AUTOMATIC FIRE WATER SPRINKLER SYSTEM (AFWS)

FOR COMPRESSORS, LPG COLUMNS, TRANSFORMERS

AT ONGC, HAZIRA PLANT ON LSTK BASIS (Tender No. 8A5RC18003)

TECHNICAL BID PACKAGE VOLUME II

INSTRUMENTATION Engineering Services, ONGC Hazira

SECTION 3

INSTRUMENTATION
3.1 General

The purpose of this specification is to define the general requirements and philosophy of
instrumentation system for “Automatic Fire Water Spray (AFWS) System for Compressors,
Columns and Transformers at ONGC, Hazira Plant” including all instrumentation required to
be installed at site under this project.

All the items required for the proper operation & completion of the total system shall be
furnished by the contractor, even though not specifically mentioned in this specification but
required to complete the work.

Contractor‟s scope of work shall be as listed below for instrumentation and control system on
a LSTK basis.

(i) Design and Engineering

(ii) Procurement, Shop testing and supply
(iii) Installation, field calibration / testing and commissioning

The description and requirements contained in this specification are indicated in brief and
may not include all details. However, it is the responsibility of Contractor to develop
approval procedure and execute the job on a package basis in accordance with the job
specifications relevant codes and good engineering practices for smooth & successful
Operation of the Plant.

3.2 Design and Engineering

3.2.1 Contractor shall carryout design and engineering of instrumentation and controls based on the
other technical requirements described in various sections of this bid package. Documents
and drawings shall be prepared by Contractor and furnish to Company for approval as a
minimum. Any other document/drawing not listed but required to carryout the engineering
and for integration with other equipment / packages of the existing plant shall also be
prepared and furnished to Company for approval.

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 AUTOMATIC FIRE WATER SPRINKLER SYSTEM (AFWS)
FOR COMPRESSORS, LPG COLUMNS, TRANSFORMERS
AT ONGC, HAZIRA PLANT ON LSTK BASIS (Tender No. 8A5RC18003)

TECHNICAL BID PACKAGE VOLUME II

INSTRUMENTATION Engineering Services, ONGC Hazira

3.2.2 The design and engineering work shall also include review of post-order vendor drawings
and documents for all instruments

3.3 Procurement, Shop testing and supply

3.3.1 All instruments shall be procured from vendors given in a list for this purpose. In case, any
item is to be supplied from a vendor other than mentioned in the list, Contractor shall obtain
prior written approval from Company for the same before placement of order as per
procedure mentioned in the bid package.

3.3.2 All equipment supplied shall be of field proven quality, both with respect to design and
materials. No prototype instrument or instrument of an experimental nature shall be offered
or supplied.

3.3.3 The Purchase Requisition (PR) for each item shall be prepared by using instrument datasheet
/ standard formats and shall contain all information including the make and model no. of each
instrument, in addition to the material specification. Where the datasheet / standard format is
not available for any of the instruments. Contractor shall use ISA format for the same. In
case, Contractor intends to follow his own format for those instruments for which the data
sheet / standard format are not included in the bid document, it shall necessarily contain all
information as in ISA format, as a minimum.

3.3.4 All arrangement for shop testing and calibration of all instruments shall be carried out by
Contractor. Company or its authorized representative may carry out stage / final inspection of
any or all items of work / supply before shipment / installation.

3.4 Installation, Field testing / calibration & commissioning

3.4.1 Contractor shall carry out installation of all instruments as described. This activity shall
include but not limited to installation of all field instruments, cabling and hook up with
annunciator panel in the control room, installation of junction boxes, interconnection between
instruments and junction boxes, laying of cables from field to control room, tagging and
pair/core identification of all field cables.

3.4.2 Testing & Calibration

Testing of impulse lines, instrument air lines, pneumatic signal tubes and instrument cables

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 AUTOMATIC FIRE WATER SPRINKLER SYSTEM (AFWS)
FOR COMPRESSORS, LPG COLUMNS, TRANSFORMERS
AT ONGC, HAZIRA PLANT ON LSTK BASIS (Tender No. 8A5RC18003)

TECHNICAL BID PACKAGE VOLUME II

INSTRUMENTATION Engineering Services, ONGC Hazira

including special instruments / items if any, and calibration of all instruments shall be carried
out as per the requirements

3.5 Scope of Work

3.5.1 Contractor shall be responsible for all types of Instrumentation work including, but not
limited to the following:

Complete design, detailed engineering, preparation of drawings / documents, sizing,

selection, procurement, installation, cabling dressing, cable tray supporting, testing,
calibration, loop checking and commissioning of all spray system and their accessories,
installation material etc., including supply of commissioning spares, arranging all types of
equipment for testing, calibration, as required for “Automatic Fire water Spray System for
Compressors ,Columns & Transformers at ONGC, Hazira plant”.

3.5.2 Supply of all items (field located and control room located) related to instrumentation
described in the technical documents attached in the bid document.

3.5.3 All additional instruments and controls necessary for safe and efficient operation of the unit
which are not listed specifically in the document but which are required as per vendor‟s
experience/ recommendation and for safety of the plant operation, shall be in the scope of
Contractor without any time cost implication to Company.

3.5.4 In case, the Contractor removes/disconnects any existing system/equipment or damages any
equipment/system during the course of execution of work, it will be the responsibility of the
Contractor to reconnect/repair thel\ system / equipment without any cost implication to
Company.

3.5.5 Contractor shall be required to provide Quartz bulb detector (QBD) which shall respond to
fire in the vicinity where the QBDs are installed. Normally, the QBDs shall be interconnected
through a pressurized pneumatic circuit. In healthy condition, it shall remain pressurized to a
pressure of 3.5 Kg/sqcmg. In the event of fire, the near most QBD will get exposed to excess
heat and it will break giving way for release of air pressure. As a result, the pressure of the
pneumatic circuit will get reduced from it‟s normal value. This situation will be sensed
through a pressure switch (PSL) set at a pressure of 2.5 Kg/sqcmg. In the event of release of
pressure, the pressure switch NC contact will open and thus generating alarm in the
annunciator panels in the control room.
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 AUTOMATIC FIRE WATER SPRINKLER SYSTEM (AFWS)
FOR COMPRESSORS, LPG COLUMNS, TRANSFORMERS
AT ONGC, HAZIRA PLANT ON LSTK BASIS (Tender No. 8A5RC18003)

TECHNICAL BID PACKAGE VOLUME II

INSTRUMENTATION Engineering Services, ONGC Hazira

3.5.6 There shall be independent Remote operated Valves (Full bore Ball valves with pneumatic
spring return actuators) in all units of the instant scope of work. The ROV shall go to full
open status on air fail situation.

3.5.7 Deleted.

3.5.8 The brief scope of work shall include but not limited to the following

(a) LPG Column & Stripper Column- 14 no.s,Compressors-33 no.s & transformers -10
no.s

The system shall consist of (but not limited to) QBD detectors on a pressurized pneumatic
line, ROV, spray nozzles etc. All column shall be equipped with ring of piping with open
spray nozzles. Pipe line from fire header up to the ROV will be filled up with pressurized
water. As soon as heat is detected by quartz bulb on a pneumatic ring, it shall burst resulting
in releasing of air pressure of a pneumatic ring which will result in opening of ROV. Water
shall start flowing from all medium velocity spray nozzles, extinguishing the fire and cooling
the surrounding area, simultaneously, audio visual fire alarm signal shall be generated at
annunciator panel in the Control room & repeated as mentioned in the scope of work chapter
1.32.

The actuation of ROV shall be through pilot valve as per prevailing pressure in the QBD
circuit. ROV can also be operated through operation of either a three way valve or through
actuation in pull station to release the pressure.

In case of compressors, except explosion proof motor ,all area shall be equipped with ring of
piping with open spray nozzles.

3.5.8.1 Operation instruction boards with schematic is to be installed by LSTK contractor near the
ROVs.

3.5.8.2 The annunciator panel in the main control room shall be interfaced with the potential free
contacts from Pressure switches installed in each of the 57 units. The alarms shall be repeated
as mentioned in the scope of work chapter 1.32. Further, vendor to keep provision of Spare
contacts for ROVs (to indicate Open/close status) which may be integrated in future with
project “Revamping of F&G system”.
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 AUTOMATIC FIRE WATER SPRINKLER SYSTEM (AFWS)
FOR COMPRESSORS, LPG COLUMNS, TRANSFORMERS
AT ONGC, HAZIRA PLANT ON LSTK BASIS (Tender No. 8A5RC18003)

TECHNICAL BID PACKAGE VOLUME II

INSTRUMENTATION Engineering Services, ONGC Hazira

3.5.8.3 All annunciation components except the alarm horn and auxiliary contact relays (if used)
shall be mounted integrally in a protective enclosure. Mounting clamps which present a flat
surface to the front panel face shall be provided for panel mounting the assembly. All
connections (i.e. trouble contact, speaker, test, acknowledge and test-push-buttons) shall be
made on screw type terminals. Sufficient spares (minimum 10%) terminals shall be provided
to accommodate all spares / future alarm point in the display. Access shall be provided to
allow checking and / or changing the wiring to these terminal strips.

Lamps shall be capable of removal and replacement from the panel front via individual snap
out windows or a swing out hinged door on which all windows are mounted.

3.5.8.4 It will be the responsibility of contractor to install the pneumatic header from a suitable tap
off point with separate supply lines for ROV actuator and QBD circuit. The pneumatic circuit
shall be made of ½” OD SS 316 tubes network with Tees, elbows and connectors. All Tube
fittings shall be made of SS316 and of twin ferrule design to provide a leak proof system.

3.5.8.5 It will be the responsibility of contractor to test some sample fire detectors (QBD) through
heat simulation, prepare detailed report of testing, establish accuracy as per technical data
sheet. The detectors shall be calibrated at factory before dispatch.

3.6 The design and installation of instruments shall be generally in accordance with ISA / API
recommended practices. The material specifications and practices shall, in general, conform
to appropriate ASTM or equivalent standards. All standards, code of practices to be followed
up shall be of the latest edition.

3.7 Unless otherwise specified all field instruments shall have ingress protection to IP 65.

3.8 All electronic / electrical instruments and equipment shall be suitable for area classification
as per IEC codes certified intrinsically safe equipment or explosion proof enclosures may be
considered. All intrinsically safe instruments shall be certified by the statutory bodies like
CENELEC, BASEEFA, UL, FM, PTB, ATEX etc.

3.9 Materials of construction of instruments shall be consistent with temperature, pressure,

corrosion conditions and other process requirement.

3.10 All the cables termination required for internal wiring shall have proper glands.
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 AUTOMATIC FIRE WATER SPRINKLER SYSTEM (AFWS)
FOR COMPRESSORS, LPG COLUMNS, TRANSFORMERS
AT ONGC, HAZIRA PLANT ON LSTK BASIS (Tender No. 8A5RC18003)

TECHNICAL BID PACKAGE VOLUME II

INSTRUMENTATION Engineering Services, ONGC Hazira

3.11 Double compression type cable glands shall be used for glanding of cables with instruments,
junction boxes, local control panel etc.
3.12 Instrument power circuits specially all digital inputs and outputs shall be individually
protected from fault with the help of fuses. Power supply to the individual instrument shall be
disconnectable from switch and protected with the help of fuse.

3.13 The complete instrument system shall be designed for fail safe operation.

3.14 In case, cable routing need to cross road, the cables shall be taken through steel pipes at a
depth below 0.5 meters.

3.15 Additional bracing / stiffening, modification etc. if required to the existing structures due to
increased load or due to site conditions and not visualized at the time of engineering but
required at site for completion of work as per specification or Engineer in-charge, the same
shall be incorporated and provided by the Contractor as a part of his firm scope of work.

3.16 Documents to be submitted by contractor for Review / approval / information of ONGC:

A) During detailed Engineering :

a) Proposed cable schedule
b) Data sheets for all types of Field devices (ROV, QBD ,Pressure switch,
Annunciator, Control cables, etc)
c) Un-priced copies of all purchase orders for third party items.
d) Complete bill of material.
e) Annunciator Panel internal wiring diagram.

B) As built documents:
a) Hazardous area certificates for all Field devices.
b) Test certificates for cables.
c) Warranty / Guarantee certificates for all third party items.
d) Data sheets for all types of detectors, parts catalogue, Operation manual
for Annunciator panel, panel wiring diagram and any other documents as
relevant for operation and maintenance of the panels.
\

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 AUTOMATIC FIRE WATER SPRINKLER SYSTEM (AFWS)
FOR COMPRESSORS, LPG COLUMNS, TRANSFORMERS
AT ONGC, HAZIRA PLANT ON LSTK BASIS (Tender No. 8A5RC18003)

TECHNICAL BID PACKAGE VOLUME II

INSTRUMENTATION Engineering Services, ONGC Hazira

3.17 Supply of all installation and erection materials such as impulse tubing / piping, pipe fittings
and valves, tubing, tube fittings, cable tray/duct and tray supports, all types of consumable
and accessories or mounting all instruments and instrument supports.

3.18 All type of FRLS cables such as signal, alarm, control, between the following shall be
provided

 Individual instrument to field junction box

 Equipment/instrument to local panel
 Local panel to field junction box
 Field junction boxes to control room

3.19 Supply and laying of Main cable duct, FRP tray, angle tray, structural supports, consumables
for cable laying and routing within the plant and upto control room(if not possible in the
existing tray/system etc.) Preparation of duct/trench (RCC/Buries) from control room to plant
battery limit as applicable.

3.20 Supply, Installation & commissioning of Explosion proof Junction boxes with ingress
protection IP-65 and explosion proof cable glands for signal, alarm and power etc. All tubes
and tube fittings shall be of SS.

3.21 Supply & Installation of all pipes and pipe fittings for instrument air supply distribution and
tubes and tube fittings for instrument air supply etc.

3.22 Supply of any other erection material necessary for installation and commissioning of
instruments and special instrument items.

3.23 Supply of start-up and commissioning spares for all instruments.

3.24 Submission of all required P&ID diagrams, drawings and documents for approval.
3.25 All analog outputs/inputs shall be wired through zener barriers while the digital
inputs/outputs shall be through interposing relays.

3.26 All piping/interconnection shall be carried out as per approved P&ID diagram.

3.27 Junction boxes etc. shall be connected using GI earthing strip to electrical earthing grid in the
plant.

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 AUTOMATIC FIRE WATER SPRINKLER SYSTEM (AFWS)
FOR COMPRESSORS, LPG COLUMNS, TRANSFORMERS
AT ONGC, HAZIRA PLANT ON LSTK BASIS (Tender No. 8A5RC18003)

TECHNICAL BID PACKAGE VOLUME II

INSTRUMENTATION Engineering Services, ONGC Hazira

3.28 Submission of final test report, calibration report etc.

3.29 DRAWINGS / DOCUMENTS REQUIRED FROM CONTRACTOR

The following documents shall be submitted by Contractor for Owner‟s information / review
/ records
TABLE – 1

Sl. DESCRIPTION FOR FOR REMARKS

No. REVIEW RECORD
1 (a) Sizing calculations for valves,
-- √
nozzles
2 Material Requisition and MR – (I), PR (A)
Purchase Requisition for all √ √
instruments
3 Documents / drawings list and
(A) √
schedule
4 Instrument details summary -- √ -
5 Cable / Tubing schedule -- √ -
6 Instrument duct / tray / trench -
(I) √
layout
7 Instrument location, JB √ -
√
location
8 Air/water supply/distribution -- -
√
drawing
9 Instrument Index (I) √ -
10 Sub-vendor list (A) √ -
11 a Installation standards (I) Review required
for those items for which the
√ standards are not enclosed in the
document

12 b Instrument mounting details (I) √

13 Certificates (statutory / test -
(I) √
calibration / inspection)
14 Installation, operation and -
(I) √
maintenance manuals

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 AUTOMATIC FIRE WATER SPRINKLER SYSTEM (AFWS)
FOR COMPRESSORS, LPG COLUMNS, TRANSFORMERS
AT ONGC, HAZIRA PLANT ON LSTK BASIS (Tender No. 8A5RC18003)

TECHNICAL BID PACKAGE VOLUME II

INSTRUMENTATION Engineering Services, ONGC Hazira

Sl. DESCRIPTION FOR FOR REMARKS

No. REVIEW RECORD
15As-built drawings/documents (A) √ -
16Sub vendor drawings / -
-- --
documents
17 Instrumentation / Electrical
(I) √
interface details
18 Spare parts list NA NA For owner‟s review and ordering.
19 Any other drawings / document not Legend :
mentioned in the above list but required
during erection, commissioning, or for ( I) :  for information
reconfiguration of system, shall also be (A) :  for approval
supplied by the vendor.
NOTES :

a. Contractor is fully responsible for guaranteed operation of all instruments. Company‟s

review/approval shall not absolve the responsibility of Contractor.

b. Contractor shall prepare and submit the „As Built‟ drawings/documents duly certified by the site
I/c, along with a certificate that there are no changes in the as built drawings from the AFC / IFC
drawings after commissioning.

4.0 Electrical Construction

a) The installed electrical equipment component parts & associated wiring in the panel shall be in
accordance with the practices outlined in NEC, latest edition, for non-hazardous area. The panel
itself shall meet the requirement for NEMA-I (General purpose indoor) electrical enclosure.

b) Cable glands are to be provided in panel to clamp the incoming / outgoing cables, Glands to be
of Double Compression type and nickel plated brass. Gland plates to be provided to facilitate
cable gland installation.

c) Cables shall be terminated on terminal blocks, wherever necessary. Terminals shall be of screw
clamped, spring loaded, stacking type, on rails, 600 V rated, KLIPPON or equal. Insulation
material shall be melamine. Terminals to be sized to accept, as a minimum 4 Sq. mm cross-
section conductors. No more than two conductors shall be terminated at each terminal. All

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 AUTOMATIC FIRE WATER SPRINKLER SYSTEM (AFWS)
FOR COMPRESSORS, LPG COLUMNS, TRANSFORMERS
AT ONGC, HAZIRA PLANT ON LSTK BASIS (Tender No. 8A5RC18003)

TECHNICAL BID PACKAGE VOLUME II

INSTRUMENTATION Engineering Services, ONGC Hazira

terminal blocks to be raised 300 mm above panel gland plate. Housings for terminals blocks
(terminal box), when used, shall be sized with accessibility and maintenance in view. All
terminal blocks to be mounted on anodized metallic or plastic stand-off. Vendor shall provide
minimum 10% spare terminals on panel. Terminals shall be flame retardant type.

d) IS barriers, wherever used, shall be located at panel bottoms so that field cables can terminate on
them with minimum run inside the panel.

e) Wiring within the panel shall be in flame-retardant type plastic raceways, enclosed with cover
and slotted. Interconnection wiring shall be 1 Sq. mm cross-section stranded copper conductor,
PVC insulated 600 V rated, flame retardant type. Power cable shall be 3 core, 2.5 sq. mm cross
section conductor, PVC insulated and laid up in PVC sheathing, 600 V rated, flame retardant
type. Panels to be supplied completely pre-wired including spare points of modules / controllers
etc., so that it requires only field termination. Wiring in raceways, shall be clamped properly.
Where wiring is run outside raceways, they shall be run in bundles, secured with plastic wire
ties or cable lacing at regular intervals not exceeding 300 mm and routed in horizontal or
vertical planes only. Wires to run parallel in bundles and bundle cross-section be circular.

f) Separate raceways shall be used for power supply wiring, DC and small signal wiring and IS
wiring. Parallel runs of AC and DC wiring closer than 300 mm shall be avoided.

g) Panel shall be provided with dedicated power supply feeders. This box will receive a feeder
cable on the input side and distribute power using copper bar for phase and neutral line.

h) The 24V DC main power supply feeder to the box shall be protected by a suitably sized circuit
breaker with manual trip lever. The breaker shall be housed in suitable surface mounted
enclosure. All components shall be suitable for 24 V DC + 10% Power distribution to
controllers and associated group of auxiliary relays circuits shall be via fused terminals with a
blown fuse indicator, and input/output fuse status alarm.

Panel Ground and signal ground shall be separate. Signal ground shall be provided for circuit
grounds of Electronic instruments Detector Circuit shields, Drain wire of cable shields, I.S.
Barrier earth etc. For this purpose an insulated ground bus bar 25 mm wide x 6 mm thick of
copper material shall be provided which shall run along the entire panel length. Ground wiring
shall be directly connected to the ground bus bar by means of suitable wire lugs. Intermediate
terminals are not allowed. This ground bus bar shall be provided with grounding terminals at

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 AUTOMATIC FIRE WATER SPRINKLER SYSTEM (AFWS)
FOR COMPRESSORS, LPG COLUMNS, TRANSFORMERS
AT ONGC, HAZIRA PLANT ON LSTK BASIS (Tender No. 8A5RC18003)

TECHNICAL BID PACKAGE VOLUME II

INSTRUMENTATION Engineering Services, ONGC Hazira

both ends. Terminals shall be compression type suitable for AWG No. 4 copper ground cable.
The same shall be provided on each panel structure for panel grounding. ;

Each panel and other equipment supplied, as a part of project shall be provided with an earthing
lug.

Creation of multiple grounds in a loop shall be avoided. Where unavoidable, signal isolators
shall be used. Special precautions shall be observed to ensure proper grounding of I.S. Barriers.
Two independent and distinctly identified wires shall be run from barrier earth bus bar to
Ground. The resistance between the barrier earth and the ground shall be less than one (1)
OHM.

Terminals in a terminal block to be identified by their individual numbers located integral with
the terminal itself. Wiring at terminals shall be identified by the terminal number and
termination service at the other end of the wire. Wiring at Instr. & accessories such as relays,
push buttons etc. shall be identified by item tag no. and terminal service at the other end of wire.

Suitably sized Terminals shall be provided for terminating main power supply cable. The size
shall be decided by the contractor.

Internal LED lighting shall be installed within the Annunciator panel to provide adequate
lighting for maintenance of equipment. An On/Off control switch shall be provided for this
purpose in a surface mounted enclosure near both the panel doors. The lighting fixtures must not
interfere with doors or other equipment which must be accessible and space shall be provided
for bulb replacement.

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