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ORBITINDIA ENGINGEERING
CONSULTANCY SERVICES

DATE 23/10/2018
DOC.
CLIENT PARSOL CHEMICAL PVT LDT NO. 001
DESIGN BASIS REV.
PROJECT BIBSA UNIT-1 NO. 00

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 C O N T E N T S

1. GENERAL REQUIREMENT

6. INTRINSICALLY SAFE SYSTEM REQUIREMENT 5

7. POWER SUPPLY AND DISTRIBUTION 6

8. PLANT CONTROL AND AUXILLIARY SYSTEM 6

9. GROUNDING 12

10. INSTRUMENT CONNECTIONS 12

11. CABLING PHILOSOPHY 12

12. SPARE PHILOSOPHY 14

13. INSTRUMENT AIR DISTRIBUTION 14

14. TAGGING AND PAINTING OF INSTRUMENT EQUIPMENT 14

15. GENERAL INSTALLATION REQUIREMENTS 14

16. INSTRUMENT SPECIFICATIONS 15

17. INSTALLATION 37

18. ENGINEERING FORMAT 40

19. APPLICABLE PROJECT SPECIFICATION 41

ANNEXURE – I: STANDARD PROCESS CONNECTIONS FOR INSTRUMENTS

ANNEXURE – II: STANDARD DRAWINGS FOR THERMOWELL

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1. GENERAL REQUIREMENT

1.1 As a minimum, all instruments and enclosures in field shall be weatherproof as per IEC-60529 to
min IP-65. (This requirement is typical. May be accepted if deviated by Instrument Vendor )

1.2 All electronic/electrical instruments and equipment’s shall be suitable for area classification as per
IEC codes and shall be tested by any recognized authority like CENELEC, ATEX, CMRI, ERTL
etc. and shall be certified by PESO/CCOE Nagpur in India. (Check if Process Material is
Hazardous)

1.3 Units of Measurement:

Glossary Units
Area m²
Density kg/m³
Energy, electrical kWh
Energy, mechanical kJ
Energy, thermal kJ [BTU]
Length m (mm for dimensions / inch for piping)
Level mm or m, %
Mass kg or t (ton)
Moment torque Nm
Power kW
Flow, mass kg/h
Flow, volumetric m³/h or m³ (n)/h (*) [SCFD]
Frequency Hz
Pressure (absolute), fluid bar a
Pressure (relative), fluid bar g
Pressure, barometric mbar
Pressure, differential bar or mbar
Sound level dB (A)
Temperature °C (Celsius)
Time h (Hours), min (Minutes), s (Sec)
Velocity m/s
Viscosity, absolute, dynamic cP (centipoise)
Voltage V (Volt)
Volume m³ or m³ (n) (*)
Wobbe Index MJ/Sm³ [Btu/Scf]

Multiples or sub-units are allowed for 10³ and 1/10³ only

(*) m³ (n): Normal conditions are defined as 0°C and 1 013 mbar.
m³(s): Standard conditions are defined as 15 °C and 1 013 mbar.

1.4 Ranges for instruments shall be selected in general, such that in normal process operation the
indication is between 40% and 60% of span for linear and between 60% and 80% of span for
square root inputs. Ranges for process switches, if used, shall be selected, in general, such that
the set point falls preferably in the middle 30% of full adjustable range i.e. the set point shall fall
between 35% and 65% of adjustable range.

1.5 All process switches shall be provided with hermetically sealed contacts rated for the specified
application. Contacts shall be SPDT type unless otherwise specified. Intrinsic Safe switches shall
have gold plated contacts

1.6 Accuracy of various types of instruments used shall be as per below table:

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TYPE OF INSTRUMENT ACCURACY REPEATABILITY

Pressure and Differential +/- 0.5% +/- 0.1%

Pressure Transmitter
Temperature Gauges
Temperature Transmitters
Pressure Gauges
Differential Pressure Gauges
of calibrated range or better of calibrated range or better
+/- 2%
of calibrated range or better
+/- 0.25 %
of full scale
+/- 2%
of calibrated range or better
+/- 2 %
of calibrated range or better

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5.7 Electronic transmitters shall generally be two wire type. These shall have transmission/output
signal of 4-20 mA DC + HART and shall be capable of delivering rated current into external load
of at least 600 ohms when powered with 24 V DC nominal voltages.

1.8 All electronic instruments requiring separate power supply, shall generally operate on 230 VAC,
50 Hz. Instruments operating at 24 V DC shall also be acceptable.

1.9 Smart transmitters shall be used in analog mode only unless otherwise specified.

5.10 All electronic transmitters shall be provided with sunshade made of GRP material. ( Not required
as Instruments will be installed inside Building )

5.11 All tubes sizes used shall be preferably of metric sizes. Impulse tube shall be 6 mm OD or 12mm
OD, 316 stainless steel, seamless tubes as a minimum.

5.12 All tube fittings shall be flare-less compression type three piece construction design

5.13 Pneumatic signal tube shall be 6mm OD or 12mm OD SS316 tube.

5.14 All Electronic Transmitter housing shall be Die cast Aluminum, Epoxy painted.

6. INTRINSICALLY SAFE SYSTEM REQUIREMENTS (( Check if Process Material is Hazardous )

6.1 All intrinsic safety barriers shall be active type isolating barriers only. Zener barriers shall not be
used.

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

7. POWER SUPPLY AND DISTRIBUTION

7.1 Power supply shall be made available at the following voltage levels, unless otherwise specified:

For Control Systems, Analyzers,

Instruments requiring external power 230V AC ± 10% (UPS), 50Hz, 1 Phase

For Instruments, Relays,

lamps, Switches, Push Buttons 24V DC

Interrogation voltage for MCC interface

For signal from MCC 110V DC ±10%
For Signal to MCC 24 VDC

Panel /cabinets lighting, Fan, Utility Socket 230V AC ± 10% (NON-UPS), 1 Phase
For Solenoid valves 24V DC through

7.3 All instruments, Control Systems (PLC and DCS) and analyzer system shall be able to operate at
the following UPS specification:
Voltage level 230 VAC ± 10%
Frequency 50 Hz ± 1%

7.4 For Instruments requiring external 230V AC power, power circuits shall be individually protected
from fault with the help of Miniature Circuit Breakers (MCBs).

8. CONTROL SYSTEMS

8.1 Control and monitoring function of field instruments shall be done by DCS / PLC system from
Main Control Room.

8.3 Number of operator stations, : 2Nos.

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8.4 Redundancy philosophy for DCS/PLC shall be as follows:

[x] Controllers:
[x] CPU Redundant

[x] Process input/output card back-up [x] Redundant I/Os for closed loops & I/O
related to
[x] Non-Redundant I/Os for rest

[x] Power supply unit back-up : Redundant

[x] Network bus : Redundant

8.6 PACKAGE CONTROLS SYSTEMS

8.6.3 Compressors ( Check if this is applicable )

(i) Type
[x] PLC Based [ ] Through DCS / PLC

(ii) Location of System

[x] In Field [x] In Rack Room

(iii) Interface
[x] Serial Link with PCS [x] Hardwired Interface with DCS/PLC
(As Required)

9. GROUNDING

9.1 All control room mounted panels (including panel mounted bulk supply earth) shall be connected
to the ‘Body Ground’ bus which is isolated from 'AC mains earth'. The total resistance of system
ground shall be less than 5Ω unless otherwise recommended by system manufacturer.

9.2 All circuit grounds, shields, drain wires and safety barriers (if used) shall be secured to 'Safety
Ground' which is isolated from 'AC mains earth’. This bus shall typically be 25 mm wide and 6
mm thick, made of copper. The resistance of ‘Safety Ground’ shall be less than 1Ω.

9.3 All field mounted panels, shelters, instruments, JB’s, carrying voltage more than 24 V shall be
connected to 'AC mains earth'.

9.4 Shield wires of all instruments will be connected to Control room end only. The Instrument side
shield shall be properly cut and insulated ensuring that it does not touch to instrument casing or
cable gland.

9.5 Colour coding for grounding copper cable shall be Green / Yellow.

9.6 Instrumentation grounding system at Control building shall be connected at two points to the
electrical earthing system.

10. INSTRUMENT CONNECTIONS

10.1 The instrument connections installed on vessels, tanks, standpipes and piping shall be per
ANNEXURE-I.

10.2 Pneumatic instrument connections of ¼” NPT (F) shall be used for signal and air supply. ½” NPT
(F) connection may be used where ¼” NPT (F) is not sufficient.

10.3 Electrical cable entry connection shall be ½” NPT (F)

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11. CABLING PHILOSOPHY

11.1 Instrumentation Cables shall be laid in trays for above ground installation. Tray Material shall be
galvanized. .

11.2 MCT Block – For cable entry in Control Room. ( Check if Required )

11.3 Cables

11.3.1 All cables shall be flame retardant low smoke (FRLS) as per IEC 60332 Part III, Cat. A. All Fire
resistant cables shall be as per IEC 331 Cat. A.

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11.3.2 Instrument signal cables shall be polyvinyl chloride (PVC) insulated and PVC sheathed cables of
rated voltage 300/500 V with primary insulation of 85°C PVC as per IS-5831 Type –C.

11.3.3 For signal and control cables, inner jacket Colour shall be black. Outer jacket Colour shall be light
blue for intrinsically safe application and black for others.

11.3.4 All multi pair cables shall have 6 pair / 12 pairs while multitriad cable shall have 6 triads / 8 triads.

11.3.5 All power supply cables shall be as per IS-1554 Part I. Minimum conductor size shall be 2.5 mm 2.
All these cables shall be PVC insulated and armoured (Check if armoring is required ?) and
FRLS.

11.4.Junction boxes, Cable glands

11.4.1 Separate junction boxes and cables shall be considered for following:

 Intrinsically Safe Analog Inputs / Outputs (4 - 20mA)

 Non Intrinsically Safe Analog Inputs / Outputs (4 - 20 mA)
 Intrinsically Safe Contact Inputs
 Intrinsically Safe Contact Outputs (e.g. Solenoid Valves)
 Non Intrinsically Safe contact Inputs / Outputs.

11.4.2 Junction Boxes used for terminating intrinsically safe signals, shall be Ex ’e’ certified suitable for
Zone-1, Gr. IIA, T4. JBs shall be made of SS316 material (Material to be decided ). Plate
thickness shall be min 2 mm.
In general, multi-pair cable entry for 6 Pair / 6 Triad JB shall be 1” ET with check nut & for 12-
Pair / 8 Triad JB, it shall be 1 ½” ET with check nut.

11.4.3 Junction Boxes used for terminating non-intrinsically safe signals, shall be Ex ’d’ certified suitable
for Zone-1, Gr. IIA, T4. JBs shall be made of SS316 material. In general, multi-pair cable entry for
6 pair / 6 triad jb shall be 1” NPT (F) & for 12-pair / 8 triad jb, it shall be 1 ½” NPT (F).

11.4.4 The junction boxes shall be weatherproof to IP-65. (Deviation from Vendor shall be acceptable)

11.4.5 Each JB shall be provided with 2 multi-cable entries with one entry plugged with weather-proof /
Ex-proof plugs as required.

11.4.6 All spare cable entries shall be provided with suitable weatherproof / Exproof plugs as required.

11.4.7 Cable entries shall be from bottom, for all cables (multi-pair & single pair).

11.4.8 All cable glands shall be of SS304 for on-shore application & SS316 (Material to be decided ).

11.4.9 All cable glands shall be weatherproof to IP65 for on-shore area & IP-66 for off-shore area. For
flameproof application cable glands shall be provided with CMRI certification / CCOE approval
along with weatherproof certification.

12. SPARE PHILOSOPHY

12.1 Engineering Spares

Engineering Spares for all control systems & construction materials shall be provided as per
guidelines provided in respective specifications.

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12.2 Mandatory Spares:

Mandatory spares for each instrument & system shall be as per mandatory spare parts philosophy

12.3 Two Year Operational Spares:

A list of Recommended Spares for two years operation for all the applicable items shall be
provided by vendor.
13. INSTRUMENT AIR DISTRIBUTION

13.1 Instrument air distribution shall generally be through instrument air manifold fabricated from 1”
pipe with isolation and drain valves. Where the instruments are located sparsely, the branch way
may be applied. 10% spare connections shall be provided in each manifold.

13.2 Each instrument using air shall be equipped with its individual isolating valve.

13.3 Air distribution manifold, isolating valves, tubing fittings shall be of min. SS316.

15. GENERAL INSTALLATION REQUIREMENTS

15.1 All pressure / differential pressure instruments shall be provided with 2-way / 5-way manifolds as
per the installation standards, and shall have accessibility. All primary piping / tubing (impulse
lines) shall have a slope of 1 in 10 on the horizontal run.

15.2 All threaded joints shall be joined by PTFE tapes.

15.3 Impulse lines shall be supported at 1.5 meter intervals.

15.4 Mounting of instruments / JB on the stanchion or instrument support shall generally be at the
height of 1.3 mars form the grade level / finished floor level.

15.5 Extension in the impulse piping/tubing of suitable length may have to be provided for those
instruments installations where process fluid temperature is higher / lower (Cryogenic services)
than the maximum withstanding temperature of the instrument/diaphragm.

15.6 All direct mounted instruments like thermowells for RTD / temperature gauge, pressure gauges;
pressure switches etc. shall be installed in such a way that they have good readability and
accessibility.

15.7 All the cables entering in Field Instrument / Central Control Rooms shall be through MCT.

15.8 All tubes/branch cables shall be properly laid on cable trays which shall be supported at 1.5 m
intervals.

15.9 Main cable trays shall be supported at 3 m interval.

15.10 The capillary of all capillary type instruments shall be supported properly and shall be protected
against mechanical damage.

16.1 FLOW INSTRUMENTS

16.1.1 D/P Type Flow meters and Orifices

D/P type flow meters employing square edged concentric orifice plates shall normally be used
where the piping sizes are 2 inches and larger.

(1) Orifice plates

(i) Design standard

[ ] ASME Fluid Meter
[x] ISO 5167
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 [ ] DIN 1952
[ ] BS 1042

(ii) Materials
[x] 316 SS
[ ] 304 SS

(iii) d / D (Beta) ratio:

[x] Between 0.25 and 0.75

(iv) Drain and vent holes:

[x] Yes, only for condensable fluid or gas entrainment in liquid
[ ] No
[x] Both Drain & Vent

(2) Type of pressure taps

Nominal Pipe Size Type

(i) 12in. and smaller [x] Flange taps

(ii) Smaller than 2 in. [x] Corner taps

(iii) 14in. and larger [x] 1D-1/2D (Radius) taps

[ ] Vena contracta taps

(3) Orifice flanges

Orifice flanges shall be specified in accordance with the Piping Specification and
following standard:

[x] ANSI B16.36 (up to 12”) Note-3

[x] ANSI B16.5 (14” and above)

Note-3: Flange rating minimum 300#

(4) Carrier rings for corner tappings

(i) Type of carrier rings
[x] Separated ring and orifice plate
[ ] Integrated ring and orifice plate

(ii) Carrier ring facing, rating and materials

(a) Facing and rating:
[x] As per Piping Spec
[ ]
(b) Materials
[x] As per Piping Spec or equivalent
[ ] The same materials as orifice plate

(5) Marking of orifice plates

Tag number, diameter (mm) of orifice, nominal pipe size (in), flange rating, materials and
UPSTREAM (or “UP”) shall be engraved on the upstream face of the tab handle.

(6) Upstream / Downstream Straight lengths:

The minimum upstream and downstream straight lengths required for installation of
orifice shall be as specified in the P&IDs. Where it is not available in P&IDs, the values
without parentheses ("zero additional uncertainty" values) given in ISO 5167 part 2 for
Orifice plates shall be followed to the extent possible.
16.1.2 Variable Area Flowmeters (Rotameters)

(1) Applicable service conditions (except purge meters)

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 (i) [x] Rangability of more than 4:1 is required
(ii) [x] Local indication/control is required
(iii) [x] Nature of fluid, such as viscous and crystallizing

(2) Indicator type

(i) [x] Magnetic coupling linked type

(ii) [ ] Direct reading type

(3) Body

(i) Type
[x] Metal tube type
[ ] Glass tube type (only non-critical flows, e.g. purge, seal, flushing etc.)

(ii) Flow direction (except purge meter)

[x] Bottom to top
[ ] Side to top [ ] Only gas service
[ ] Side to side [ ] Only gas service

(iii) Connection (except purge meter)

[x] As per Piping Spec

(4) Materials (Except purge meter)

(i) Body : [x] As per Piping Spec or better

(ii) Elements : [x] SS 316

(5) Protections

(i) Float damper : [x] Gas service

[ ] Pulsating flow

(ii) Cooling fins or extension well:

[x] High temperature service (150 °C and above).
[x] Low temperature service (0 °C and below).
[ ] the type as specified by MFR’s recommendation

(iii) Jackets: [ ] Crystallizing fluid at ambient temperature

16.2 LEVEL INSTRUMENTS

16.2.1 Major Level Control System

(i) [ ] Local control and remote readout to control room

(ii) [x] Remote control from control room
(iii) [ ] Local control

16.2.2 Level Transmitters

(1) Differential pressure instruments shall be the standard level transmitters for process
control applications.

(2) Other types of level instruments such as electrical capacitance, ultrasonic or radar type
may be used for special applications.

(3) All external level instruments, individual connected or flanged connected, shall be
equipped with isolation valves (each level measurement must be equipped with its own
process valve), drain and vent connection if required.

(4) Diaphragm material shall normally be SS316 or better.

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16.2.3 Other type level instruments

Other type level instruments such as ball float type level switches with external float chamber,
float or displacement type tank gauges, capacitance type, Radar, Ultrasonic type etc. shall be
considered individually to the service conditions.

16.2.4 Level gauges

(1) Type

(i) [ ] Transparent
(ii) [x] Magnetic

(2) Installation

(i) [x] In tank (for atmospheric tanks only)

(ii) [x] External Chamber

(3) Specifications

(i) General requirements:

(a) [x] Max C-C distance or unsupported lengths shall be 2 mtrs

(b) [x] Non-frosting type for temperature 0 °C and below.

(c) [x] Large chamber type for liquids that vaporize or condense rapidly
at ambient temperature.

(d) [x] Bi-Colour flapper / rotocyl indicators

(ii) Mounting style: [x] Side-Side

(iii) Process connections: [ ] 3/4 in. flanged

[ ] 3/4 in. screwed
[ ] 2 in. flanged for large chamber type
[x] As per Annexure - I

(iv) Accessories [x] 1/2 in. drain valve

[ ] 1/2 in. vent plug
[ ] Bottom Flange for Float removal
[x] Float stopper

(v) Material of Body chamber / flange: [x] As per Piping Spec or equivalent

(vi) Overlapping Range [x] 50 mm visible length for staggered level gauges

16.2.5 Level Switch

(a) Type [ ] Capacitance type (For special application)

[x] Float
[x] Displacer

(b) Material of Probe [x] SS316

(c) Type of electric contacts: [x] Microswitch

[x] Hermetically sealed type
[x] SPDT [ ] SPST
16.3 PRESSURE INSTRUMENTS

16.3.1 Pressure Gauges

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(1) Nominal dial size

(i) Local gauges : [x] 100mm [ ] 150mm

(ii) Receiver gauges : [x] 100mm [ ] 150mm

(2) Connections

(i) Local gauges : [x] 1/2 in

[ ] GA [ ]R [x] NPT (M)
(ii) Receiver gauges : [x] 1/4in.
[ ] RC [x] NPT (M)
(3) Types

(i) Local gauges : [x] Weatherproof

[x] Glycerine filled (for Vibrating services)
[x] Blow-out disc
[x] Solid front
[x] Pulsation Dampner

(ii) Receiver gauges : [ ] Board mounted

[x] Weather proof
[ ] Indoor type
(4) Case materials

(i) Local gauges : [x] Metallic

[ ] Synthetic resin
[x] SS
(ii) Receiver gauges : [x] Metallic
[ ] Synthetic resin
[x] SS
(5) Element materials

(i) Local gauges : [x] SS 316

(ii) Receiver gauges : [ ] Bronze
[x] SS 316

(6) Protections

(i) Pigtail siphons shall be provided for:

[ ] Steam service
[ ] Hot vapor service of temperature above 80 ° C

(ii) Over range protector (gauge saver) shall be provided where a pressure gauge
shall not withstand to a protuberant pressure due to unavoidable operation.

(iii) Pulsation dampener shall be provided for pulsating services (discharge piping of
reciprocating pumps and compressors).

(iv) Diaphragm protection shall be used where necessary to protect gauges from
corrosive fluid, crystallizing fluid, fluid including solids and high viscous fluid. The
connection size and the material shall be as follows:
(a) Connection : [x] Flanged : [x] 2in. [ ] 3in.
[ ] Screwed : [ ] 1/2 in.

(b) Materials :
Diaphragm : [x] 316 SS or better
Flange : [ ] As per Piping Spec or equivalent
Capillary : [ ] Refer to par. 2.4.3 (2) (I)

(7) Small pressure gauges

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 Small pressure gauges equipped for pneumatic instruments e.g. valve positioners, air
filter regulators etc. shall normally be specified by the manufacturer who supplies the
parent-instrument.

(8) Draft gauges – Not Applicable

In general, the gauges shall be provided for each process heater to measure draft at the
burners, and in the stack, if required by the process. The type of gauges shall be as
follows:
[ ] Vertical case and flush mounting type
[ ] Horizontal case and flush mounting type
[ ] Dial gauge type
[ ] Flush mounting type
[ ] Wall mounting type

16.3.2 Locally mounted pressure switches

(1) In general, pressure switches shall be avoided. Alarms / trips set limits shall be derived
from analog transmitters in control room.

(2) When pressure switch is used, materials and connections shall be the same specification
as pressure gauge.

(3) Types:
[x] Non-indicating type
[ ] Indicating type
[x] Adjustable set point : [x] 1 setter [ ] 2 setters (High and Low etc.)
: [ ] Fixed differential pressure
: [x] Adjustable differential pressure

(4) Type of electric contacts:

[x] Microswitch
[x] Hermetically sealed type
[x] SPDT [ ] SPST
[x] Gold plating for Intrinsic safe type.

16.3.3 Pressure and D/P Transmitters

(1) Pressure and DP transmitters shall be intrinsically safe and SMART type with HART
protocol, however used in analog (4-20 mA DC) output mode.

16.4 TEMPERATURE INSTRUMENTS

16.4.1 Thermowells

Temperature elements like thermocouples, RTD, bi-metallic sensor and liquid/gas filled sensor
shall be equipped with thermowell, except where they are not feasible to install in the service
such as skin temp. measurement, bearings of rotating machine, etc. The specifications shall be
as follows:

(1) Constructions:
[x] standard (Refer Annexure-II for standard Dwg)
[x] Drilled bar stock

(2) Connections:
[x] Flanged
Refer ANNEXURE-I for other details

(3) Material of thermowell :

[x] SS 316

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16.4.2 Resistance Temperature Detectors (RTD)

RTD (Pt 100 Ω at 0 °C) shall be considered as standard method of temperature measurement.

The elements shall be MgO insulated and metal sheathed type and shall be of three-wire system,
Duplex type. The applicable operating temperature range will be (-) 200 to 500 °C. Dual element
type probes are preferred. Both elements shall be isolated from each other & thermowell. Both
elements shall be wired upto terminals in element head. Only single element shall be wired to
transmitter

(1) Standard : [x] IEC 60751 [ ] JIS C1604 [ ] SAMA RC21-4

[ ] DIN 43760 [ ] BS 1904

(2) Sheath diameters (mm): [ ] 3.2 [ ] 4.8 [x] 6 [ ] 8.0

(3) Sheath materials: [ ] 304 SS [x] 316 SS

(4) Skin Element : [ ] 3 Wire RTD [ ] Pad type

(5) Accuracy Class : [x] Class A [ ] class B

Note 4: For skin temperature monitoring, RTD type elements are considered. Other
measuring technologies are not considered.

16.4.3 Thermocouples

(1) Standard
[x] IEC 60584
[ ] ANSI MC 96.1
[ ] DIN 43710
[ ] BS 4937

(2) Thermocouples:

Thermocouples shall be used for temperature above 500 °C. Type ‘K’ thermocouple shall
be used. Thermocouples shall normally be of Magnesium Oxide (MgO) insulated and
metal sheathed type and the hot junction shall be ungrounded to the sheath. Dual
element type probes are preferred. Both elements shall be isolated from each other &
thermowell. Both elements shall be wired upto terminals in element head. Only single
element shall be wired to transmitter

16.4.4 Locally mounted temperature transmitters

(1) Locally mounted temperature transmitters

[ ] Not use (EMF or RTD signal is directly input to receiver instrument)
[ ] Current transducer integrated with temperature element (EMF/RTD) with
indication
[ ] Current transducer separated from temperature element (EMF/RTD)
[x] Current transducer (EMF/RTD input with LCD indication, 2” pipe mounted
16.4.5 Dial Thermometers

(1) Type:
[x] Bimetal type
[x] Liquid/Gas filled type with temperature compensator (Note 5 & 6).
[x] Fixed angle type (for filled thermal system)
[x] Every angle type (for bimetallic)

Note 5. Filled thermal system temperature instruments shall be used where bi-metal
type is not feasible.
6. Mercury filled instrument shall not be used.

(2) Indicator:
[x] 100mm dial

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 [ ] 150mm dial
[ ] Adjustable pointer

(3) Thermobulb:
[ ] Nickel plated brass bulb
[x] Stainless steel bulb
[x] Sliding union connection
[x] 1/2in. [ ] R [x] NPT (M)

(4) Capillary tube (if applicable)

[ ] Copper tube with stainless steel armour
[x] Stainless steel tube with stainless steel armour
[x] MFR STD length (approx. 3m) as a general

16.5 ANALYZERS ( Check )

16.6 FIRE & GAS DETECTORS ( Check )

16.7 CONTROL VALVES

16.7.1 Sizing Basis

(1) Cv (valve capacity) calculation:

[ ] ANSI /FCI 62-1 [x] ANSI/ISA S75-01

Note 7: Manufacturer’s formula may be used in order to determine the suitable size after
purchase order.

(2) Valve sizing:

Valve sizing and capacity shall normally be determined in consideration of the following
points.

(i) Cv calculation shall be based on a flow rate of:

[x] 1.3 [ ] 1.5 [x] times the normal flow rate
OR
[x] 1.1 [ ] 1.2 [x] times the normal maximum flow rate and

[x] Whichever is greater

(ii) Valve travel during normal operation shall be:

(a) at minimum flowrate, not less than : [ ] 10% [x] 20%
(b) at maximum flowrate, not greater than : [ ] 80% [x] 90%

(iii) Minimum body size

(a) Pipe size > 1 in. [x] Min 1 in.
(b) Pipe size < 1 in. [x] The same size as pipe
[ ] Min. 3/4 in
[ ] Min. 1 in.

(3) Noise level

[x] Not exceed 85 dBA at normal operation

Note 8: Maximum allowable sound level dBA measured at 1m from pipe surface and 1m
downstream of the valve outlet.

16.7.2 Body Materials and Rating

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 (1) Materials : [x] As per Piping Specifications
(2) Rating : [ ] Min. 300# for globe valve
[x] As per Piping specifications

16.7.3 Connections of Body

(1) Flanged connection : [x] As per Piping Spec.

(2) Welded connection : [ ] As per Piping Spec.
(3) Screwed connection : [ ] As per Piping Spec.
(4) Wafer / Lug Design : [x] As per Piping Spec.

16.7.4 Face to Face dimensions

[x] ANSI / ISA-S75.08 (01 to 09) for Globe Valves

[x] ANSI B 16.10 for other valves

16.7.5 Valve type

In general, valve types shall be as per P&IDs.

16.7.6 Valve Trim

(1) Characteristic

Characteristic of plug shall be selected as follows.

(i) [x] Equal percentage

[x] General process conditions
[x] Having large variations in valve pressure drop

(ii) [x] Linear

[ ] Minimum flow control for compressor and pump
[ ] Split control and parallel control by 2 valves
[x] Small Cv and low noise valves as designated by MFR
[x] Operated by remote hand controller
[x] Having small variation in valve pressure drop
[ ] Over pressure control in steam or gas service
[x] Level control
[ ] On-off service

(iii) [x] Quick opening

[x] On-off service

(2) Materials

[ ] 304 SS
[x] 316 SS
[ ] Stellited seat face for erosive service 440B/C.S.S is used instead of Stellite but
not for corrosive fluid.

(3) Seat leakage

The following leakage class conformed to ANSI/FCI 70-2 shall normally be applied to
each type of valve.

Class Application
[ ]I : Manufacturer’s recommendation
[ ] II : Double ported valves or cage guided valves
[ ] III : Valves as determined by

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 [x] IV : Single ported valves (Control valves)
[x] V : Metal Seated valves (On-Off valves)
[x] VI : Soft seated valves (On-Off valves)
Note 9: Allowable leakage class shall be as per process specific requirements.

16.7.7 Packing Glands:

[x] Teflon packing (Operating temp. < 200 °C)

[x] Graphite packing (Operating temp > 200 °C)
[x] Reinforced PTFE may be used above 200 °C upto 260 °C

Note 10: Materials used for packing shall be asbestos free.

16.7.8 Bonnets

(i) Operating temperature > 200 °C

[ ] Finned bonnet
[ ] Extension bonnet
[x] Bonnet type as specified by MFR’s recommendation

(ii) Operating temperature < 0 °C and for subzero ( Not Applicable )

[ ] Extension bonnet as per BS6364 (minimum 250 mm)
[ ] Bonnet type as specified by MFR’s recommendation

(iii) Severe service condition of leakage (e.g. deadly poisonous fluid)

[ ] Bellows seal type

16.7.9 Valve Actuators

(1) Valve actuators shall be pneumatic only. Motorized / Electrically operated actuators shall
not be used. Valve actuators shall normally be of spring diaphragm or piston type. All
actuators shall be adequate to fully stroke the valve under the maximum differential
pressure specified by the process requirements.

(2) The following air pressure shall normally be used to determine the actuator spring and/or
the size of actuator.

(i) Without positioner :[ ] 0.2-1.0 kg/cm2g

(ii) With positioner : [x] Upto 4 kg/cm2g
(iii) On-off valve without positioner : [x] Upto 4 kg/cm2g
(iv) Maximum ......... kg/cm2g may be allowed in special case, subject to approval

16.7.10 Handwheel

[x] Handwheel (as per P&ID)

[x] Bypass line for valves (as per P&ID)
[ ] Used as a limit stopper of valve stroke

16.7.11 Valve Positioners- Smart type, 4-20 mA, 2 Wire HART

(i) Valve Positioner

[x] Control Valve [x] All [ ] As per P&ID
[ ] On-off Valve for partial stroke testing [x] None [ ] As per P&ID

(ii) Gauges for positioner [x] Supply [x] Outlet

16.7.12 Auxiliary devices

(1) Limit switches – Type Inductive Proximity type, 2-wire

They shall be equipped for the following valves so as to indicate the open or closed
position.

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 [x] Emergency Shutdown Valves / On-Off Valves
[x] Control valves (As per P&ID)

(2) Solenoid Valve:

3 Way, Universal type, Class F coil insulation, operating voltage 24 VDC, Intrinsic Safe,
SS body with SS316 trim.

Application [x] Used as the pilot valve to trip a shutdown valve On/Off valve
[ ] On-Off control valve in utility services (e.g. pilot gas, etc.)

(3) Air Filter Regulator:

Each control or on-off valve shall be provided with separate AFR. Filter size shall be 5
micron. Body MOC can be stainless steel or non-flammable plastic. AFR shall be with
manual SS drain valve with metal bowl.

(4) Other auxiliary devices

A lock up relay, pilot relay, booster relay, volume tank etc. shall be provided wherever
required as parts of the actuating system in order to achieve the required stroke-speed,
fail-safe action etc.

16.8 SAFETY AND RELIEF VALVES

16.8.1 Sizing Basis

Safety and relief valves shall be sized in strict accordance with:

(1) [ ] USA Code and practice:

[ ] ASME Section I (Power Boilers)
[x] ASME Section VIII (Pressure Vessels)
[x] API RP 520

(3) [ ] Other
[ ] Indian Boiler Regulations

16.8.2 Type
The valves shall normally be of direct spring loaded type and provided with full nozzle type. For
special service conditions, following types may be considered:

(1) [x] Conventional Spring Loaded:

[x] As standard selection

(2) [x] Balanced bellows type:

[x] Variable back pressure more than 10% of set pressure
[ ] Corrosive fluid

(3) [x] Thermal relief type

[x] Thermal expansion of liquid or gas (Size 1” x 2”)

(4) [ ] Vacuum relief type

[ ] Storage tank

(5) [x] Pilot operated type

[x] Operating pressure close to the set pressure (less than 10%)

16.8.3 Bonnet Construction

(1) [x] Plain closed bonnet for general service:
[x] Screwed cap
[ ] Bolted cap
[ ] Test gag
[ ] Open lever (for steam and air where conforms to ASME SEC VIII)

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 [x] Packed lever

(2) [ ] Exposed spring bonnet:

[ ] for superheated steam at over 232 °C where conforms to ASME SEC-I
[ ] Open lever
[ ] Test gauge

16.8.4 Materials
(1) Body:

[x] As per Piping Spec or better

(2) Trim (e.g. Disc, nozzle etc.)

[x] SS 316 / SS316L

(3) Spring

[x] -29 °C to 250 °C - Cadmium / Nickel plated carbon steel

[x] above 250 °C - Tungsten alloy steel
[x] below -29 °C - SS316

(4) Bolt & Nut

Bolt [x] ASTM A320 Gr. B8 Cl. 2

Nut [x] A194 gr. 8

16.8.5 Connections and ratings

(a) Flanged connections : [x] Yes [ ] No
[x] As per Piping Specification, if the flange can withstand against the maximum
impact strength calculated by the manufacturer.

(b) Welded connections : [ ] Yes [x] No

[ ] As per Piping Spec.

(c) Screwed connections : [ ] Yes [x] No

[ ] As per Piping Spec.
[ ] Thermal expansion relief valve
[ ] 3/4 in or smaller

16.8.6 Code Stamps

[ ] Yes [x] No
[ ] ASME stamp

16.9 ALARMS AND INTERLOCKING SYSTEMS

16.9.2 Interlocking System

(1) Switch and trip action on normal operation

Input Output
[x] Closed circuit (Open at trip) Energized (De-energized at trip)

(2) Interlocking units

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 [ ] Electro-mechanical relay
[x] PLC
[x] PCS

(3) Functions

(ii) Manual reset by:

(iii) By-pass switch:

16.10 INSTRUMENT PANELS

16.10.1 Control Panels

(1) General

(i) Mounting location:

[x] Indoor [ ] Non-hazardous

(ii) Construction:
[ ] Free-standing open type
[x] Free-standing closed type

(iii) Graphic: [ ] Yes [x] No

[ ] Semigraphic [ ] with process alarm lights

(2) Dimensions

(i) Overall dimensions:

[x] Maximum 800W x 2000H x 800D (mm)
[ ] Maximum 1,500W x 2300H x 2000D (mm)
[x] 1,200W x 2000H x 800D (mm) (For Marshalling Cabinet Note 12)
[ ] Reference drawing no.............................
Note 12: Marshalling cabinet shall have double door with front & rear access

(ii) Front panel:

[x] Steel plate of 1.6 mm thickness

(3) Internal wiring:

All of the internal wiring shall be completed at shop before shipment. The wiring manner
shall be as follows:

(i) Wire way:

[x] PVC duct
[ ] Metallic duct
[ ] Conduit pipe

(ii) Terminals:
[x] Screwless compression ring type
[ ] Tubular screw terminal with pressure plate

(ii) Panel wiring:

[ ] 0.5 mm2 min. [x] 0.75 mm2 min
(4) Name plates

(i) Markers for wires, tubes, terminals, connectors, switches, circuit breakers, panel
number etc. shall be permanently affixed on them.

16.10.2 Local Control Panels

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 Local control panels will be similar to the specifications as described in par 16.10.1 except for the
following specifications:

(1) Mounting location:

[x] Outdoor [ ] Indoor: [ ] Shed

(2) Type:

(i) [x] Weatherproof [ ] with roof [ ] Dust proof

(ii) [x] Free standing

(iii) Electrical classification

[ ] Explosion proof type as specified in the classification of hazardous area
[ ] Non-hazardous
[x] Purged
[x] Non-hazardous panel with all panel components certified as Ex-proof or
Intrinsic Safe

16.11 CONTROL SYSTEM

16.11.2 Operator’s Console for PCS

(1) Type:
[x] Conventional
[ ] Mini-DCS
[ ] Existing control room

(2) Quantity of OWS with operator’s key board:

[x] 2 DCS

16.11.3 Printer for DCS

(1) Alarm-printer : [x] Yes. 1 pcs [ ] No

(2) Log-printer : [x] Yes. 1 pcs [ ] No

16.11.4 Control Units

(1) Enclosure of control units:

[ ] Cubicle
[ ] Control panel

(2) Controller (processor):

[x] Multi-loop controller
[ ] Single loop controller

(3) Process interface:

[x] Multi-point I/O card
[ ] Remote I/O

(4) Power supply system for field instruments (4-20mA DC signals):

[ ] MFRSTD
[x] Multi-point power supply unit:
[ ] Single loop power supply unit:
[ ] with isolator
[ ] with fuse per I/O

16.11.6 Marshalling Boards with Terminal Block for external signal cable
[x] Yes
[ ] No

16.11.7 Cable Way in Operation Room and Rack Room

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 (1) Operation room:
[ ] Pit [x] Free access floor
[ ] Overhead

(2) Rack room:

[ ] Pit [x] Free access floor
[ ] Overhead

16.11.8 Internal Wiring

All of internal wiring of equipment’s shall be completed at shop before shipment.

The wiring manner shall be as follows:

(1) Wire way

[x] PVC duct
[ ] Metallic duct

(2) Terminals for external cable (except for multi-pin connector of system cable)
[x] Screwless compression ring type
[ ] Tubular screw terminal with pressure plate

(3) External wiring for thermocouple and RTD

[ ] Interconnected with terminal block
[ ] Directly connected to panel instrument
(4) External wiring for intrinsic safety circuit:
[ ] Directly connected to the safety-barrier or intrinsic safety instrument
[x] Screwless compression ring type
(5) Markers for wires, terminals, connectors, switches, circuit breakers, etc. shall be
permanently affixed on them.

17. INSTALLATION

17.1 Process tappings for Instrument

Process tappings for instrument connected to piping, vessels, and equipment shall be as
specified in ANNEXURE-I, unless other special connections are required.

17.2 Instrument Pressure Piping

17.2.1 Type of Pressure Piping

(1) [x] Piping (as per Piping Spec)

[x] Pressure rating : [ ] All [x] > ANSI-900# & above

(2) [x] Tubing:

[x] Pressure rating : [ ] All [x] upto ANSI-600#
[ ] Analyzer’s tubing only

17.2.2 Pipe or Tube Size (nominal diameter)

(1) Pipe size : [x] 1/2 in.

(2) Tube size : [x] 12mm out dia [ ] 1/2 in out dia

17.2.3 Materials for Pipe, Tube and Fittings

(1) Piping : [x] As per Piping Spec

(2) Tubing : [ ] 304 SS [x] 316 SS

17.2.4 2/3/5-valve manifold:

[x] Equipped with Pressure & D/P instrument

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 [ ] Provided by other than instrument manufacturer
[ ] Fabricated at site

17.2.5 Installation of Instruments

[x] Grade mount (on ground or platform)

[ ] Pipe mount (on process piping)

17.3 Air Supply Piping and Signal Tubing

17.3.1 Air Supply Piping

(1) Piping Style:

[x] Branch piping [x] Header piping with manifold valves

(2) Air set (air filter and regulator with output gauge) for locally mounted instruments
[x] Equipped with each instrument

(3) Piping Materials:

[x] As per Piping Spec
17.3.2 Signal Tubing

[x] Signal tube:

(i) [x] 6mm or 12 mm OD [ ] 1/4 in. out dia.

(ii) [ ] Copper tube [ ] Aluminum tube [x] 316 SS

[ ] Polyethylene tube [ ] 304 SS

(iii) [ ] With PVC sheathed

(iv) Installation [x] in cable trays Note 13

[ ] in conduit
[ ] direct without cable trays
Note 13 – Cable trays shall be supported at a regular interval of 1.5 mtrs.

[x] Tube fittings:

(i) [ ] Bronze with chrome plated

[ ] 304 SS
[x] 316 SS

(ii) [ ] Conventional type

[x] Double Compression type

17.4 Cable Way

17.4.1 Main Cable Way

(1) Type:
[x] Overhead type : [x] Tray [ ] Duct

:[ ] Open rack (ladder type)

[x] Underground type :[ ] Trench

[ ] Trough
(2) Construction

(i) Duct / tray

(a) Materials:
[ ] Electrolytic zinc-coated steel plated and/or frames
[x] Hot dip galvanized steel plates and/or frames for on-shore

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 (b) Protection cover: [x] Yes [ ] No

(c) Cable separator: [x] Yes [ ] No

Group 1: Power, grounding
Group 2: EMF, RTD, pneumatic signals
Group 2: Intrinsically safe signals (4-20mA, On-off signals etc.)
Group 2: Non-IS signal
Group 3: Fibre Optic cables

(ii) Trench/Trough

(a) Trench:
[ ] Concrete trench : [ ] with cover
[ ] Buried cable

(b) Trough:
[ ] Concrete trough : [ ] with cover

(iii) Separation between Signal & power cabling

Separation between Signal & power cables upto 230VAC

[x] 150mm (For ducts & trenches)

Separation between Signal & power cables above 230VAC

[x] 600mm (For 380/400 V)
[x] 600mm (For 660/690 V)
[x] 1200mm (For 6600 V)
[x] 300mm (For Crossing at right angle)

Com. Power
Signal cables cables cables

150
mm

(iv) Allowable sectional area for cable laying:

[x] Spare 20%

17.4.2 Branch Cable Way

[ ] Conduit pipe (NOT USED)

[ ] Closed conduit piping
[ ] Open conduit piping

[x] Tray:
[ ] with cover [x] without cover

17.5 Instrumentation Cables

TYPE OF CONDUCTOR SPECIFICATIONS

CABLE Sec. Area (mm2) Type Insulation

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Signal Cables Electrolytic copper [x] PVC [x] FRLS
[x]- 4 to 20 mA [x] 1.5 conductor of 7 strands [x] PVC sheathed
[x]- Digital Input with each strand of [x] Al backed Mylar
[x]- RTD For Single pair / 0.43 mm dia. for 1.0 tape shield along with
Triad, Multitriad mm2 and 0.53 mm drain wire (individual
dia. for 1.5 mm2, and overall shield)
twisted pair [x] Armoured
[x] 1.0
[x] 1.5

For Multipair

Control Cables Electrolytic copper [x] PVC [x] FRLS

[x]- SOV [x] 1.5 conductor of 7 strands [x] PVC sheathed
with each strand of [x] Al backed Mylar
For single pair, 0.53 mm diameter tape shield along with
multipair drain wire (overall
shield)
[x] Armoured

Thermocouple [x] 16 AWG Solid conductor [x] PVC [x] FRLS

Extension [x] PVC sheathed
Cables For single pair [x]Shielded
[x] KX (overall)
[x] Armoured
Power Cable Min 2.5 Stranded / Solid [x] PVC [x] FRLS
[x] PVC sheathed
[x] Armoured
Grounding Min 2.5 Stranded / Solid [x] PVC [x] PVC sheathed
Cable [x] Unarmoured

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