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PAC PROJECT

INSTRUMENTATION SPECIFICATION
SECTION-IV

SECTION-IV
ELECTRICAL INSTRUMENT
INTERFACE PHILOSOPHY

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PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-IV
INDEX
SR.
NO.
1
2
3
3.1
3.2
3.3
3.4
4
5
6
7
8
9
10

TOPIC
INTRODUCTION
ABBREVIATIONS
POWER INTERFACES
INSTRUMENT POWER SUPPLIES
LIGHTING SUPPLY/ANALYSER HOUSE SUPPLY
PACKAGE UNIT SUPPLY
ELECTRICAL HEAT TRACING & LO HEATERS CONTROL
CONTROL & MONITORING INTERFACE
MANAGEMENT SYSTEMS
E&I PLANT DESIGN INTERFACES
EARTHING
AREA CLASSIFICATION
I/O INTERFACES CONTROL DOCUMENT
MOTOR OPERATED VALVES (MOVS)
ATTACHMENT
ANNEXURE-I,
INSTRUMENT/ELECTRICAL
INTERFACE
DATABASE

PAGE
3
3
4
4
4
5
5
5
6
8
8
10
10
10

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PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-IV
1.0

INTRODUCTION

This Electrical and Instrument interface specification defines the basic division of
responsibilities between the two disciplines and involves both specialists engineering as
well as design functions.
In addition, this specification indicates how to organize the different interfaces.The
definition of the split of work and division of responsibilities as outlined shall be followed
unless specific circumstances dictate otherwise. These deviations shall be properly
recorded and routed as job instructions within the disciplines task forces for each project
with approval of OWNER. It is the responsibility of both the E&I lead engineers of
BIDDER that the procedures as described in this specification are followed.
Interface control documents shall be prepared by the agreed responsible discipline of
BIDDER for each interface activity (power supplies, process I/Os, etc) at the start of the
project. These interface control documents shall be maintained, updated and
communicated by the agreed responsible discipline in pre-planned intervals during the
development of the project. This shall be approved by OWNER before finalization.
2.0

ABBREVIATIONS:

The following abbreviations are used in this specification:


AC
=
DC
=
DCS =
E
=
EMC =
DCS =
FO
=
HV
=
I&CS =
IFC
=
ILD
=
IMCS =
I/O
=
IRC
=
LV
=
MC
=
MCC =
MOV =
PA
=
P&ID =
PMS =
SCADA =
UPS =
VSD =

Alternating Current
Direct Current
Distributed Control System
Electrical
Electro Magnetic Compatibility
Emergency Shutdown System or Programmable Logic Controller
Fiber Optic
High Voltage
Instruments & Control Systems
Interface Cabinet Analog
Instrument Loop Diagram
Integrated Motor Control System
Input / Output
Interposing Relay Cabinet (Digital I/O interface)
Low Voltage
Marshalling Cabinet
Motor Control Centre
Motor Operated Valve
Public Address System
Piping & Instrumentation Diagram
Power Management System
Supervisory Control And Data Acquisition
Uninterruptible Power Supply
Variable Speed Drive System

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PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-IV
3.0

POWER INTERFACES

3.1
3.1.1

INSTRUMENT POWER SUPPLIES


In general the instrumentation systems and external powered instruments
requiring a supply > 50 V AC, BIDDERs Electrical group shall provide the
power supply system dedicated for BIDDERs I&CS group, including
emergency or standby equipment such as generators and UPS systems,
power distribution boards and safety switches. However, in this case this
shall be tapped off from the main TDI plant control room building UPS
ACDB, which is located at @ 1 km away from the proposed locations.
The various feeders of 110 V AC UPS supply from UPS ACDB located at
main TDI plant control room located 1 km away from the proposed site
shall be available in required qty with required amperage. The detail
engineering of cable size, cable tray lay out and routing, procurement of
cable/cable trays and laying, etc. shall be by BIDDER.
Power supply distribution panels at central cabinet room for both
system/non-system power shall be the responsibility of BIDDER I & C
In case sizing of power supply cable > 2.5 mm2, engineering, design and
supply shall be by BIDDER Electrical. The information and requirements
for all BIDDER I&CS users for which BIDDER Electrical shall provide the
electrical power, shall be communicated by BIDDER I&CS to BIDDER
Electrical by means of the I&CS power supply interfaces list.
Bidder shall ensure 110 V AC -1% & +2% at 50 Hz -3/+1 Hz quality
power supply at Central Cabinet room from OWNERs main TDI project
control room UPS/ACDB. Further distribution for DCS shall be by subvendors. However, while designing instrumentation load in instrument
system PDBs from the UPS ACDB feeders, care shall be taken to ensure
that the max. capacity of each of the mains incomer feeder from UPS to
Instrumentation shall be with max current rating of 10% of the UPS
capacity in total amperage, at 110 V AC. Also all instrumentation loads
shall be catered via two diff. redundant feeders from two different buses
of UPS ACDB.
For field instrumentation requiring 110 V AC, this shall be 110 V AC -2%
& +1% at 50 Hz -3/+1 Hz at field devices (wired from centrally located
non-system UPS PDB from central cabinet room only), including all cable
drops. The same UPS ACDB bus redundancy philosophy shall be
followed for all field instrumentation loads also. However, the complete
instrumentation system, including DCS/DCS , Field instrumentation and
various package unit systems, shall be designed to run from 90 V AC to
120 V AC at 50 Hz 3/+1 Hz.
UPS power supply (110 V AC, 50 Hz) for whole instrumentation system
shall be equipped with half an hour battery back-up source as a minimum,
for safe shutdown of plant, in case of total power failure.

3.1.2

3.1.3
3.1.4

3.1.5

3.1.6

3.1.7

3.2
3.2.1

LIGHTING FOR INSTRUMENTS /PANELS/ANALYSER HOUSES:


230 V A.C. Lighting for Level Gauges and various local panel as well
complete lighting of central cabinet room, central control room and central
engineering room shall be included in the E / I&CS power supply

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PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-IV

3.2.2
3.2.3
3.2.4

3.2.5

3.2.6

3.2.7
3.3
3.3.1

3.3.2

3.4
3.4.1

interfaces list with a reference to the level gauge tag number for which
the lighting fixture is required. This shall be by BIDDER Electrical.
For level gauge, supporting bracket (part of level gauge assembly) and
fixture specification is the responsibility of BIDDER Electrical.
Engineering, design and supply by BIDDER Electrical
Distribution boards, if applicable, shall be located on the outside of the
analyzer house and shall be suitable for hazardous area classification of
the plant. However for each analyser, the individual 110 V AC UPS
supply cables (in required sizes) will be laid from central cabinet room
located non-system UPS PDB by BIDDER I&C. Instead of laying 3 core
power cable from central control room located non-system UPS PDB to
each analyser, there shall be 2 core cable for each analyser. The final
safety earth cable in redundant loop format from each analyser shall be
brought to a common safety earth pit located near control room for
instrumentation safety earth purpose. These earthing cables from each
analyser houses, local panels, etc. to control room safety earth pits shall
be redundant.
No UPS supply shall be provided to analyzer house, local panel for any of
the instruments by BIDDER Electrical, directly from MCC. These shall be
laid from the various UPS non-system PDB panels, located at central
cabinet room by BIDDER I &C, as per requirement.
For Electric motor operated valves, position switches shall be connected
to DCS via Electrical / Instrument interface panel (IRC) via interposing
relays only. Hence from MOV all the signals including torque switches,
limit switches, etc. shall be wired to MCC and from MCC, the required onoff indication limit switches signals shall be wired to instrumentation
system for indication/control/logic purpose to I&C. Hence it is the
responsibility of BIDDER Electrical including supply of cables, glands,
terminations, etc. from field MOV to MCC and MCC to
electrical/instrument interface cabinets.
Power supply to these MOVs is also the responsibility of BIDDER
Electrical.
Power supply to PACKAGE UNITS
This shall be provided by BIDDER I &C from the central cabinet room
located non-system UPS PDB panel located at only one location to each
of the package units in the field. Further sub distribution shall be carried
out inside the package unit by package unit vendor.
230 V A.C. power supply required for non-instrument purpose shall be
provided by BIDDER Electrical to all package units, directly from MCC in
panel shed lighting, shelter illumination, etc. However, local instrument
panel inside illumination shall be by BIDDER I&C, which will be wired
form central cabinet room located 230 V AC utility PDBs by BIDDER I&C.
ELECTRIC HEAT TRACING & LO HEATERs
Electrical heat tracing power supply shall be provided by BIDDER
electrical from MCC. This refers to process pipe line/equipment heat

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PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-IV

3.4.2

3.4.3

3.4.4

4.0
4.1

4.2

4.3

4.4

4.5

tracing, etc. For analyser sample tube heat tracing, etc., it is BIDDER I&C
responsibility to provide 110 V AC UPS supply for sample heat tracing
line from centrally located non-system UPS PDB.
Various Lube oil heater circuits, in general, shall be controlled by DCS by
BIDDER I&C. For the purpose, there shall be separate and dedicated
Lube oil level and temperature transmitters installed on the LO tank.
LO heater shall automatically start and stop from DCS interlock/Logic on
Low LO temperature and High LO temperature/ Low LO level,
respectively, via two separate DCS DO for auto start and process trip, via
interposing relays in IRC driven by DCS Logic.
Additionally, there shall be manual start and stop facilities from DCS
graphic as a soft target. This soft target will actuate a DCS DO, which will
be wired via IRC panel located interposing relays to MCC for start and
stop of LO heater manually.
CONTROL AND MONITORING INTERFACES
The E&I interface point for process and safeguarding systems
measurement, monitoring, control and protection I/Os is the IRC and/or
the IFC which shall be located in the central cabinet / marshalling room
within I&C premises.
The IFC will be used for analogue signals (e.g. VSDS). From this panel,
all 4-20 ma signals shall be wired to relevant I&C DCS marshalling
panels.
Since there shall not be any RTD or T/C type input cards in DCS/DCS ,
all Motor bearing/winding related trips shall be realized by BIDDER
Electrical via their MCC SCADA. Only the redundant software
communication link from MCC SCADA to DCS shall be made available to
I&C for making all such RTD and T/C real time indications/alarms
available to DCS operator on graphics. Hence there shall not be any
motor bearing/winding trip related hard wired signal exchange between
DCS and DCS and DCS to MCC.
Engineering, procurement and laying of cables and all termination from
MCC/Field Motors to MCC SCADA, logic realization in SCADA with
sequence of event reports, etc. shall be carried out by BIDDER Electrical
for all these signals.
All potential free/dry contacts for pump / motor running indications, MOV
open/close limit switches, etc. from MCC/SWB or VSD panels from
electrical shall be wired to IRC via interposing relays and by BIDDER
Electrical, including design, procurement and installation/laying of various
cables between MCC/SWB/VSD panels to IRC. IRC panel shall be of two
types, i.e. DI IRC, which will accept all input signals to DCS wired from
MCC via interposing relays and the DO IRC which will provide various pot
free digital output contact from DCS to MCC via interposing relays. The
relays in IRC for interposing purpose shall be by BIDDER I&C. All RUN
signals shall be hard wired between MCC and DCS. The redundant
software communication link between SCADA and DCS shall be used to
monitor various other signals like motor trouble, motor fault, ready-to-start
signals which are not used in control or interlock/logic by I&C in DCS. If

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PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-IV

4.6

4.7

4.8

4.9

4.10

4.11

4.12

4.13

any of these signals is used in control, interlock / logic or decision making


purpose at DCS, the same shall also be hard wired from MCC to DCS.
All Digital output commands from I&C DCS systems for various purpose
like Motor Trip/Auto-Manual Command( if used), Emergency Stop, etc.
shall be wired from respective DSC panels to IRC via interposing relays
by BIDDER I & C.
All Auto/Manual switches shall be configured in DCS as soft targets on
DCS graphic accessible to operator with dynamic status. The
Auto/Manual logic shall be realized in DCS along with other process
parameters and/or running pump/motor run signals. The auto start
commands generated from DCS DO shall be hardwired to MCC via
interposing relays located in IRC. Hence no field LCS by BIDDER
Electrical shall be with A/M switches. The normally energized status of
relays shall be maintained in normal condition and when relay gets deenergized, auto start command shall be sent to MCC from DCS.
All Digital output commands from interposing relays meant for Electrical
MCC/SWB/VSD panels, etc. from IRC shall be accommodated in IRC.
They shall be wired from IRC panel to MCC/SWB/VSD panel by BIDDER
Electrical. All cables shall be designed, procured and laid by BIDDER
Electrical. The normal energized status of DO relays/Process trip will
keep the pump/unit / section in running condition. On actuation of trip, the
de-energized status of relay shall trip the pump/motor.
All IRC/IFC panels shall be of standard RITTAL make panels with
1200mm (W) x 800mm (D) x 2100 mm(H) size, with RAL7032 color and
shall be located at central cabinet room within the premises of I & C. It is
the responsibility of BIDDER I & C
All cabling between the IRC/IFC and MCC/SWB or other electrical
control panels (i.e. VSDS panels), field Motors, etc. is the responsibility of
BIDDER Electrical. The multi pair cables shall be separate for DI and DO
exchange between MCC and DCS.
The measurement of power factor, frequency, speed, power consumption
and other typical electrical signals to be processed / handled in
instrumentation systems is the responsibility of the BIDDER Electrical
discipline. I&CS will be responsible for incorporation of these
measurements into their system(s) from the interface point (IFC) to
respective DCS /DCS panel. Measurements shall preferably be presented
by BIDDER Electrical as isolated analogue signals of 4-20 mA DC, or this
may be via Electrical SCADA redundant software communication link to
central DCS, if such information are meant only for information purpose in
the DCS.
The monitoring and alarms annunciating associated with motors,
switchgear, transformers and any other electrical equipment, which are to
be, annunciated on instrument panels and/or in I&CS are the
responsibility of BIDDER Electrical. BIDDER I&CS will be responsible for
incorporation of these alarms into their system(s) from the interface point
(IRC) or via software communication link between MCC SCADA and
DCS.
BIDDER I&CS will be responsible for the detailed control, alarm,
safeguarding requirements as shown on the P&ID's and passing all

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PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-IV

4.14
4.15

4.16

4.17

4.18

5.0

signals required for electrical control to the interface point as detailed for
each project.
BIDDER I&CS shall include the tag number on the interface document.
Instrument Loop Diagram shall show the complete loop inclusive a
reference drawing number with respect to the electrical wiring up to the
point of interface, i.e. IRC/IFC.
For all pumps/motors, emergency stop command, BIDDER I&C shall use
a Mushroom Push Button with key lock, installed on Operator console.
This buttons shall operate a 24 V DC interposing relay located in IRC.
The potential free contact from these relays shall be wired to relevant
MCC/SWB/Motors at Electrical Substation by BIDDER Electrical for
stopping those motors. The other spare contact of such relay from IRC
shall be wired by BIDDER I&C as a feed back to DCS as digital inputs to
their system for registration of pressing of push buttons with alarms on
DCS and DCS graphics.
This emergency push buttons shall be in addition to any Trip/Auto stop
contact generated from DCS interlock from I&C System. In this case the
two contacts (Em. Stop and process trip) shall be wired to
MCC/SWB/Motors by BIDDER Electrical in their protection circuitry in
series.
In genral, remote start from Operator Console from Central Control room
is not envisaged for any Motor/Equipments. These shall not be provided,
unless process group requires such facilities for a few of very critical
equipments, which will be decided during detail engineering.

MANAGEMENT SYSTEMS
Motor management and power management system ("intelligent" or
smart switch gear) are the responsibility of BIDDER Electrical. Since
these systems will be integrated with Distributed and/or Other control
systems (i.e. DCS) via redundant software communication link, close
coordination and exchange of data and protocol agreement shall be
established between the BIDDER E&I. The SCADA being designed,
procured and implemented by BIDDER Electrical shall have the following
minimum hardware / functionality for its interconnectivity with central
DCS.
a.

b.
c.
d.
e.

An isolated 2 Wire RS485 Serial Communication Link as an


Interface ( Modem , over RS232C or current loop interfaces are not
acceptable)
A proper communication media like twisted pair, screened/shielded
cable laid between Electrical and Instrument cabinet room.
MODBUS RTU protocol with complete memory map, configuration
details, etc.
The scan time shall be better than 2 to 3 seconds for transferring
all parameters of SCADA to DCS.
Electrical System/MCC SCADA shall be integrated with centralized
DCS. This shall be integrated with centralized DCS located at

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PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-IV

f.

central control room with one way information exchange purpose in


DCS (from MCC to DCS). The communication link between
SCADA and DCS shall be over redundant serial RS485 interface
with MODBUS protocol. There shall not be daisy chain
configuration on RS485 serial link between SCADA and DCS. One
SCADA shall be connected with one dedicated RS485 dual
redundant serial link with DCS. No other RS485 devices shall be
clubbed on this serial link.
The DCS, being a master time keeper on the entire plant wide
network for uniform time stampings, the MCC SCADA shall also be
synchronized with DCS time via NTP and GPS system via suitable
interface with hardware firewall.

6.0

E&I PLANT DESIGN INTERFACES

6.1

CABLE TRAY/LADDER / TRENCH ROUTING

6.1.1

6.1.2

Each discipline of BIDDER is responsible to provide the required input of


the cable tray / ladder routing. The coordination within various other
department of BIDDER like Piping, Civil, Structural and Pipe-support with
respect to main tray/ladder routing (e.g. space management, road
crossings etc.) will be done by BIDDER Electrical for both disciplines.
Underground/trench cables routing is not allowed.
An overall tray/ladder drawing (study) shall be prepared by BIDDER
Electrical, with input from I&CS and will clearly indicating the following:
a.
b.
c.

Tray/ladder routes, including termination points of runs, space and


segregation requirements including spare capacity
Elevations (for trays), Road crossings where applicable
Segregation required between I&CS and Electrical cable
tray/ladder.

In general
All high voltage cables carrying Electrical control voltage
signal/current shall be routed in separate ducts/tray
b.
All low voltage instrument signals like Run indication ( carrying 24
or 5 V DC interrogation voltage from DCS), low voltage electrical
signals like VSD 4-20 ma input/outputs, etc. shall be laid in a
separate tray/duct
c.
All communication cables, PA system audio cables, telephone
voice cables, Fiber optic cables shall be routed through separate
duct/trays
All the ducts/cable trays between instrument central cabinet room and
electrical substation/MCC room shall be sized in such a way to have 50%
spare capacity for future use.
All main cable ducts between MCC and Central cabinet room shall be
min. 5 MM thick GI MOC duct with 3 mm thick SS304 MOC closed cover
and all trays shall be either ladder or perforated tray of aluminum MOC.
a.

6.1.3

6.1.4

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PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-IV
6.1.5

7.0

All MCC cables from MCC to central cabinet room shall be brought inside
via separate dedicated MCT frames the MCT blocks which will be
identified as an Electrical MCT. The low voltage and high voltage MCT
block segregation shall be maintained via separate entries of MCT blocks.
EARTHING

7.1

The main earthing, involving static earthing, protective earthing, lightning


protection and instrument earthing systems are the responsibility of
BIDDER Electrical.

7.2

The provision of earthing facilities on and within instrument equipment,


instruments and any specific shielding requirements are the responsibility
of BIDDER I&CS. However necessary earth pits shall be provided by
BIDDER Electrical as per the requirement of BIDDER I & C. For the
purpose BIDDER I&CS will provide an instrument earthing philosophy
and relevant typical earthing block diagram to BIDDER Electrical.

8.0
8.1

9.0
9.1

10.0
10.1

10.2

AREA CLASSIFICATION
This is the responsibility of the BIDDER Electrical discipline in close
coordination with Process. Area classification schedules, layouts and if
required sections will be prepared, from which both BIDDER E and I&CS
disciplines shall obtain the material selection requirements to ensure
suitability in the specific areas. However, as far as instrumentation is
concerned, the overall concept of all field instrumentation execution shall
be for general purpose instrumentation without any explosion protection
but with weather protection to IP65 as a minimum.
I/O INTERFACES CONTROL DOCUMENT
A common database will be filled with information from BIDDER I&CS,
BIDDER Electrical and BIDDER Process Group, based on various
process requirement, facilities and interlock/control necessity. A
consolidated format is attached herewith as Annexure-1.
Motorized Valves / MOVs:
To the extent possible, the MOV shall not be used in the plant. However,
if the requirement can not be avoided, it shall be the responsibility of
BIDDER Electrical for all type of procurement, erection, commissioning,
power supply provision, laying of necessary cables from Substation and
final operation, testing and maintenance of the same shall be carried out
by BIDDER Electrical. The body/bonnet and trim MOC and other
specifications/ construction of MOV shall be as per mechanical
specification of this ITB.
At few locations, if MOV is equipped with various position sensors, these
shall be SNAP action type micro switches. These shall be wired from field
to MCC by BIDDER Electrical and from MCC, via Digital Input interposing

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PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-IV
relays located in IRC, the same shall be either given to DCS, if used in
interlock/logic. If these switches are used only for indication purpose in
DCS, the same shall be brought to DCS via MCC SCADA over software
communication link.

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