Terminal strips & terminals shall be suitably numbered

2.5 mm2

Nameplate Fixture

Gasket

BPCL

Junction boxes shall have doors which shall be hinged type and these shall be fixed by plated countersunk screws.

Quantity of Cable glands & plugs shall be as per requirement.

Junction box numers based on cable schedule along with data sheet shall be submitted by contractor for approval

Data Sheets: P.017398/P.017399-G-11077-I001

ATHR CHKD

ASU MKR KNS

APPD

PROJECT:

LNG UNLOADING,

STORAGE AND


AVINASHI (TAMIL NADU)

& PANANCHERY (KERALA)0 24.05.21

*

Multi CableCable Gland

Terminals

Options

CLIENT:Sheet No. 7 of 8

Annexure 1

NOTES:

JUNCTION BOXES

General

Single

Cable

No. of Entry

Cable Gland

Screwed

Surface : Light blue & Inside : White

3 nos for JB with 12 TB, 6 nos for JB with 24 TB. - 1/2" NPT(F)

3 nos for JB with 12 TB, 6 nos for JB with 24 TB. - 1/2" NPT(F)

Page 890 of 921

Tender-document-6LNG-992fa0.pdf - Bharat Petroleum

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