PACKAGE UNIT

INSTRUMENTATION
SPECIFICATION, TBE AND VDR

CHAYAPAT L.
Dec 12, 2014

Table of contents

1.

Introduction

2.

Instrument scope of work in the package unit

3.

Guidance on option selection

4.

General requirement for field instrument in package unit

5.

General requirement for instrumentation system

6.

General requirement for instrument installation

7.

General requirement for test and inspection

8.

General requirement for documentation

1. Introduction

1. Introduction
What is purpose of package unit instrumentation specification?
- To ensure that the instrumentation supplied as part of packaged
equipment systems is consistent with the plant instrumentation
requirement
- To covers the material, specifications, work, services and
responsibilities that shall be provided or executed by the Vendor
and by Purchaser for instrumentation associated with 'major
mechanical equipment' (Compressors, boilers, fired furnaces,
filters, lube oil systems, gas generators, etc.).

2. Instrument scope of work in

the package unit

2. Instrument scope of work in the package unit

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

2. Instrument scope of work in the package unit

2.1 Option A
Scope of Vendor
The Vendor shall supply the equipment package, complete with process tappings and the
instruments that are an integral part of the proprietary equipment, e.g. speed governors,
overspeed trip, proximitors, vibration pickups, etc.
The Vendor's scope of supply includes the functional specification, special tools, special
test equipment, drawings and documents. When installing instruments, allowance shall be made
where necessary for any tracing, insulation and housings that may be required.
Vendor Competence
The Vendor's competence is limited to instrumentation that is considered an integral part of
the proprietary equipment.
Scope of Contractor
The Contractor shall design, engineer, supply and install all remaining field instrumentation
and installation materials and all cabling between the field junction box(es) and the (F)AR.
The Contractor shall be responsible for the configuration of the DCS, IPS (Logic Solver) or
subsystem to perform the required control and IPF (SIF) functionality, etc. as specified by
the Vendor's functional specification.

2. Instrument scope of work in the package unit

2.2 Option B

2. Instrument scope of work in the package unit

2.2 Option B
Scope of Vendor
The Vendor shall supply the equipment package, complete with process tappings and the
instruments that are an integral part of the proprietary equipment, e.g. speed governors,
overspeed trip, proximitors, vibration pick-ups, etc.
In addition, the Vendor shall supply any instrument installation materials required. The
installation materials shall be as specified on the engineering documentation prepared by
the Contractor and issued to the Vendor. The detailed design of the installation shall be the
responsibility of the Vendor.
The Vendor's scope of supply shall include the functional specification, special tools,
special test equipment, drawings and documents.
Vendor Competence
The Vendor's competence is limited to instrumentation that is considered an integral part of
the proprietary equipment, and to the installation of installation materials.
Scope of Contractor
The Contractor shall design, engineer, supply and install all remaining field instrumentation
and all cabling between the field junction box(es) and the (F)AR.
The Contractor shall be responsible for the configuration of the DCS, IPS (Logic Solver) or
subsystem to perform the required control and IPF (SIF) functionality, etc., in accordance with the
Vendor's functional specification.
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2. Instrument scope of work in the package unit

2.3 Option C

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2. Instrument scope of work in the package unit

2.3 Option C
Scope of Vendor
The Vendor shall supply the equipment package complete with field-mounted instruments
installed.
All instrumentation in the scope of supply of the Vendor shall be supplied and installed
according to the Principal's standards.
The Vendor's scope of supply includes functional specification, special tools, special test
equipment, drawings and documents.
Vendor Competence
The Vendor shall have been deemed competent by the Principal to meet the Principal's
standards.
Scope of Contractor
The Contractor shall design, engineer, supply and install all cabling between the field
junction box(es) and the (F)AR.
The Contractor shall be responsible for the configuration of the DCS, IPS (Logic Solver) or
sub-system to perform the required control and IPF (SIF) functionality, etc., in accordance
with the Vendor's functional specification.

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2. Instrument scope of work in the package unit

2.4 Option D

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2. Instrument scope of work in the package unit

2.4 Option D
Scope of Vendor
The Vendor shall supply the equipment package complete with field-mounted instruments
installed.
All instrumentation in the scope of supply of the Vendor shall be supplied and installed
according to the Vendor's standards.
The Vendor's scope of supply shall include the functional specification, special tools,
special test equipment, drawings and documents.
Vendor Competence
The Vendor's instrumentation standards used for the equipment package shall have been
accepted by the Principal.
Scope of Contractor
The Contractor shall design, engineer, supply and install all cabling between the field
junction box(es) and the (F)AR.
The Contractor shall be responsible for the configuration of the DCS, IPS (Logic Solver) or
sub-system to perform the required control and IPF (SIF) functionality, etc., in accordance
with the Vendor's functional specification.

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2. Instrument scope of work in the package unit

2.5 Option E

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2. Instrument scope of work in the package unit

2.5 Option E
Scope of Vendor
The Vendor shall supply the equipment package complete with field instrumentation,
control room instrumentation and (F)AR instrumentation. The required control and IPF (SIF)
functionality, etc. are pre-configured in the (F)AR instrumentation. Field instrumentation within the
equipment package boundary shall be installed by the Vendor.
All instrumentation shall be supplied to the Principal's standards.
The Vendor's scope of supply shall include the functional specification, special tools,
special test equipment, drawings and documents.
Vendor Competence
The Vendor shall have been deemed competent by the Principal to meet the Principal's
standards.
The Vendor shall be competent to manage complex interfaces between other equipment
and other Vendors.
Scope of Contractor
The Contractor shall specify, route, supply and install all cabling between the field junction
box(es) and the equipment package cabinet(s).
The Contractor shall install all control room and (F)AR equipment and any instruments
supplied as part of the package but not installed by the equipment package Vendor.
The Contractor shall be responsible for the interfacing requirements of the equipment
package with the DCS and IPS (Logic Solver).

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2. Instrument scope of work in the package unit

2.6 Option F

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2. Instrument scope of work in the package unit

2.6 Option F
Scope of Vendor
The Vendor shall supply the equipment package complete with field instrumentation,
control room instrumentation and (F)AR instrumentation. The required control and IPF (SIF)
functionality, etc. shall be pre-configured in the (F)AR instrumentation. Field instrumentation
within the equipment package boundary shall be installed by the Vendor.
Instrumentation shall be supplied to the Vendor's standards, except that each instrument
shall be given a tag number following the Principal's tagging system.
The Vendor's scope of supply shall include the functional specification, special tools,
special test equipment, drawings and documents.
Vendor Competence
The Vendor's instrumentation standards used for the equipment package shall have been
accepted by the Principal.
Scope of Contractor
The Contractor shall specify, route, supply and install all cabling between the field junction
box(es) and the equipment package cabinet(s).
The Contractor shall install all control room and (F)AR equipment and any instruments
supplied as part of the package but not installed by the equipment package Vendor.
The Contractor shall be responsible for the interfacing requirements of the equipment with
the DCS and IPS (Logic Solver).

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2. Guidance on option
selection

18

3. Guidance on option selection

The flowchart below should be used to select one of the options in item
no.2. It describes how the option selection process shall be approached by
the Contractor.
The Contractor shall demonstrate to the Principal that all steps in the
selection process have been followed in selecting the most suitable option
for the particular equipment package.

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3. Guidance on option selection

20

4. General requirement for field

instrument in package unit

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4. General requirement for field instrument in

package unit
4.1 Design Philosophy
The design philosophy of package unit shall be the same as project design philosophy or plant
instrument design philosophy.
This section shall be described all general requirements for instrument design in the package
unit. Details are as follows:
4.1.1 Genera Instrumentation
Signal: The instrument transmitter signals shall be:
a) Electronic Transmitter:
4-20mA (loop powered) at 24VDC digital signal
based on HART or Foundation Fieldbus protocol
b) Pneumatic:
0.2 1 kg/cm2g (only for local control loops)

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Power Supply:

110VAC (10%) 50Hz (3%) (UPS) for control & instrumentation

Explosion Proof:

EEx-ia IIC T4 for Instrumentation & junction box. Ex-p (Type X) for Local
panel. If intrinsic safe certification is not available, then Flameproof (EExd
IIC T4) shall be used.

Weather Protection:

IP 65 minimum for all outdoor instruments, junction boxes & Local

Panels

Electrical Connection:

1/2 NPT(F) for Transmitters

4. General requirement for field instrument in

package unit
4.1.1 Genera Instrumentation

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

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

Impulse Tubing:

( Refer to project design philosophy)

O/D x 0.065 wall thickness /316 SS. Size/Material

4.1.2 Code & Standard

( Refer to project design philosophy)

4.1.3 Units of measurements

Flow
Liquid
m3/h (Chemicals : l/hr)
Gas
Nm3/h
Steam
kg/h
Level
%, mm
Pressure
kg/cm2g, mmHg (Vacuum)
Temperature
C
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4. General requirement for field instrument in

package unit
4.1.4 Connection Details

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4. General requirement for field instrument in

package unit
4.1.5 Accuracy of Instruments

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4. General requirement for field instrument in

package unit
4.2 Requirement for field instrument
The procurement of all instruments shall be strictly from the manufacturers listed in Client
approved vendor list included elsewhere in this bid package. If Client vendor list does not cover
some instrument items, the package vendor shall submit the sub vendor list for such instrument
items for Client approval.
4.2.1 Transmitters
The SMART type transmitters supported by HART or Foundation Fieldbus protocol, based
on 4-20mA 24VDC, shall be used for all electronic transmitters.
The SMART transmitters shall be capable of communicating with Hand-Held
Communicators. Separate transmitters shall be used for shutdown & control loops.
Considering the site under lightning prone area, all field transmitters shall be provided with
surge Protection devices.
For Pressure & Differential pressure type transmitters the Process connections shall be 1/2
(NPTF) and from the side/horizontal to the transmitter. Range calibration units for flow
measurement shall be mmH2O.
4.2.2 Level measurement
For level measurements using DP type transmitters, flanged diaphragm seal type DP
transmitters shall be used.
For all types of tanks Guided wave Radar type level gauging system (including interface
level) shall be used. Servo type level instrument (with density measurement) shall be
considered as second level instruments on tanks.
Displacement type level Instrument shall not be used.
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4. General requirement for field instrument in

package unit
4.2 Requirement for field instrument
4.2.2 Level measurement
The zero elevation & zero suppression are required for DP level transmitter.
Stand pipes with isolation valves shall be used for LG/LTs. Maximum length for standpipes
shall be 4600 mm. Standpipe (if required) shall be used for Level measurements only.
Separate nozzle shall be provided for pressure instruments. Stand pipes shall not be used for
shutdown applications.
4.2.3 Valve Manifold
As far as possible all transmitters shall have traditional flange design for easy
interchangeability without impulse line modifications in future and shall have integral drain
and vent.
Mounting bracket shall be provided c/w instrument transmitter and suitable for 2 pipe
installation for all transmitters.
The fabricated valve manifold shall be provided for all pressure measurements ,except for
close coupled hook-ups where integral manifolds shall be used. In general transmitters for
hydrocarbon service shall be installed close coupled if there is any accessibility problem, then
can be installed on grid level according to installation standards with minimum length of
impulse tubing
2-way
: Pressure measurement
3-way & 5-way : D/P measurement (Level & Diff pressure & Flow measurements)

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4. General requirement for field instrument in

package unit
4.2 Requirement for field instrument
4.2.4 Pressure Gauge
Bourdon type pressure gauges shall be used. However for pressure less than or equal to
1kg/cm2-g Diaphragm type or Capsule type shall be provided.
Dial size shall generally be 110 mm (4.5) minimum and cases shall be screw on or bayonet
bezel with stainless steel , blow-out protection shall be provided at the backside.
The gauge shall be oil filled type. Pulsation damps shall be fitted at the input connection, or
liquid filled gauges shall be used on pulsation service applications.
Siphons shall be provided for pressure gauges on steam, or hot condensable gas service
(above 75 C).
Excess flow check valves shall be provided for gauges operating on pressure > 70 kg/cm2.
Gauge saver shall be provided wherever design pressure exceeds 130% of selected range.
Diaphragm seal type to be used for corrosive service.
Solid front type gauges shall be used for ranges 60 kg/cm2 & above.

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4. General requirement for field instrument in

package unit
4.2 Requirement for field instrument
4.2.5 Temperature Transmitter
Temperature transmitters shall be field mounted HART compatible OR Foundation Fieldbus
Type. Head mount transmitter shall not be used.
The temperature transmitter should be installed as close to the measuring element as
practical. Individual temperature elements shall have head mounted terminal connections.
All transmitters shall be capable of communicating with Hand-Held Communicators All
Transmitters shall have integral LCD indicator in engineering units and be furnished with test
terminals and bypass diode to facilitate field testing without disconnection of integral indicator.
The transmitters shall have over-range protection to 1.3 times the maximum range of the
instrument.
Dual compartment housing shall be provided for all Temperature transmitters for easy
termination.
Display shall be rotable.
Conventional transmitter shall have universal input for thermocouple / RTD and output 420mA DC for 2-wire system.
Transmitter output signal shall be linear and directly proportional to the measured
temperature.
Transmitter shall have automatic cold junction compensation for thermocouples. Burnout
protection (selectable Up Scale / Down Scale) must be provided for temperature transmitters.

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4. General requirement for field instrument in

package unit
4.2 Requirement for field instrument
4.2.6 Temperature Elements
Thermocouple shall generally be mineral insulated Duplex type. Type K (Class 1) shall be
used for temperature up to 1100 oC. Thermocouple shall be Ungrounded.
Resistance Temperature Detectors (RTD) shall be Duplex, 3 wire type Pt100 (Class A), used
for -200 to 600 oC
4.2.7 Thermowell
The thermowells shall have 1-1/2 flanged connection generally. Screwed connection shall
not be used. For thermowell mounted on equipment/vessel, the flange rating shall be 300 #
as a minimum or higher as per equipment rating.
Flange material shall be SS 316 as a minimum or better as per piping /equipment class.
However for thermowell mounted on pipe line the flange rating shall be as per pipe class.
The thermowell rods can be welded to the flange if the application permits it or drilled from
solid type 316 stainless steel bar-stock or better material as determined by corrosive
conditions.
The line 6 & smaller line if thermowell is installed in Elbow, then the line size shall be 3
minimum. And for line installation, the line size at thermowell installation shall be expanded to
6 according to API 551.
The nozzle standout for thermowells shall be 150 mm minimum.
The vendor shall consider and issue the resonant wake frequency calculation (as per ASME,
PTC 19.3, fw/fn <0.8) as a part of vendor documentations.

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4. General requirement for field instrument in

package unit
4.2 Requirement for field instrument
4.2.8 Temperature Gauge
Bimetallic type only to be used. The Dial size shall be 150 mm (6) nominal and instruments
shall be every angle head type for visible installation.
4.2.9 Control Valves / On-Off Valves
Control valve shall generally be Globe type. For higher sizes Butterfly type may be
considered depending on the application.
On-Off Valves shall be Ball type with Tight shutoff (TSO) leakage class.
The valve CV selected shall be larger than the maximum calculated Cv. The valve
characteristic Selected should produce a travel of 35 to 65% at normal/operating flow rate.
The Combination of valve Cv and characteristic should generally produce a valve operating
range of 10 to 90% of travel for all of the flow conditions specified.
The trim material for general service shall be 416 SS or alternatively 316 SS with Stellite
sheath or solid stellite minimum. The guide bushing or bearings shall be Type 440C stainless
steel. An acceptable alternate is 17-4 pH SS or Stellite.
The trim material for general service containing H2S or for Caustic service shall be 316 SS.
An acceptable alternate is 316 SS with Stellite sheath or solid Stellite.
The SMART type positioner supported by HART protocol shall be used for the modulating
control valves. The SMART positioner shall be capable of communicating with Hand-Held
Communicators. Output gauge shall be provided.

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4. General requirement for field instrument in

package unit
4.2 Requirement for field instrument
4.2.9 Control Valves / On-Off Valves
Solenoid valves shall be 24VDC, certified EEx-ia IIC T4, class H, three-way universal type as
a minimum. The solenoid valve shall be powered from the associated control system, and
shall be supplied complete with suppression diodes.
Wherever solenoid valves are used for control valves in modulating services, the solenoid
valve shall be installed between positioner output & actuator & de-energising of SOV shall
bring control valve to failure poison by venting the actuator.
A field manual reset (FMR) shall be provided for critical trip application.
Limit switches : On-Off valves / Shutdown valves shall be equipped with both open & close
limit switches. And control valve shall be provided with limit switch for indicating the fail-safe
position only.
Intrinsically safe valve Limit switches shall be actuated directly from the stem / shaft. They
shall be adjustable and unaffected by vibration. They shall be hermetically sealed. Inductive
type limit switches shall be used.
Control Valves shall be supplied, equipped & tubed with air filter regulator (with output
gauge), electro-pneumatic positioner, boosters (if required) and solenoid valves (if
applicable). Air tubing shall be stainless steel (SS 316).
The minimum control valve size shall be 1. Where the line size is less than 1 inch or the
selected valve size could be used a 1 valve body with a reduced trim shall be used.
Standard valve body sizes shall be used. Control valves 1 and larger shall be flanged
generally, valve Face- to Face dimension shall follow API6D.

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4. General requirement for field instrument in

package unit
4.2 Requirement for field instrument
4.2.9 Control Valves / On-Off Valves
Control valves shall be specified to provide an acceptable noise level when continuously
operating to meet local area requirements but shall generally be less than 85 dBA at 1 metre
from control valve body.
Packing material : For Fluid Temperatures up to (232C) packing shall be a TFE material
either of the molded Teflon V-ring or braided type. For temperature above 232 C, Grafoil,
graphite ribbon / filament, or Kevlar packing shall be used.
Control valves to be provided with upstream and downstream 3/4'' drain valves, which are to
be blind flanged. Control valves not having block and bypass provision shall have hand
wheel.

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5. General requirement for

instrumentation system

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5. General requirement for instrumentation

system
General

35

Machines or Package Units shall be equipped with a PLC based control system (no relay
technique). The PLC with dual processor, dual power supply, dual I/Os (i.e. Redundant
CPU, Power supply & I/O cards) in general shall be provided. If Vendor has to supply a
PLC to control his machinery or package unit, the PLC shall be located in a suitable panel.
The method of control shall be clearly specified in the machine or package unit requisition
as well as be indicated on the interface sketches as part of the requisitions.
If the system is controlled by a Vendor PLC, the PLC shall be equipped with a serial
communication facility (Modbus) which will be connected to the plant DCS Wherever data
of the serial link will be used for calculations or non critical control loops, the serial link shall
be redundant. Commands (start, stop), trip or critical control loop signal shall always be
hardwired between DCS/SIS & package Unit.
Dual communication busses shall be used simultaneously, with automatic switch over to the
spare bus upon failure of the primary bus. The system shall automatically check both
busses and alarm on the failure of either one.
The serial link shall be completely commissioned in a so called integration test before
shipment of the PLC/Panel. Machines or units, which are controlled by the DCS The
package vendor has to supply suitable software description / specification as well as to
provide suitable descriptions / date for the programming and graphic design of the DCS.
The Graphic design of vendors control system shall be inline with purchasers Graphic
design specification .
Safety relevant systems can be integrated in the plant SIS system.

5. General requirement for instrumentation

system
General

For DCS/SIS controlled machines or units, the Vendor shall execute functional test for the
control system to ensure that vendor can provide the requested guarantee for the overall
function and design of the machine and / package without split of responsibilities or
guarantees. All other requested tests (e.g. running test, performance test etc.) shall be
carried out by Vendor fully under Vendor responsibility.
In case a machine or unit requires special electronic devise (e.g. special burner
management system for package boiler, speed governor for steam turbines, anti-surge
controller for compressors, etc.) the electronic units are in the scope of the Vendor.
In general, any critical trip signal which lead to a plant trip shall be 2 out of 3 (triple field
instruments) and provided by vendor.

5.1 General Purpose Packages (Utilities IA Compressor / Nitrogen plant) for example
In general, Packages will be controlled by their own control system and shut-down safety
protection instrumentation. These shall allow for stand alone operation i.e. package start up,
shut down and continuous control. Packages shall be started (and stopped) from the package
interface panel. When the package is running in a steady state the local control set point may
be switched to remote and the main plant DCS will then take control.
The package control system can be in accordance with the following:
Packages shall be provided with fully redundant control and safety protection systems
(PLC) with respect to power feeders, internal power supplies (and power conditioning),
system processors, I/O cards (inclusive of backplanes / racks / cabling, process controllers,
communication cards etc) as a minimum.
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5. General requirement for instrumentation

system
5.1 General Purpose Packages (Utilities IA Compressor / Nitrogen plant) for example
Shutdown signals and common fault/alarm signals to/from the machine control panels and
main plant DCS/ SIS shall be hardwired. However for smaller packages, control/interlocks
can be carried out in plant DCS/PLC system & same may be excluded from package
vendor scope.
5.2 Intrinsically Safe System Requirements
Following points must be considered while designing an intrinsically safe system:All intrinsic
safety barriers shall be active type isolating barriers.
Each instrument in the Zone 0 & 1 hazardous area and the intrinsic barrier shall be certified
for intrinsic safety.
Each input and output in a loop shall have separate barrier. No barrier shall be shared
between two loops or inputs / outputs.
Any intrinsically safe loop requiring any device to be connected in the hazardous side (Zone
0 & 1) permanently or temporarily shall also be intrinsically safe.
All barriers shall be of MTL or P&F and shall follow AVL of the main control/shutdown
systems (DCS/SIS).
5.3 Software Design Requirements
PLC based systems shall be programmed using either ladder diagram logic or symbolic
function block logic diagram as per IEC 1131. DCS systems, based on the main plant DCS
platform with similar specifications, shall use the identical standards and templates used for
the main plant system. The PLC / DCS configuration shall be logically structured to allow
additions, deletions and other minor modifications without causing a major program
revision.
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5. General requirement for instrumentation

system
5.4 Hardware Design Requirements
The PLC / DCS shall have the capability of being easily field programmed and
reprogrammed through a portable terminal. This device shall also have the capability of
monitoring the program online for trouble-shooting purposes. It shall also be capable of
storing the logic on magnetic, optical or flash storage media for backup purposes. The
necessary software required for package operation shall be provided by package vendor. In
this case, no external hardware is required.
The hardwire interface signals between the plant DCS / PLC / F&G (Fire and Gas System)
and Package control system shall be as follows,
For commands originating from Package control system (panel) & terminating in Plant
DCS/SIS, pot-free contacts with contact rating 230VAC 5A shall be provided & the
corresponding relays shall be supplied by package vendor in package panel .
For commands & set-points originating from Plant DCS/SIS & terminating in Package
panel pot-free contacts with contact rating 230VAC 5A shall be provided, the relays &
isolators shall be supplied by DCS vendor.
Each input and output point shall have a status indicating light mounted on the module. This
light shall indicate the powered state.
Input and output points on a module shall be grouped for specific areas or pieces of
equipment to minimize the number of operating functions affected when a module has
failed, and must be replaced.
Circuits shall not be split between I/O racks or channels. All connected outputs shall be
individually fused.
All memory modules shall have battery backup unless the type of nonvolatile memory used
is guaranteed to maintain its contents indefinitely without power.
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5. General requirement for instrumentation

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5.4 Hardware Design Requirements
The serial ports shall have diagnostics to check the health of the communication with the
DCS and switch automatically to the back up (if Redundant link is applicable) in case of
communication failure and also generate a system alarm.
If the distance between the vendor PLC & plant DCS is above 500mtrs,then Fiber optic link
shall be used for data transfer from PLC to DCS. Necessary hardware i,e Interface unit ,
patch cords ,media converter etc. inside PLC cabinet shall be supplied by vendor.
5.5 System Diagnostic Requirements
The system shall include a full diagnostic facility which shall intelligently identify all system
faults and failures to ensure a fully operable system is maintained.
All system faults and failures shall be alarmed in the DCS, UCPs and annunciator panel.
5.6 Hardware Installation
The PLC/DCS processor shall be identified with an instrument application number.
All I/O racks shall be identified by rack or channel number.
All wires and terminal strips shall be clearly marked with a permanent tag.
Each point on the I/O modules (cards) shall be tagged with the field devices instrument tag
number where possible or alternatively the channel number shall be on the wiring tag. The
I/O wiring shall be tagged with the PLC/DCS address to which it is terminated.
5.7 Cabinet Design
5.7.1 Cabinets in the control room (UCP: Unit Control Panel)
All equipment shall be housed within free-standing steel cabinets. The cabinets shall be a
standard Rittal cabinet, Cabinet Colour (RAL7035) complete with a removable gland plate
and front & rear lift-off opening doors.
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5. General requirement for instrumentation

system
5.7 Cabinet Design
5.7.1 Cabinets in the control room (UCP: Unit Control Panel)
Control panels, in general, shall be of free standing, totally enclosed construction,
fabricated from 3.2 mm thick steel plate.
Cable entry shall be at the bottom of the cabinet. Vendor is to allow sufficient space below
removable gland plate to accommodate the bending radius of the cables and to facilitate
the installation of the cable glands. Cable glands will be provided by others. Punch of holes
by others on site.
Doors shall be secured by a locking system. A single key shall fit all door locks.
Cabinet ventilation shall be arranged so as to avoid Hot-Spots. Forced ventilation, shall
consist of twin parallel units each rated for 100% duty. All air entry and exits shall have
removable, cleanable filter elements.
Fan failure alarm shall be provided. Vendor to generate a common trouble alarm & provide
it on the Annunciator, through a relay.
5.7.2 Local Control / Operation Panel in Outdoor (LCP: Local Control Panel / LOP:
Local Operation Panel)
LCP / LOP shall be skid-mounted on the Machine or installed near the Package, if
applicable. All on-skid instrumentation shall be wired into the LCP / LOP(if applicable). All
necessary cables, cable trays, cable glands, required for the on-skid wiring shall be
provided by Vendor.
The Panel shall be standard Rittal cabinet with appropriate paint for the environmental
conditions stated.
Cable entries shall be at the bottom of the cabinet.
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5. General requirement for instrumentation

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5.7 Cabinet Design
5.7.2 Local Control / Operation Panel in Outdoor (LCP: Local Control Panel / LOP:
Local Operation Panel)
The critical push button (Start, ESD switch(pull to enable type),Remote /Local with locking
arrangement etc.) & lamps (ready to start etc.) shall be provided for start up which shall be
clearly identified in vendor P&ID during detail engineering. Each switch, lamp & control
device shall have a nameplate on the panel exterior
An Annunciator shall be provided on Local Control Panel. The Annunciator window
associated with any trip input shall flash on initiation, go steady when the alarm is
acknowledged, change to a different steady color when initiating device has reverted to
process normal condition (i.e. available for logic reset), and extinguish when logic reset has
been activated.
When the control panel is installed in hazardous area, it shall be of an air purge type. And
then these switches & lamps shall be of Flame proof type. For machines having vibration
measurement a local display unit for vibration & temperature monitoring (certified) shall be
provided/located in a purged enclosure at LCP.
For interface signals with the main plant control systems, the terminal blocks (TBs) shall
also be grouped based on the system it is connected (e.g. separate TBs for DCS, SIS, etc)
and segregated based on the signal type (e.g separate TBs for Analogue, Digital & Serial
Interface Communication signals).
.

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5. General requirement for instrumentation

system
5.8 Power supplies
Only a single or redundant (if applicable) 110V or 220V AC 50 Hz power supply (UPS) shall
be provided to the vendors control system panel at one point (located in Control room,
Satellite rack room, any switch house/building or Field) by the EC (Contractor). Further
distribution of this power or any derived power (e.g. 24V DC etc) required for any of the
vendors equipment/instrument located in the control room or field is in the Vendors scope,
unless indicated in the Interface sketch otherwise
Vendor shall provide all necessary internal power supply units for System components and
these shall be sized for the total possible complement of I/O that could be accommodated
with the Cabinet.
Vendor shall be responsible for all power supply distribution within the cabinet and to
external system components.
5.9 Spare capacity
Generally, automated control systems shall be kept the following spare capacity at final:
Spare cabinet /rack space for a potential increase in I/O hardware by 15% (free space
only)
15% installed spare circuits, sub-circuits and terminals distributed throughout the
system and IO channels distributed amongst the various types of inputs and outputs.

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6. General requirement for

instrument installation

43

6. General requirement for instrument

installation
General
In general all the package vendors to supply pre assembled, Tubed & Wired Instrumentation
Systems, to minimize the site construction work.
6.1 Instrument Air Supply
Air supplies for field mounted instruments and the local control panels shall be provided
from a single main air header connection (provided by EC (Contractor) at one location). The
Vendor shall provide all necessary sub-headers and branches required to feed each
instrument or machine internal to the packaged equipment skid.
Pipe(3) shall be provided from Isolation valve of Air Header up to the Air manifold. Further
distribution shall be done through the Air manifolds (6 Way Or 10 Way).Instrument air
manifolds made out of 2 inch Seamless SS pipe. Each valve, or other user device, shall be
identified by the instrument tag number.
Air tubing shall be minimum 316 stainless steel.
6.2 Process Impulse/ Pneumatic Tubing
The minimum material requirements for instrument impulse tubing after the first block valve
shall be in accordance with the following:
Tubing : Seamless 316 stainless steel to suit the highest design pressure/temperature
application.
Fittings : Double ferrule 316 stainless steel compression type manufactured by
Parker, Swagelok make only.
Impulse line valve after the first isolation valve & drain valve shall be gate valves,
except for equalization valves in case of DP transmitters which shall be globe type.
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6. General requirement for instrument

installation
6.3 Instrument Wiring
Instrumentation cables shall comply with the following requirements:
SWA cables can be installed without conduit. FRP (Fibreglass Reinforced Plastics) or SS
(Stainless Steel) cable tray shall be used. All cables shall be tagged on each side of the
cable. Vendors standard cables/wires can be used for the internal wiring in vendors panels
and enclosure. However all wiring shall be tagged as required in general requirement for
cable tag no.
Multicore cables shall have a minimum of 20% spare pairs. Spare pairs of multicore cables
shall be connected to terminals both in field junction boxes and at the control cabinet end.
All cables in plant areas and between the control room and field ,also inside package
vendors Battery limit shall be run overhead FRP or SS cable tray supported on steelwork
and avoiding hot surfaces. The cable support infrastructure shall be of suitable materials for
the area in which it is to be installed; giving consideration to mechanical strength and
corrosion resistance.
Instrument signal cables shall be run separated from power supply cables and on different
trays. Intrinsically safe (IS) signal cables are to be run on different trays and have separate
junction boxes from those used for non-IS signals (if any). The cable tray shall be
segregated upon the voltage level (24VDC v.s. 110/220VAC). The safety related signal
cables (SIS and F&G) can be run on the same tray of non-safety related signals (DCS).

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6. General requirement for instrument

installation
6.3 Instrument Wiring
Separate junction boxes shall be used for signals connected to different systems like Main
ESD PLC, DCS , Package PLC, Machine Monitoring system ,Fire & Gas System
etc.Further it shall be segregated based on signal type as given below:
a) Intrinsically safe Analogue inputs/outputs (4-20 mA).
b) Flameproof Analogue inputs/Analogue outputs (4-20mA).
c) Thermocouple inputs.
d) RTD inputs.
e) Intrinsically safe Digital inputs
f) Non-Intrinsically safe Digital inputs
g) Intrinsically safe Digital outputs & SOV
f) Non-Intrinsically safe Digital outputs
g) Vibration signals
h) Gas & Flame Detectors.
I) Power
Intrinsically safe barriers for all such signals wherever required shall be provided by vendor.
Both ends of cables shall be glanded and the cable armour is to be earthed at one end only,
always in the field.
All junction box gland plates are to be pre-drilled. The cable entries to be provided for the
holes sizes and quantities specified during detail Engineering.
To achieve insulation and continuity of the screen, the drain wires shall be accommodated
using terminals within the box, which are to be mounted on insulators to avoid making
contact with the junction box or any other electrically conductive medium.
Each junction box (as applicable) shall be provided with external earthing lugs suitable for 4
mm2 earthing connection.
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6. General requirement for instrument

installation
6.3 Instrument Wiring
Field junction box cable entries shall be at bottom only. All junction boxes shall have predrilled and tapped entries according to the selected cable glands (by Engineering
Contractors). Spare holes shall be provided and fitted with certified plugs.
Breathers shall be installed on all junction boxes to avoid condensation within the
enclosure.
For intrinsically safe certified instruments EExe IIC T4 Zone 1, 2 certified FRP/GRP/SS
Junction boxes, with a minimum ingress protection of IP 65 with certified suitable for area
classification shall be provided.
For non-IS signals EEx d IIC T4 Zone 2 certified Die cast Aluminum(LM-6) min. 5 mm thick
junction box with double compression EExd certified SS304 gland (NPT) shall be provided.
Junction boxes shall be sized to accommodate the incoming cables. All spare threaded
entries shall be fitted with the appropriately certified plugs. All on-skid wiring shall be
completed at vendors shop.

47

7. General requirement for test

and inspection

48

7. General requirement for test and inspection

General
The equipment/systems should not leave the Vendors premises for shipment without an
operational test witnessed by the Client/PMC representatives. The following provides guidance
to normal testing requirements.
7.1 System Functional Test
The FAT at system vendor works shall be witnessed by the client & PMC. Before starts to
witness the FAT, the vendor shall have performed a complete system functional test in
accordance with the Vendors standard procedure as well as a test of all the HMI displays, I/O
points, digital and analogue functions etc.
7.2 Test Equipment & Simulation Facilities
The Vendor shall provide all necessary test equipment and simulation facilities required for
witness tests, and supply manpower in order to:
Review acceptance test criteria
Schedule and arrange test facilities
Demonstrate the system according to acceptance test criteria
Analyse and interpret test results for client/PMC personnel
Provide assistance in case of system malfunctions during the acceptance test period.
For packaged equipment linked to the main plant DCS via a serial link it may be necessary to
carry out an integration test, during the DCS FAT, to confirm the functionality of the serial link,
and the correctness of the Modbus mapping via actual simulation of data on the vendor
communication card.

49

7. General requirement for test and inspection

7.2 Test Equipment & Simulation Facilities
A test rack shall be provided by Vendor for the Modbus test. The complete Modbus link shall be
ensured and commissioned including indication on the DCS operator screen and Vendor panel
screen if applicable.
7.3 Field Instruments
All Inline instruments and instruments connected to package control system shall be witnessed
100% for the vendor provision.
All Local mounted instruments (for e.g. gauges) to be installation according to vendors
standard or principal's standards.
Testing and calibration certificates to be provided by package vendor.

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8. General requirement for

documentation

51

8. General requirement for documentation

The Vendor shall be prepare and submit, as a minimum, the following (if applicable)
documents for instrumentation
1) Instrument Index
2) Instrument Data Sheets (ISA standard is preferable.)
3) Package Control & Interface philosophy
4) Wiring Diagrams / Junction Box Termination Detail
5) Hardwire Signal List (IO List) between Vendor PLC & Purchaser Control System (DCS/SIS)
6) Soft wire Signal List / Serial Interface with Purchasers DCS
7) Hardwire Signal List (IO list) for Machine Monitoring System
8) DCS Graphic Plan
9) Sequence / Interlock Logic Diagram & Description
10) Function Description of loops to be controlled by the Plant DCS/SIS.
11) Instrument Loop Diagram (Note 1)
12) Instrument Drawings (by Sub-Vendor)
13) Instrument Panel General Arrangement for(equipment layout and internal wiring diagram)
i) Local control panel(s) / Local Gauge Board.
ii) Unit Control Panel .
14) Sizing calculation of Safety Relief Valves & Control Valves.
15) Construction Drawings (if the site work is required by EC (Contractor))
16) Operation and Maintenance Manual for all instruments and control system
Note 1: Instrument Loop Diagrams supplied by Vendor shall be the loops from vendor's
instrument to the package control system only. In case of package instruments and
interconnection signals connected to the plant DCS/SIS/F&G etc., the respective engineering
contractor shall prepare the loop drawings.
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