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SPEC NO.

5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS

SECTION: C6

SHEET 1 OF 34

INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS 1.0 Operation, controls and monitoring for all the equipment supplied under this package will be implemented in Purchaser's steam turbine control system. Vendor will furnish the following information for implementation of necessary controls. Detailed P & IDs including tag numbers and secondary descriptions, functional descriptions of the sensors (like alarm, interlock, trip etc.). The tag numbering philosophy will be as per Purchasers procedure. Recommended Control schemes and write-ups. Scope i) All Instrumentation and Control equipment within battery limits are included in Vendor's scope including Three numbers of vacuum transmitters, two nos. Level transmitters for each of the following loops: Hot well Level control,CEP and initial filling line control, Instruments for Condensate Extraction pumps, air evacuation system, Standpipes for level switches& Transmitters , GSC condensate inlet & outlet valves, Pressure Transmitters, Air ejector - steam side and exhaust side valves will be motorized valves and will be interfaced with Purchasers control system. ii) Control valves with SMART positioners. iii) Local indicating panels, if any, duly powered. iv) All erection hardware, JBs, Transmitter racks as required. v) All cables and cable accessories upto JBs. vi) Power supply distribution Boards, if required. vii) Any other I&C equipment as required for control / monitoring of all the equipment supplied. viii) Provision for On-line Conductivity monitoring in Hotwell. ix) Start up and Commissioning spares as required for the complete system. The package will be treated as one contract and required internal communication etc. between Vendor and his Sub vendors of field instruments will not result in contractual problems to the Purchaser. Instruments supplied will be as per approved P & IDs during detail engineering.
ISSUE R0 TCE FORM 329 R3

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1.2 2.0

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS

SECTION: C6

SHEET 2 OF 34

3.0

Recommended Control Schemes: Recommended schemes along with write-up for all the controls as deemed necessary for the Air cooled condenser & auxiliaries, to be implemented in Purchasers TG system will be furnished by Vendor. (i) Recommended Analog Controls for Vendors Equipment/Systems for implementation in Purchasers system This includes all auto controls required for the system. Recommended schemes along with write up submitted by Vendor will be Final Schemes for straightaway implementation, clearly indicating sensor tag nos., legend, interlock requirements, settings for time delays, controller etc. Each block in the scheme will be clearly explained in the associated detailed write-up. Each functional block in the scheme will be accompanied by associated characteristic curve for implementation. All the control system requirements will be clearly brought out with no Holds to avoid any future correspondence. Vendor will account for any delays in implementation of these controls in Purchasers system for want of information/ clarification. (ii) Recommended logic diagrams for control systems to be implemented in Purchasers DCS for drives [ON/ OFF, inching, Solenoid etc.] This includes controls of all LT drives, motor operated valve, solenoid valves, protection & autostandby of LT drives. Schemes will be Final Schemes for straightaway implementation, clearly indicating sensor tag nos. legend, settings for time delays switches etc. Each block in the scheme will be clearly explained in the associated detailed write-up. All the control system requirements will be clearly brought out with no Holds to avoid any future correspondence. Review of the schemes will not be done by Purchaser. Vendor will account for any delays in implementation of these controls in Purchasers system for want of information/clarification. (iii) Sequence logic for auxiliaries start up/shut down/load up/load down This will include all controls (Analog and Binary) Vendor will furnish functional block diagram clearly identifying the various steps for the sequential and auto starting, sequential and auto shut down of the auxiliaries as demanded by air cooled condenser operational requirements at the different stages of operation. A detailed write-up clearly explaining the above will also be furnished. Vendor will ensure that the source instrument requirements indicated in the recommended schemes match exactly with the instruments indicated in the flow schemes and instrument list submitted by Vendor.
ISSUE R0 TCE FORM 329 R3

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS

SECTION: C6

SHEET 3 OF 34

All the required set points will be indicated on the recommended schemes. (iv) Air cooled condenser Vendor will list all the recommended control schemes and logic diagrams which are required for the protection and control of Air cooled condenser auxiliaries (which have to be implemented in Purchasers system) one below the other in a single place. Against each loop, Vendor will clearly list the following under separate columns:a) Tag Nos. along with service descriptions of sensors required for implementation of the loop, which have already been provided by Air cooled condenser vendor on his piping/equipment. b) Service descriptions for sensors/instruments to be provided by Purchaser on Vendors piping. c) Service description for sensors/instruments to be provided by Purchaser on Purchasers piping. The recommended schemes along with write up will be furnished as an Annexure to the Consolidated list referred in the specification. The recommended schemes will be functional block diagrams which can be easily understood and implemented. It is Vendors responsibility to co-ordinate with Automation Vendor for the correct implications of their requirements. Vendor will provide the required data/information to Client/Automation Vendor. Vendor will participate during the turbine FAT along with the Client. Vendor will also participate in SAT and commissioning of his equipment along with the Client. 4.0 4.1 TERMINAL POINT DETAILS All instruments (binary/ analog) and Remote operated valves/dampers/power cylinders all modulating type/isolating services in Vendors scope will be terminated at local area junction boxes conveniently located. Sampling points for Analysers will be provided. Sampling points will include Hotwell (provision of withdrawal type conductivity analyser) and Condensate Extraction pump discharge lines. For sampling points the tap points will be provided with 2 Nos. root valves on process side. All the sampling points will be brought to a common location with 2 Nos, isolating valves on termination side. Sample ports at accessible locations for statutory / emergency checking will be provided by Vendor. Instrument air supply distribution: Purchaser's instrument air will be made available at one point only at the Battery Limit & auxiliaries package. Instrument Air header pressure is 4.5 Kg/Cm2g 1 Kg/Cm2 g. Vendor will distribute the air supply to various equipment of I&C system. Subdistribution
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4.3

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS

SECTION: C6

SHEET 4 OF 34

branch headers in Galvanised carbon steel pipes and threaded fittings will be by Vendor. 4.4 Power supply will be made available by purchaser at Vendors Battery Limit at one point only. Purchaser will provide redundant bulk feeders only for the following types of voltages 110 V AC, 1 phase 50 Hz - UPS; In addition, single feeder of 220 V AC,1 phase 50 Hz Normal power supply is provided for lighting, utility socket. Vendors terminal point is inclusive of Junction Boxes. Performance test points as applicable with suitable isolation valves a) Temperature test points on non-pressure systems will be terminated with thermowells with screwed caps or blind flanges as the case may be. b) Pressure, level, flow and sampling test points will be terminated at a convenient location with nipple and screwed plug after the tap point isolating valves. 5.0 Vendor to note that the equipment supplied as part of this package is an integral part of Turbine controls and hence implemented in Purchaser's system (TG - Vendor's Control system). It is Vendors responsibility to ensure timely and correct inputs to Purchaser's system (TG Vendors scope). The interface logic to integrate Vendor's vacuum and condensate system with main Turbine integral controls implemented in Purchaser's system (TG Vendor's system) will be furnished by Vendor. Vendor will envisage participation in turbine engineering meetings (Minimum Two) with purchaser and TG vendor to freeze the interface requirements. Vendor to note that Purchaser's system output will only be potential free contacts for binary drives and 4-20 mA signals for analog drives. Vendor to offer final control elements and valves suitable for the same. The power supply feeders for Vendors Solenoid valves will be supplied by Vendor. Preferably Solenoid valves will be 24 V DC directly powered from turbine system of Purchaser. The following engineering documents in Purchaser's format, in soft and hard copies will be furnished for Purchasers review and Approval, information as a minimum: I/O List Drive / Solenoid valve list JB schedule Cable schedule Alarm and SER point list Instrument List Instrument datasheets
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10.0

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS

SECTION: C6

SHEET 5 OF 34

Control write up Logic diagrams Operation & Maintenance manuals Catalogues and Model decodification details of Instrumentation equipment 11.0 All set points, function curves, recommended operation modes etc. will be furnished by Vendor Makes and technical features of all I&C equipment included in Vendor's scope is subject to Purchaser's approval during Detail Engineering. Tests and test procedures for Vendors I&C equipment is also subject to Purchaser's approval Supervision of erection, testing, Field calibration and commissioning of all the supplied I&C equipment is in the scope of Vendor. Vendor to list the power supply load for the following, as applicable : -110 V UPS , Single phase 50 Hz for field instruments -220 V, single phase 50 Hz for lights in transmitter racks etc., 15.0 Spares (Optional) Minimum one number or 10 % of each type and quantity of Instruments. Control valves - one set of manufacturer's recommended spares for valve, Actuator and positioner. I & C equipment design and sizing will comply with National / International codes and standards. All documents will be furnished as per Purchasers format in both hard and soft copies. Instrument datasheets will be as per ISA format / Purchaser's format with notes indicating special/salient features of the instruments. Sizing calculations for valves etc.will be submitted along with the datasheets for Purchasers review. Instrument datasheets are subject to Purchaser's approval. Instrumentation List will include P & ID no., Line number, Make, Model no., Range with Units, Source and destination of signals as a minimum. Vendor will include in their P& Ids all the specified requirements including Tag numbers, functional description of the signals like alarm, SER , Interlock ,Trip ,control loop references for both OLCS and CLCS , Legend etc.,. Also Vendor will indicate all Field mounted, Local Panel mounted, and displayed Measurements using Standard ISA symbols and submit for Purchasers Approval. Vendor will submit the recommended logics for the equipment included in the package to be implemented in TG Control system, with the specified details, approve the TG Control system vendors Control scheme/Logic diagram,
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SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS

SECTION: C6

SHEET 6 OF 34

witness and clear the FAT at TG vendors works at his own cost, participate in commissioning and be responsible for the successful commissioning of his supplied equipment from TG Control system. For modulating drives, TG Controls system terminal point is isolated 4-20 ma output. For binary drives, Purchaser's terminal point is potential free contact. It is Vendor's responsibility to provide all the interface equipment as required.The interface signals to TG system shall be terminated at Junction Boxes at a single place. All binary outputs provided from Bidders system cabinets/local panels for connection to Purchasers system will be potential free contacts with a rating of 5 amps at 220 V AC or 0.2 amps at 220 V DC. It is the Vendor's responsibility to provide all the interface equipment as required. Any commissioning delays because of Vendors delay in furnishing the required inputs, approvals etc., will be attributed to Vendor. 18.0 Cables Multipair / Multicore cable will be of 6 Pair/12 Pair or 12 Core/24 Core construction. Multipair / Multitriad cables will be overall shielded. Conductor will be 7 stranded with cross sectional area of 1.0mm2. For power cables minimum cross sectional area will be 1.5mm2. Higher sizes will be selected based on power consumption of instruments.

Field cables will be 1 Pair/2 Pair/2 Core/1 Triad. Conductor will be 7 stranded with cross sectional area of 1.0mm2. For power cables minimum cross sectional area will be 1.5mm2. Higher sizes will be selected based on power consumption of instruments. Thermocouple extension cables will be 16 AWG for single pair construction. Instrument Cables will be blue PVC coated and TRIAD will be of Black colour. Direct cross ferruling philosophy will be adopted for all field instruments, JB's, panels and cabinets. Cabling between equipment supplied by Vendor (Eg: Field instruments, LPB's to Junction boxes etc.) is in Vendor's scope. Cables for interface from Bidder's Junction Box to TG PLC/MCC is in Purchaser's scope. All the cables supplied by Vendor shall be laid in cable trays, conduits and all the cable accessories including cable glands, lugs etc., is included in Vendor's scope. All I&C cables will be armoured. 19.0 Field instruments All instrumentation equipment shall be as per internationally accepted regulations. Statutory approvals as applicable for Design and Manufacturing
ISSUE R0 TCE FORM 329 R3

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS

SECTION: C6

SHEET 7 OF 34

is in Vendors scope. For Statutory approvals required at site , Vendor will provide necessary Technical assistance to Purchaser to obtain the same. The I & C equipment design will be suitable for continuous operation under the specified environmental conditions.System supplied is 2 wire system except in case of Temperature Elements. 19.1 Selection of Ranges for Instruments The ranges of the instruments will be selected based on the following philosophy indicated below: For pressure and vacuum measurements, the maximum operating pressure will be within 70 to 80% of the maximum scale range. All pump suction measurement will cover the negative pressure range also and all vacuum measurements will cover the negative pressure as well as the positive pressure as the case may be. (b) For temperature measurement, the maximum operating temperature will be within 80 to 90% of the maximum scale range. (c) For pressure switches and temperature switches, set points will fall within 40% to 70% of the scale range selected. (c) For level measurement, the maximum of the range will cover the overflow point or six inches below the top of the vessel and the minimum of the range will be six inches above the bottom of the vessel. Also, the gauge glasses will be stacked with overlap to cover permissive, alarm and trip levels. (d) For flow measurement, the maximum range will be fixed at about 10 to 15% above the maximum operating flow. All the instruments, Control units, Junction boxes, Local panel Enclosures will be Weatherproof to IP 65 and Ex-proof as applicable confirming to area classification of hazardous area for the proposed gas. Vendor will furnish the test certificates for the same from statutory body such as FM/UL, CENELEC or equivalent.Suitable vaccum protection will be provided for instruments as applicable. Canopies will be provided for all Field instruments, Junction boxes. Junction boxes will have bottom entry to avoid dust and water ingress. 19.2 Size of Tapping point stub, No. and size of Root Valves for different type of measurements will be as indicated below and as per Table-3. Sl No. Quantity of root valves Size of stub and root Service Condition valve (a)

A. Pressure and differential pressure measurement (i) 2 25 NB >=40 bar OR 425 degree C

ISSUE R0 TCE FORM 329 R3

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS (ii) 1 15 NB

SECTION: C6

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< 40 bar AND 425 degree C.

B. Pressure and Differential Pressure (Oil System) (iii) 1 25 NB >=40 bar OR 425 degree C < 40 bar AND 425 degree C.

(iv)

25 NB

C. Level measurement a) Level Gauge & Switch (i) 2 25 NB >=40 bar OR degree C 425

(ii)

25 NB

< 40 bar AND 425 degree C.

b) Level transmitter (displacement type) (i) 2 40 NB >=40 bar OR 25 degree C < 40 bar AND 25 degree C.

(ii) c) (i)

40 NB

Stand pipe for level measuring instrument 2 80 NB >=40 bar OR degree C 425

(ii)

80 NB

< 40 bar AND 425 degree C.

d. (i)

Flow measurement 2 25 NB >=40 bar OR degree C 425

(ii)

25 NB

< 40 bar AND 425 degree C.

e.

Sampling system measurement (steam & water service)

ISSUE R0 TCE FORM 329 R3

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS (i) 2 25 NB

SECTION: C6

SHEET 9 OF 34

>=40 bar OR 425 degree C < 40 bar AND 425 degree C.

(ii)

25 NB

The instrument tappings/stubs will be provided with necessary isolating valves. 19.3 General All field instrumentation will be weatherproof and dustproof to IP-65 as a minimum. All Pressure/Differential Pressure Transmitters, Flowmeters, Analysers will be microprocessor based. All transmitters will be SMART transmitters with HART Protocol when connected to AUTOMATION SYSTEM in digital mode suitable for AUTOMATION SYSTEM (Delta V from M/S Emerson) being used. All transmitters will be provided with local indicators and will be compatible with hand held communicator. All temperature Elements will be provided with Temperature transmitters in closed racks.All switches will be potential free with 220VAC, 5amp contact rating . Wetted part MOC for all Pressure/Differential Pressure Transmitters, Thermowells will be minimum SS316. For all other instruments MOC will be as per vessel/piping specification or better. Air filter regulator with gauges will be provided for all instruments, which requires instrument air supply. Suitable double compression cable glands & plugs will be used for all Instruments. Electrical entry will be 1/2 NPT (F). In the event of non-availability, suitable adaptors will be used. For duplex temperature elements, DPDT switches, Limit switch boxes one cable entry with 2 pair or other type of cable will be used, if two separate cable entries are not available. Interrogation voltage / Transmitter power supply envisaged is 24 V DC from TG PLC. For switches, contact rating will be 220 V DC, 0.2 A or 220 V AC, 5A. Final control Elements will be suitable for remote operation. Refer Table 1 for Recommended makes, Table 2 for applicable Instrument codes and standards, Table 4 for Units of measurement. 19.3.1 Flow instruments Meter-run assembly will be used for line sizes 1.5 & below. Meter run assembly will be with carrier rings & corner taps with minimum 20 D upstream & 6 D downstream lengths. Integral orifice transmitter with meter run can also be used for line sizes 1.5 and below.
ISSUE R0 TCE FORM 329 R3

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS

SECTION: C6

SHEET 10 OF 34

Flange taps will be used for orifice plate assembly for line size 2 thro 8, whereas D & D/2 taps will be used for line sizes greater than 8. Annubar will be used when very low pressure loss in bigger line sizes is required or in case of low upstream pressure. Annubar will preferably be retractable type. Venturi tube will be used for low pressure loss applications in smaller line sizes. For in-line flow indicators with line sizes 2 & below, variable area flowmeters will be used. All variable flowmeters will be metal tube type. Above 2 line sizes orifice plate assembly with DP indicator calibrated and marked in the Flow Units will be used. Same philosophy will be adopted for flow switches. PD meters will be provided with upstream filter/air eliminator with strainers. Pressure Instruments Pressure gauge dial size will be 150mm. Sensing element & movements will be of SS-316 while bezel/casing will be of SS-304 or die-cast aluminium. Chemical seal type pressure gauges & transmitters will be provided as per process requirement. On pumps with pulsating discharge, glycerine filled gauges or pulsation Dampners will be used. Gauges will be provided with over-range protection of 130% max pressure All pressure gauges will be provided with blowout disc. Wherever gauges are exposed to vacuum, vacuum protection will be provided. The entire pressure instrument will be provided with isolation valve. Two/Three way manifolds will be used for Pressure/ DP Transmitters. Syphon will be used for steam service. All pressure gauges will be provided with gauge cock having depressurising facility and swivel type gauge adapter having copper gaskets. Pressure Gauges will be provided with the Range in Bar. Temperature Instruments Temperature element will be 3-wire Pt 100 RTD up to 300 oC . For higher temperature measurements thermocouple will be used. Duplex type element will be used. Remote mounted Temperature Transmitters will be provided. All field temperature indicators will be Bimetal temperature gauges, every angle type. Dial size will be 150 mm with SS-304 bezel/casing. RTD or T/C alarm card will be used for generating the contact, instead of field temperature switches. Thermowells up to 500mm insertion length will be drilled from SS-316 barstock. Other material will be used as required by process. Above 500
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19.3.3

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS

SECTION: C6

SHEET 11 OF 34

mm the Fabricated Thermowells will be used. Thermowells in the Pipeline will have Process connection of 1 NPT(M), unless and until specified. Combustor temperature measurement will be by radiation pyrometer and R-Type T/C with silicon carbide tube as thermowell. Temperature transmitter will be provided at Turbine outlet. 19.3.4 Level Instruments Generally all level transmitters will be DP cells with flanged connection on HP side. Remote seal on LP. Flushing connection will be provided wherever required by the process. Use of Displacer type level transmitter will be minimised. However this will be used for measurement of interface level. All level gauges will be transparent or reflex type with auto shutoff valve, drain valve & vent plug. Magnetic type will be used when glass can not be used. Central support will be provided for all the level gauges having center to center distance of 2000 or more. For level indication more than 2500mm, 2 number level gauges with 50 mm staggering will be used. Jacketing or steam tracing requirements will be as per process requirements. 19.3.5 Control Valves & On-Off Valves All control valves will be provided with Electro-pneumatic positioner. E/P Positioner will be Conventional with HART. All limit switches will be Two wire Proximity Type with Namur input. All solenoid valves will have 24 V DC. Jacketing or steam tracing requirements will be as per process requirements. Noise at the control valve outlet will be limited to 85 dbA at 1 meter distance. Leakage class will normally be class IV for control valves & class VI for onoff valves. Control valve will be sized such that at normal flow rate valve opening is 60% to 80%. Valve actuator will be sized to operate at air supply pressure of 3.5 Kg/cm2g for power cylinder and 1.4 Kg/cm2g for diaphragm actuator. Open/Close time for on-off valves will be < 5 seconds. In general the type of the valve will be Globe. However for line sizes 6 or greater Butterfly valve will be selected.

ISSUE R0 TCE FORM 329 R3

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS

SECTION: C6

SHEET 12 OF 34

Minimum size of the valve will be 1". Non Standard valve sizes such as 1.25", 2.5" & 5" will not be used. Generally for 2" & smaller control valves, bypass will be provided except where such provision will introduce process hazards. Trim material will be SS-316 minimum; better materials will be selected based on fluid compatibility. For high Differential Pressure or Steam services stelliting will be provided 19.3.6 Safety relief valves All thermal-relief valves will be 3/4 x 1 screwed with 0.06 orifice area. All rupture discs will be provided with disc holders. Jacketing or steam tracing requirements will be as per process requirements. 19.4 Field instrumentation will have a minimum ingress protection of IP65 in accordance with IS 2147/IEC 529. In case of instruments in hazardous area, the intrinsically safe, explosion proof/flameproof instruments will be certified to specific hazardous area class by statutory body such as FM/UL, CENELEC OR EQUIVALENT. Purging will not be used unless specifically called for. P&I Diagrams will identify all instrumentation in accordance with symbols shown on the P&I Legend Sheets. DESIGN PHILOSOPHY Materials of construction for instrument equipment will be consistent with corrosion resistance and the pressure and temperature conditions of the process fluids involved. Generally the parts in contact with the process fluid will be of a material equal to or better than that used for the related vessel or line. Where instrument design prohibits the use of these materials, or where a suitable material cannot be reasonably procured, the instruments will be isolated from the process by means of a chemical seal which will be identified on P&ID. The following materials will not be used in contact with the product: Aluminum Zinc Asbestos Brass, Bronze, Copper Heavy metals including Mercury, Antimony and Cadmium. Plastics containing free Phenol, formaldehyde or plasticisers.

19.5 19.6

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SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS

SECTION: C6

SHEET 13 OF 34

Pressure & temperature rating Pressure and temperature rating of instruments and components will conform to the design rating of the process system to which they are connected. Instruments which can be exposed to vacuum will have under-range protection to full vacuum. 19.7 Hazardous area requirement Classification of Hazardous Area is indicated elsewhere. All instrumentation located or partially located in hazardous area will be suitable for classified hazardous area. The preferred method of protection is by Intrinsically safe (EExia) circuits using galvanic isolated safety barriers. Alternate methods of protection, are subject to approval by client/consultant. Flameproof (EExd) Pressurised enclosures (EExp) Increased safety (EExe) CENELEC / BASEEFA / FM / UL /EQUIVALENT approved certification will be supplied for all electrical / electronic equipment in the hazardous area. The use of other recognized approval authorities will be subject to approval by the Engineer. Accessibility All instruments will be accessible from grade or platform for measurement. In case of gas service where instruments are mounted above the taps, the installation of platform will be considered, if accessibility is not available. Ladder will be provided for all such platform. This should be properly coordinated with the piping group. Analogue signals In case of Smart transmitters, the minimum requirement will be as follows. Communication Protocol will be HART (Latest Version) and will be suitable for asset Management System. Accuracy of transmitters will be +0.1% of range or better for a rangeability of 1:15. The accuracy includes the combined effect of linearity, hysterisis and repeatability. Hand held configurator will be used for remote calibration, remote configuration and diagnostics. It will be possible to connect the configurator in the main control room or junction box located in field. Smart transmitters will be microprocessor based and will incorporate nonvolatile RAM, which will store configuration data of transmittal. Retrofit type Smart Model will not be accepted. Where two wire transmitters can not be sourced, transmitters will be powered externally by 24Vdc (preferred). The range of a transmitter will be specified such that its normal operating point is within the middle third of the calibrated range. Transmitter accuracy, repeatability and rangeability will be suitable for their intended use.
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SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS

SECTION: C6

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Control valve positioners will be with integral E/P converters powered from the control system. (Rosemount-Fieldview)

Transmitters will be two-wire smart 4-20 mA dc powered, from the control system. 19.10 Digital signals Process switches will be SPDT with noble metal contacts, wired normally closed for the safe condition, with contacts opening in the Alarm State. Digital signals will be powered from the control system. Position switches will preferably be inductive two-wire proximity type unless and until mechanical contact has been specified elsewhere. In case of 24V DC Voltage level the solenoid valve will be necessarily I.S. type. Motor control signals : Remote control of motors will typically comprise of the following: START / STOP control output Drive RUNNING control input REMOTE/LOCAL SELECTOR SWITCH (Soft switch) SPEED SET POINT control output to VFD (where appropriate) Current/Load Indication for specific drives. The interface between Motor Control Center and the control system will be indicated to electrical department. Wherever possible, provision will be made for an interfacing Cabinet for Electrical and Instrument, preferably in the MCC room to reduce the number of cables. Pneumatic control signals Pneumatic control and transmission signals will be 0,2 to1.0 Bar FLOW INSTRUMENTS Mass flow meters Coriolis flow meters (Micro motion only) will be used for product critical flow measurement, as they measure accurately the mass flow of fluids with varying density over a wide rangeability and with minimum pressure loss. Mass flowmeter will not be used for Steam Flow. In case of line size less than 2 and the accuracy is not main criterion straight tube meters may be used. In case of bent Coriolis U tubes, it will be supported in accordance with the manufacturers instructions to prevent piping vibration affecting the instrument. The meter must be orientated in the pipe work to allow for selfdraining. The preferred method of installation is, vertical with flow upwards. Vortex flow meters will be used for general process / utility service, and are preferred to differential pressure devices such as orifice plate. The meter may be installed either horizontally or vertically. The straight run requirement will be in accordance with the piping geometry.
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SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS

SECTION: C6

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Variable Area meters Variable area meters may also be considered for clean process / utility service and are particularly suited for Nitrogen purging applications. The Meter design will be preferably of metal tube type. The flow regulation wherever required will be provided by means of an integral throttle valve. Installation will be vertical with flow upwards. Meters may be supplied for local indication, remote transmission of measured variable, or a flow switch output as appropriate. The use of glass VA meters will be for non critical application. Magnetic type flow meters Magnetic flow meters may be used for general process / utility service and have the advantage of an unobtrusive crevice free installation. This meter type can only be used on conductive liquids and is therefore not suitable for high purity water and solvent applications. Typical applications include metering of water, caustic and acid. The meter liner material will be suitable for the process media and design conditions including full vacuum rating where appropriate. Installation will be at the lowest point in the pipe work to ensure the meter is always liquid filled. Orifice Plates Orifice plates may be considered for general process and utility service where the above methods are commercially prohibitive. Orifice plates will be sharp edged concentric type designed in accordance with ISO5167. The orifice flanges will be designed in accordance with ANSI B 16.36. Orifice will be sized so that the normal flow rate falls at approximately 70% of the maximum chart and minimum flow not less than 30% of the maximum chart. Flange taps will be used for line sizes 50mm through to and including 200mm. For line sizes above 250mm D and D/2 tapping will be used. For line sizes less than 50mm specially calibrated orifice metering section or Integral orifice assembly will be used. Plate material will be stainless steel or superior material as required by process conditions. Plate thickness will be relative to pipe diameter and line pressure but not less than 3 mm. In general, orifice plates will be sized using 2500mm WG differential pressure for full scale transmitted range. Other permitted differential pressure ranges are 5000, 3750, 1250, 750 and 500 mm WG. The ratio of the orifice bore to inside pipe diameter (d/D) will be between the limits 0.3 to 0.75. Segmental orifice plates will be used for liquids containing solids. Quarter circle or conical entrance plates will be used for viscous liquids, or pipe Reynolds number less than 10,000.
ISSUE R0 TCE FORM 329 R3

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS

SECTION: C6

SHEET 16 OF 34

Flow straightening vanes may be considered upstream of an orifice plate for flow meter installations in large size pipes when it would be both inconvenient and expensive to provide the "required straight run".

Annubar, pitot tubes may be used for flow measurement on large diameter pipe / duct work, or where only a small pressure drop is allowed. Venturi Tubes and flow nozzle Venturi tube and flow nozzle will be sized as per ISO 5167. Flow nozzle material will be minimum SS-316. Spool piece will be provided at the flow nozzle outlet for maintenance purpose Positive displacement meters For simple local batching application, positive displacement flow meters may be used. This meter is suitable for clean liquids free from entrained vapors and provides a high accuracy output, including low flow and viscous applications. Installation will be arranged to ensure continuous flooding of the meter. An Air Eliminator with strainer and drain will be provided upstream of the meter. 19.13 TEMPERATURE INSTRUMENTS Temperature elements The preferred method of temperature measurement for temperature up to 3000C is by Resistance Thermometer Detectors (RTDs) Resistance thermometers will be duplex 3-wire type, Platinum 100 ohm at 0 C complying with IEC-751. Temperature measurement greater than 400 C will be made using NickelChrome / Nickel-Aluminum, type K thermocouples. Cryogenic temperature measurements will be made using Copper-Copper / Nickel / Aluminum, type T thermocouples. Thermocouple will be supplied in accordance with IEC-584. Appropriate extension and compensating cable will be used. Thermistor elements are not permitted except for motor winding thermal protection. Temperature elements will be supplied complete with thermowell, extension, head and integrally mounted transmitter as a complete assembly.

ISSUE R0 TCE FORM 329 R3

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS

SECTION: C6

SHEET 17 OF 34

Transmitters Transmitters should be smart, range configurable type transmitting a linearised 4 to 20 mA. Transmitters will accept the universal Input. The transmitter will be mounted remotely and wired to the element with Triad cable or compensating cable, as the case may be. In the event of temperature element failure, transmitters will be arranged to drive towards the alarm condition or safe control condition where one exists, or otherwise upscale.

Protecting Thermowells All temperature sensing devices will be installed in protecting thermowells. The thermowell material will be minimum 316SS for temperature up to 6000C and Inconel above it. Thermowells on the equipments will be flanged according to equipment specifications. The flange size will be 40 mm (1.1/2 inch) with rating and facing according to the line classification. On the pipelines the connection will be 1 NPT (M) Thermowells in high velocity service mounted on pipeline will be assessed for vibration resonance effect as per ASME PTC 19.3 For line sizes less than 80 mm (3 inch), the line size will be increased to 80 mm for the insertion of thermowells. For line sizes 150 and above the thermowell length will be selected to ensure the measurement element is within the middle third of the pipe. Standard lengths of thermowell will be used where possible, these are 225 mm, 275 mm, 325 mm, 350 mm, 375 mm, 400mm, 450 mm &500 mm. Thermowell will be machined from the Barstock for length less than or equal to 500 mm., above 500 mm the Thermowells will be fabricated type. Temperature elements on HVAC ductwork may be installed without thermowells. Connection will be by proprietary ductwork mounting brackets. Local temperature indicators Local temperature indicators will be rigid stem bimetallic dial thermometer type supplied complete with protective thermowells. Dial size will be 150 mm nominal and instruments will be heavy duty `every angle' head type. Temperature scales will be direct reading and comply with manufacturer's standard ranges. The case and stem will be in stainless steel. Scales will be selected to cover the range requirements for both normal and design conditions of plant operation. Filled system temperature indicators with capillary connected bulb may be used where reading remote from measurement points is required. Liquid/Vapor filled temperature Indicators may be considered for the services where
ISSUE R0 TCE FORM 329 R3

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS

SECTION: C6

SHEET 18 OF 34

excessive vibrations are expected. Mercury filled systems must not be used. 19.14 PRESSURE INSTRUMENTS Pressure transmitters Pressure transmitters will be referenced to atmospheric pressure. Transmitters will be smart type, with independent adjustment of zero and span at the instrument and from a remote location. Accuracy will be +/0.1% of the calibrated span.

Materials of construction will be suitable for the process media and based upon the piping specification. In general pressure transmitters should have carbon steel bodies and 316L stainless steel diaphragms as a minimum. For corrosive service suitable materials and chemical seals will be selected. Scales will be selected to cover the range requirements for start-up, normal and design conditions of plant operation. Generally analogue devices are preferred, as the measurement loop is continuously monitored for fault conditions. Where a pressure switch is selected its set point and associated switch differential will be clearly specified. Pressure switches connected to the process will have as a minimum, stainless steel measuring elements. Diaphragm elements are preferred for low-pressure applications but must provide adequate containment of process media. Pressure gauges Pressure gauge accuracy will be + 1.0% of full range. Gauges will be provided with the range marking, in Bar Dial size will be 150 mm and cases will be stainless steel screw on or bayonet bezel type. Blowout disc protection will be provided wherever required. The gauges will be orientated in such that they vent safely. Gauge windows will be constructed from safety pattern / toughened glass. Gauges will be normally Bourdon tube types. Bellows or diaphragmactuated gauges will be used for lower pressure ranges. Bourdon tube material will be 316 stainless steel, as a minimum, with stainless steel movement, except where process conditions require more stringent materials. Over-range protection will be 1.3 times the maximum scale range. Where a gauge is subject to greater pressure, a gauge protector/saver will be used. On pulsating service a Snubber/Dampner will be fitted in the input connection. For vibrating service gauge dials will be glycerine filled. Siphons will be fitted to pressure gauges on steam or hot condensable gas services. A gauge valve will be provided for isolation and calibration purposes. A primary isolation valve will be provided where appropriate.
ISSUE R0 TCE FORM 329 R3

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS

SECTION: C6

SHEET 19 OF 34

To facilitate pressure gauge removal and alignment, gauges will be connected to the piping by means of a gauge adapter and not directly into valves. Connections will be 1/2" NPTM

Chemical seals Chemical seals will be provided as required for highly viscous, corrosive, slurry, and toxic applications. Gauges fitted with chemical seals will be flanged in accordance with the piping specification. Fill fluids will be suitable for the maximum process operating temperature. Capillary tubes will be armoured stainless steel and installed such that they are continuously supported. Instrument Manifolds 2-valve manifolds will be used for secondary isolation, venting and calibration of pressure instruments. 3-valve manifolds will be used for secondary isolation, venting and calibration of differential pressure instruments. 19.15 LEVEL INSTRUMENTS Level Transmitters Normally Differential pressure transmitter will be used for the process Equipment. Chemical seal flush diaphragm type will be used for highly viscous, corrosive, slurry, and toxic applications. Float and Tape/Board type or Ultrasonic type Instrument will be used for large liquid storage tanks, depending on the Service requirements. Displacer type level instruments, where used, will be external type with side / side connections and rotatable transmitter head. These types of level transmitters will be used up to 1219 mm. Vent and drain valves will be provided. Torque Tube will be of Inconel as a minimum. Dip tube type Level measurement will be used in case of Pits, Underground tanks. Level Switches For Liquid application, Float/Displacer type level switches will be used, either external cage / internal. For Solids application the Level switches vibrating turning fork or capacitance type or paddle type. Switch material will be suitable for the fluid under use. Level switch connections will be flanged in accordance with the piping / vessel trim specification. Nozzle connections for lined vessels and pipe work will be suitably sized for switch insertion.

ISSUE R0 TCE FORM 329 R3

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS

SECTION: C6

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Level gauges Reflex type gauge glass will be used on all services except the following, where transparent type will be used i) Interface between two liquid ii) Liquids containing sediments or solids Transparent type Transparent type gauge glass will be provided with integral illuminators, wherever required. The visible portion of gauge glass will cover the range of any associated level instrument. The level gauges will be provided with the Vent and Drain valves When two or more columns are required to cover a large range, the visible portion of glass will overlap atleast 50mm. Magnetic type level gauges will be used for services such as viscous, caustic, liquids with crystals etc. 19.16 ANALYSERS pH and Conductivity Sensors will be insertion in line or flow through chamber type. A by-pass loop will be provided to allow isolation, de-pressurisation, and calibration of the electrode system. Electrodes and sealing assemblies must be designed to withstand the process conditions, including pressure, temperature and dynamic forces as well as being resistant to chemical attack. Electrodes will be temperature compensated and supplied complete with buffer reference solution. 19.17 VALVES Control valves Control valves will normally be pneumatic diaphragms or piston actuated eccentric disc type with valve characteristics to suit the control application requirements. Eccentric disc valves will be wafer type for mounting between process flanges. Butterfly valves will normally be used for larger line sizes, or where a small pressure drop is available. Butterfly valves will operate over 60 angular opening unless the valve design provides a full 90 characteristic capability. Rotary valves will be wafer type suitable for mounting between pipeline flanges. Control valves will be supplied equipped and piped with air filter regulator, Electro pneumatic positioner, solenoid valve, proximity sensor, volume booster, etc., as required. Make of positioner will be - Rosemount -field view.

ISSUE R0 TCE FORM 329 R3

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS

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Lined control valves will generally be used for corrosive applications, however where flashing or cavitation is likely to occur exotic materials will be considered. Plug type valves may be used in crystalline and slurry services. The minimum size of control valve will be 25mm. Where the pipe size is less than 25mm the pipe size will be increased locally to accommodate the valve.

Control valves glands on lethal toxic or hydrogen service will be specified with special consideration given to gland sealing such as providing bellow seals. Trim material will be stainless steel minimum for normal applications. Hardened trim material or facing will be furnished on steam, high pressure, high temperature, flashing/cavitating, suspended solid particles or erosive service as the application prescribes. Leakage rate of the valves will normally be Class IV Where tight shut-off is required, Class VI will be specified. Control valves will be specified to provide an acceptable noise level when continuously operating to meet local area requirements but will generally be less than 85 dBA at 1 meter from control valve body and less than 45dBA 20 meters within the site battery limit. Standard valves will be used and solutions to noise generation problems will be in the following order: Low noise trim Inclusion of in-line diffusers and/or silencers. Acoustic insulation. Control valves operated during emergency shutdown conditions will not be provided with either bypasses or hand wheels unless specifically shown on the P&I Diagrams. Where bypasses are provided the CV of the bypass valve will not exceed the CV value of the control valve. Control valves should preferably be installed in horizontal lines with the stem vertical and the actuator uppermost. Rotary valves will be installed with the vane-shaft horizontal. Control Valve sizing will be as per ISA-S-75.01. On off valves The valve type, materials and connections will be in accordance with the pipe specification. The on-off valve body size will be same as line size. Actuators Pneumatic spring return actuators will be generally diaphragm type for control valves and piston actuated for on-off service. The use of motor or hydraulic actuators will be restricted to special applications and will be subject to approval by the Engineer. To protect personnel and equipment actuators will on air or control signal failure drive the valve to the fail-safe state as indicated on the P&I diagram.

ISSUE R0 TCE FORM 329 R3

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS

SECTION: C6

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Double acting actuators will be normally specified for fail last position applications. Where spring return actuation cannot be provided capacity chambers may be specified to ensure the valve fails safe on motive power failure. Actuators are to be sized to drive the valve to its fail position against the shut off differential pressure. Actuators for all valves are to be sized for the site minimum operating instrument air pressure of 3.5 Kg/cm2g.

Solenoid valves Solenoid valves will be sufficiently sized, so as not to impede the valve stroking time. Solenoid coils will be mounted integral to the valve switch box Where solenoid valves are fitted remote to the valve, quick exhaust valves may be utilised to improve valve response time. Valve switch boxes A standard switch box design is preferred for all turn on off actuated valves. The switch box will comprise of two wire NAMUR proximity sensors and integrally mounted solenoid valve. Flying leads are not acceptable. Self-Operated Regulating Valves Self-operated regulating valves will be used for pressure regulation of utility supplies / equipment purging applications and are not recommended where precise control is required. Regulating valves will where possible be integral type to minimise process tapping. Pilot-operated regulation valves should be restricted to high capacity applications. Where appropriate, relief valves will be used to protect down stream equipment from pressure regulator failure. A local means of pressure indication will be provided to facilitate regulator adjustment.

19.18

SAFETY AND RELIEF SYSTEMS General Safety and relief valves will meet the requirements of the ASME unfired pressure vessel code, API RP 520, and API RP 521. Safety Relief valves Safety valves for general process service will be direct spring loaded with high lift characteristics and be flanged with minimum carbon-steel body and stainless steel nozzle, disc. and guides. Lifting levers will be provided as required by the applicable code for air, hot water and steam service.
ISSUE R0 TCE FORM 329 R3

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS

SECTION: C6

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Safety valves will be set to open at the pressure stated on the P&ID. Where variable back pressure exceeds 10% of the set pressure balanced bellows seal type valves will be used. Pilot operated valves will be considered where light gases at high set pressure are encountered and/or where operating pressure is close to set pressure. These valves will have 3% blowdown setting.

Rupture Discs Rupture discs will be reverse buckling with holders to fit inside the ID of the bolt circle of standard flanges. Jacking bolts will be supplied for disc sizes 2 and larger. Where a rupture disc is installed upstream of a safety valve an excess flow valve must be installed downstream of the disc to prevent any back pressure on the disc in the event of disc seepage insufficient to burst the disc, and a 50mm (2) dia pressure gauge provided to detect leakage or rupture. For the combination unit of Safety Valve and the Rupture disc, the capacity factor of 0.9 will be used 19.19 Control Panels Panel Construction Panel front will be fabricated from 3mm CRCA sheet while sides & back from 2mm CRCA sheet. Front sheet will be supported by main angle framework. Panel base will use 100mm x 50mm channel. Necessary foundation bolts, 1/2" x 4" long, will be supplied alongwith the panel. Panel will be weatherproof to IP55 & suitable for outdoor installation in the specified area. Panel will be provided with power distribution board for internal distribution. Panel light will be provided for internal illumination, if possible, Panel light will be provided with door interlock. Gland plate will be provided at the point of cable entry, location of which will be marked by customer on Vendor's GA drawing. An insulated 25mm x 3mm thick plated copper busbar will be provided at the point of cable entry. Body earthing stud will also be provided. Panel will be sandblasted & chemically treated before painting. Final colour shade will be informed later by customer. All front panels will have appropriate nameplates screwed to the panel body. Back of the panel instruments will also be provided with nameplates. PDB will house DP MCB for incoming power & single pole MCB for internal distribution. MCB will be DIN rail mount type. Panel Wiring Terminals will be suitable for 2.5mm2 conductor. Internal signal wiring will be minimum 1.0mm2 while power wiring will be minimum 2.5mm2. Colour coding will be white & blue for signal wiring and red & black for power wiring.

ISSUE R0 TCE FORM 329 R3

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS

SECTION: C6

SHEET 24 OF 34

Separate terminal blocks will be provided for power & signal wiring. Minimum 10 terminals & maximum 20% spare terminals will be provided in each category. 19.20 Instrument Cable Trays GI ladder/perforated trays will be used. All cable trays will be provided with cover. Junction Boxes, Cable Glands & Terminals Junction boxes will be 12 terminal /24 terminal type with separate earthing bar for screen earth. Cable glands will be suitable for the respective cable dimensions. All junction boxes will be weatherproof and dustproof to IP-65 minimum. Terminals will be suitable for rail mounting. 19.22 Impulse & pneumatic pipes/tubes & fittings All the instrument tubing will be SS316 annealed tubing as a minimum. The size will be 12mm OD with 1.5 mm thickness. Special material requirements will be as required by the process fluid. In steam service only welded fittings may be used for instrument impulse connection. Pneumatic tubing will be 6 mm OD SS316 tube. Other sizes will be as per Vendors requirements. Pneumatic signal range will be 0.2 to 1.0 Bar (G). All fittings will be minimum of SS316 compression type, unless otherwise specified for impulse tubing connection and pneumatic tubing connections. Impulse pipes, fittings and air supply and signal piping/tubing will be supplied for all the instruments under the scope of this specification. All the tubing work will be done with either with NPT threaded connection or weld joints. No impulse line will be connected with ferrule connection. Impulse lines will be kept as short as possible. Piping up to and including the first process block valve and in-line instruments will conform to the line or vessel classifications concerned. The first block valve will be installed as close as possible to the line or vessel. Instrument piping after the first block valve may be an alternative equal or better material to that of the main process line or vessel. The hookup arrangement will be approved by Consultant / Purchaser. 19.23 Instrument testing is subject to Purchasers approval during detail Engineering. Drive philosophy: (i) Local push button station will have Run and Emergency stop pushbuttons. (ii) TG PLC will have the following:
ISSUE R0 TCE FORM 329 R3

19.21

19.24

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS

SECTION: C6

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Run(Digital output pulse signal), Stop (Digital output pulse signal), Motor Running Feedback (Digital input),Motor stopped Feedback (Digital input), Motor trip Feedback. Run will be directly connected to TG PLC. Stop will be connected to MCC.Necessary interface with MCC /TG PLC as required will be envisaged by Vendor. 19.25 Motor operated valves (MOV) : Integral starters are not envisaged for Motor operated valves. One set(NO contacts) of Limit and Torque switches for MOV's will be wired to TG PLC and the other set(NC contacts) will be wired to MCC.The above two sets of contacts will be wired to separate Terminal Blocks of the JB.The following interface will be envisaged to TG PLC in addition: Valve open command (Digital output), Valve close command (Digital output),Motor trip feedback (Digital input), In case of critical / inching type valves,Valve position transmitter Feedback(Analog input) is required to TG PLC. 19.26 Actuator thermal overload NC contact will be wired to the MCC. Required interface with MCC/TG PLC will be envisaged by Vendor.

ISSUE R0 TCE FORM 329 R3

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS

SECTION: C6

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TABLE - 1 LIST OF RECOMMENDED MAKES FOR I & C EQUIPMENT SYSTEM The list of recommended makes for I&C equipment system are as listed below:SR NO 1.0 ITEM TG DCS-Control System BIDDER A. Emerson B. YIL C. ABB D. max DNA A. FISHER B. MIL C. D. A. ASCO B. KEYSTONE C. MIL

2.0

CONTROL VALVES,

3.0

ON-OFF VALVES

4.0

PRESSURE VALVES

REDUCING A. FISHER B. MIL

TABLE - 1 LIST OF RECOMMENDED MAKES FOR I & C EQUIPMENT SYSTEM 5.0 ELECTRONIC TRANSMITTERS A. EMERSON(PREFERRED) B. Yokogawa C ABB D Honeywell 6.0 ORIFICE PLATES, A. LOCAL VENTURI METERS

7.0

ANNUBAR

A. EMERSON PROCESS B. A. YOKOGAWA

8.0

ROTAMETERS INCLUDING TRANSMITTERS

9.0

B. EMERSON MAGNETIC FLOWMETERS A. EMERSON B. YOKOGAWA


ISSUE R0 TCE FORM 329 R3

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS C. ENDRESS & HAUSER

SECTION: C6

SHEET 27 OF 34

10.0

VOTEX METERS

A. EMERSON B. YOKOGAWA

11.0

MASS FLOWMETERS A. EMERSON (CORIOLIS) B. ENDRESS & HAUSER PRESSURE GAUGES A. LOCAL B. WIKA C. GI LOCAL WIKA GI INDFOS SWITZER PYRO ELECTRIC

12.0

13.0

14.0

A. B. C. PRESSURE,TEMPERATUR A. E SWITCHES B. C.

D P INDICATORS

ISSUE R0 TCE FORM 329 R3

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


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SECTION: C6

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TABLE - 1 LIST OF RECOMMENDED MAKES FOR I & C EQUIPMENT SYSTEM 15.0 LEVEL GAUGES A. WIKA B. C.

16.0

LEVEL INDICATORS A. WIKA (FLOAT & TAPE TYPE) B. LEVEL SWITCHES (FLOAT A. WIKA / DISPLACER TYPE) B. C. DISPLACER TYPE LEVEL A. FISHER XOMOX TRANSMITTERS / CONTROLLERS B. DRESSER MASONEILAN C. D. BI-METALLIC TEMPERATURE INDICATOR A. LOCAL

17.0

18.0

19.0

B. 20.0 THERMOCOUPLES / RTD A. & THERMOWELLS B. C. TEMP. TRANSMITTERS A. B. C. LOCAL

21.0

EMERSON ENDRESS & HAUSER YOKOGAWA

22.0

pH ANALYSERS, A. EMERSON CONDUCTIVITY ANALYSER B. ABB C. ENDRESS & HAUSER

ISSUE R0 TCE FORM 329 R3

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


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SECTION: C6

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TABLE - 1 LIST OF RECOMMENDED MAKES FOR I & C EQUIPMENT SYSTEM 23.0 02, CO, CO2 ANLYSERS A. EMERSON B. YOKOGAWA DELTON CABLE KEI INDUSTRIES CORD CABLE ASCO PARKER HANIFAN SHAVON NORGREN FISHER XOMOX PLACKA

24.0

25.0

26.0

A. B. C. SOLENOID VALVES A. B. C. AIR FILTER REGULATOR A. B. C.

INSTRUMENT CABLES

ISSUE R0 TCE FORM 329 R3

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


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SECTION: C6

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TABLE-2 INSTRUMENT CODES / STANDARDS SR. NO. 1.0 ITEM Control Valves DESCRIPTION STANDARD EDITION

Face to Face & End to End ANSI B Dimensions of Valves 16.10 Control Valve Seat Leakage ANSI/FCI 70.2 Flow Equations for Sizing Control ISA S75.01 Valves Control valve Noise Calculations ISA S75.17

2.0

Safety valves

3.0

4.0 5.0

6.0

Design & Installation of Pressure API RP 520 Relieving Systems in Refineries PART-I API RP 520 PART-II Flanged Steel Safety Relief Valves API STD 526 Seat Tightness of Pressure Valves API STD 527 Boiler & Pressure Vessel Code ASME SEC VIII Guide for Pressure Relief and De- API RP 521 pressurizing Systems Bursting Discs and Bursting Disc ISO 6718 Devices ANSI Orifice Plates, Steel Orifice Flanges Measurement of Fluid Flow B16.36 Nozzles, Venturi ISO 5167 Tubes Industrial Platinum Resistance IEC 751 RTD Thermometer Sensors Thermocouples-Reference Tables IEC-584 Thermocouple Part 1 Thermocouples-Tolerances IEC-584 Part 2 Thermocouples-Extension and IEC-584 Compensating Cables-Tolerances Part 3 and Identification System Instrumentation Cables BS 5308 Instrument Part-I & II Cables Specification for PVC Insulation & IS 5831 Sheath of Electrical Cables Specification for PVC Insulated IS 694 Cables Specification for Conductors for IS 8130 Insulated Electric cables and
ISSUE R0 TCE FORM 329 R3

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SECTION: C6

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SR. NO. 7.0

ITEM

DESCRIPTION

STANDARD

EDITION

Misc.

flexibles Instrumentation Symbols and ISA S5.1 Identification Graphic Symbols for AUTOMATION ISA S5.3 SYSTEM Systems Instrument Loop Diagrams ISA S5.4 Annunciation Sequence and Spec Quality Standard for Instrument Air ISA S18.1 ISA S7.0.01 IEC 529 IEC 801

8.0

Degree of Protection provided by Enclosures Electromagnetic Compatibility for Industrial Process Measurement and Control Equipment Operating Conditions for Industrial Process Measurement and Control Equipment Hazardous Area Electrical Apparatus for Explosive Gas Atmosphere-Construction and Protection Verification of Flameproof Enclosure of Electrical Apparatus Electrical Apparatus for Explosive Gas Atmosphere-Electrical Apparatus Type of Protection p Electrical Apparatus for Explosive Gas Atmosphere-Classification of Hazardous Area Electrical Apparatus for Explosive Gas Atmosphere-Intrinsic Safety i Electrical Apparatus for Explosive Gas Atmosphere-Artificial Ventilation for protection of Analyser Houses

IEC 654

IEC 79-1

IEC 79-2

IEC 79-10

IEC 79-11 IEC 79-16

Electrical Apparatus for use in ISA Class-I, Zones -0&1 S12.0.01 Hazardous(classified) LocationsGeneral Requirements

ISSUE R0 TCE FORM 329 R3

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SECTION: C6

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9.0

Flanges Threads

Purged and Pressurised Enclosure for Electrical Equipment Wiring Practices for Hazardous(Classified) Locations Instrumentation Part I-Intrinsic safety Intrinsically Safe System Assessment using the Entity Concept Threads-Pipe Threads and Screw General Purpose(inch) Ring Joint gaskets and groove for Steel Pipe Flanges Large Diameter Steel Flanges NPS26 through 60 Steel Pipe Flanges & Flanged Fittings

NFPA 496 ISA S12.4 ISA RP 12.6

ISA TR12.2

ANSI/ASME B1.20.1 ANSI/ASME B16.20 ANSI/ASME B16.47 ANSI B 16.5

NOTES: 1. Unless otherwise specified latest edition of the standard will be referred

ISSUE R0 TCE FORM 329 R3

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TABLE-3

INSTRUMENT CONNECTIONS ON VESSELS / PIPING


SR NO INSTRUMENT FIRST BLOCK INSTRUMEN VALVE T CONNECTIO N 1 1/2 1 1/2 Flanged 1 1/2 Flanged Flanged 4 Flanged ----4 Flanged 1 Flanged 1 Flanged 1 Flanged HP & 1 Flanged 1/2 NPT(F) 1/2 NPT(F) 3 Flanged 1 Flanged 2 Flanged 4 Flanged 1 Flanged 3 x 1.5 Flgd 4 Flanged 1 Flanged 1 Flanged 2 Flanged 1 Flanged 3 Flanged 1/2 NPT(F) --------------------1/2 NPT(F) 1/2 NPT(F) 2 Flanged ----3 Flanged 1/2 NPT(F) 2 Flanged 4 Flanged 1 Flanged 3 x 1.5 Flgd 4 Flanged 1/2 NPT(F) NPT(M) 2 Flanged 1 Flanged VESSEL CONNECTIO N

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0

Displacer LT- External

Displacer LT- Internal Level Gauges Standard DP cellLP Flanged DP cell HP LP Capacitance Type Inst. Level Switch- Internal Float Level Switch- External Float/ Displacer Float & Tape Level Instrument Ultrasonic Level Instrument Pressure Transmitter Pressure Gauges Pressure Gauges- Seal Type Thermowell (Note 2)

NOTES: 1. 2. 3. For any other instrument not referred above, connection will be as per individual requirement. 1 Flanged connection can be used based on availability Flanges will be as per ANSI / ASME Standard.

ISSUE R0 TCE FORM 329 R3

SPEC NO. 5770A-ME-540-003

TATA CONSULTING ENGINEERS LIMITED


AIR COOLED CONDENSOR & AUXILIARIES INSTRUMENTATION & CONTROL DESIGN REQUIREMENTS

SECTION: C6

SHEET 34 OF 34

TABLE-4 UNITS OF MEASUREMENT AND SCALES UNITS OF MEASUREMENTS Volume Heat duty Temperature Length Mass Time Pressure Mass Flow Volume Flow Density Viscosity Voltage Current Power Rotation Noise SCALES Graduation of scales will be as follows : PARAMETER Flow (orifice) Flow ((linear) Flow (variable area) Level Pressure Temperature : : : : : : : : : : : : : : : : m3 kW 0 C mm, m kg, t Sec, min, hr Bar a, Bar g, mm H2 O, kpa kg/ hr , t/hr m3 / hr, Nm3 / hr kg/ m3 Cp. V A kW, MW RPM dBA

: : : : : :

SCALE 0-10 sq. root 0-100 linear 1-10 linear 0-100 linear Direct reading Direct reading

ISSUE R0 TCE FORM 329 R3