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EN-U003(0601/W97)

PAGE 1 OF

J.O./W.O.No.
PAGE

CLIENT

INSTRUMENTATION DESIGN BASIS

10059

34

Doc. No.: 10059-DC-K-01-A

REVISION
of 34
GAIL (INDIA) LTD.

PROJECT

SIXTH FURNACE

LOCATION

PATA, UTTAR PRADESH-DIST : AURAIYA

DESIGN BASIS FOR INSTRUMENTATION

REVISION

Date

12/02/2009

Rev.
Description

For Client
Review

Prepared By

PMW

Lead.

PRD

Project
SS
This document contains proprietary information of S&W and is to be returned upon request. Its
contents may not be copied, disclosed to third parties, or used for other than the express purpose for
which it has been provided without the written consent of S&W.

EN-U003(0601/W97)

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J.O./W.O.No.
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INSTRUMENTATION DESIGN BASIS

10059

34

Doc. No.: 10059-DC-K-01-A

REVISION
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GAIL (INDIA) LTD.

PROJECT

SIXTH FURNACE

LOCATION

PATA, UTTAR PRADESH-DIST : AURAIYA

TABLE OF CONTENTS

Section

Page

1.

SCOPE.........................................................................................................................................3

1.1
1.2
1.3

GENERAL ..................................................................................................................................3
CONFLICTING DOCUMENTS .................................................................................................3
DEFINITIONS ............................................................................................................................4

2.

REFERENCED CODES, STANDARDS AND REGULATIONS.............................................4

2.1
2.2

INDUSTRY REFERENCED CODES AND STANDARDS .....................................................4


OTHER REGULATIONS...........................................................................................................7

3.

BASIS OF DESIGN AND FABRICATION ..............................................................................7

3.1
3.2

CODES, STANDARDS AND REGULATIONS .......................................................................7


MECHANICAL DESIGN...........................................................................................................8

4.

MATERIALS ..............................................................................................................................8

4.1
4.2

GENERAL ..................................................................................................................................8
MISCELLANEOUS....................................................................................................................9

5.

DESIGN REQUIREMENTS.......................................................................................................9

5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10

GENERAL
9
MEASUREMENT DISPLAYS, SCALES AND CHARTS .....................................................12
FIELD MOUNTED INSTRUMENTS......................................................................................13
CONTROL VALVES ...............................................................................................................18
ANALYZERS & GAS CHROMATOGRAPHS
26
INSTRUMENT AIR SUPPLY AND PIPING SYSTEMS .......................................................28
PIPING/INSTRUMENT INTERFACE CONNECTIONS ON VESSELS AND PIPE............28
INSTRUMENT PROCESS PIPING SYSTEMS ......................................................................30
INSTRUMENT ELECTRICAL WIRING ................................................................................31
ACCESSIBILITY .....................................................................................................................34

ANNEXURES
I - BASIC DESIGN INPUT
II - SITE DATA
III - UTILITY DATA

EN-U003(0601/W97)

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INSTRUMENTATION DESIGN BASIS

1.

SCOPE

1.1

GENERAL

Doc. No.: 10059-DC-K-01-A

REVISION
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GAIL (INDIA) LTD.

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LOCATION

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a.

This specification defines the minimum design and installation requirements for the
instrumentation including hardware, software and services to be furnished for
monitoring, control and safe operation, of the Sixth Pyrolysis Cracker Furnace which is
being added to the Gas Cracker Unit located at UP Petrochemical Complex at Pata,near
Auraia in U.P. The project number assigned is 10059.

b.

Scope of instrumentation involved is detailed engineering of those instruments


appearing in the new P& IDs for the Sixth Furnace & Instruments identified on the
existing P&IDs with revision clouds marked. The scope also covers procurement
Inspection & site assistance as described elsewhere in project documents.

c.

Engineering & procurement of Control equipment (DCS) & associated hardware &
software is covered under scope of work. Existing ESD system & I/Os will be used for
Shutdown applications. Available space in Existing Control Room & Equipment room
shall be used & Engineering of these rooms is not involved.

d.

Engineering & procurement of On line analyzers & Gas Chromatographs required for
the sixth furnace are also covered in the scope of work & a new Analyzer Shelter
dedicated for Sixth Furnace shall be located suitably near the Furnace.
Basic Design Inputs considered for this project are covered under Annexure I. Details of
site conditions & utilities and other site specific details are in Annexure-II &
Annexure III to this document.

e.

1.2

10059

CONFLICTING DOCUMENTS
In case of conflict among documents covering this scope of work, the order of precedence of
documents to resolve conflicts is, in descending order:
a.

This Specification, 10059-DC-K-20001, Instrument Design Basis specification


supersedes the proposal documentation; however, contract process control diagrams
and /or piping and instrument diagrams supersede this specification. Deviations from
this specification must be approved in writing prior to implementation.

b.

Industry Referenced Codes and Standards referenced herein ( Section 2.1.)

c.

Seller's proposal and /or standards.


Item c. may take precedence without compromise on safety, operation or maintenance
cost and where the Seller provides an unconditional performance guarantee.

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1.3

DEFINITIONS

1.3.1

Within the context of this Specification the following words shall mean:
a. must or shall - a mandatory requirement for which exceptions will not normally be
granted.
b. should - a preferred course of action for which exceptions will be granted for a superior
course of action.
c. may - an acceptable course of action for which exceptions will be granted for equal or
better course of action.

1.3.2

This Specification shall provide mandatory requirements and guidelines for:


a.

Engineering and design of instrumentation and instrument systems installations.

b.

Preparation of instrumentation procurement specifications for:


1) Flow and temperature measuring elements.
2)

Level, pressure, and temperature gauges.

3)

Process measurement transmitters.

4)

Process monitors and controllers.

5)

Control valves.

6)

Miscellaneous instrumentation, solenoid valves, signal converters etc.

2.

REFERENCED CODES, STANDARDS AND REGULATIONS

2.1

INDUSTRY REFERENCED CODES AND STANDARDS


The industry codes and standards referenced in and / or applicable to this document are listed
below. The latest revision number and / or date of each referenced industry code or standard
are applicable in effect at the start of the project. Any subsequent change shall be revised for
further impact.
a.

b.

American National Standards Institute (ANSI)


1)

ANSI-MC 96.1, Temperature Measurement Thermocouples

2)

ANSI/ISA S75.03, S75.04, Face to Face Dimensions of Control Valves

3)

ANSI B16.104, Control Valve Seat Leakage

American Petroleum Institute (API)


1)

API-RP-551, Process Measurement Instrumentation

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c.

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2)

API-RP-554, Process Instrumentation and Control

3)

API-RP-520, Sizing, Selection and Installation of Pressure-Relieving Devices in


Refineries

4)

API-STD-521, Guide for Pressure Relieving and Depressurizing Systems

American Society of Mechanical Engineers (ASME)


1)

ASME-BPVC, Boiler and Pressure Vessel Codes Section VIII, Pressure Vessels

2)

ANSI/ASME-B1.20.1, Pipe Threads, General Purpose (Inch)

3)

ANSI/ASME-B16.5, Pressure and Temperature Ratings for Pipe Flanges and


Flanged Fittings

4)

ANSI/ASME-B16.10, Face-to-Face and End-to-End Dimensions of Valves

5)

ANSI/ASME-B16.36, Steel Orifice Flanges, Class 300, 600, 900, 1500 and 2500

6)

ASME-B16.104, Quality Control Standard for Control Valve Seat Leakage

7)
d.

e.

f.

ASME MFC-3M -2004 Measurement of Fluid Flow in Pipes Using Orifice, Nozzle,
and Venturi
American Society for Testing Materials (ASTM)

1)

ASTM-A193/A193M, Standard Specification for Alloy Steel and Stainless Steel


Bolting Materials for High-Temperature Service

2)

ASTM-A194/A194M, Standard Specification for Carbon Steel and Alloy Steel Nuts
for Bolts for High-Pressure and High-Temperature Service

Fluid Controls Institute (FCI)


1)

FCI-70-1, Standard Terminology and Definition for Filled Thermal Systems of


Remote Sensing Temperature Regulators

2)

FCI-70.2, Quality Control Standard for Control Valve Seat Leakage

Insulated Cable Engineers Association (ICEA)


1)

g.

ICEA-S-66-552, Instrumentation Cables and Thermocouple Wire

International Electrical Committee (IEC)


1)

IEC 60079, Electrical Apparatus for Explosive Gas Atmospheres

2)

IEC 60534, Industrial Process Control Valves

3)

IEC 60584. Thermocouples

4)

IEC 60751, Industrial Platinum Resistance Thermometers

5)

IEC 60529, Degree of Protection Provided by Enclosures (IP Code)

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6) IEC 60801 Electromagnetic Compatibility of Industrial Process Measurement and


Control Equipment
7) IEC 61000, Electromagnetic Compatibility
h.

Institute of Electrical and Electronic Engineers (IEEE)


1) IEEE-Std 91, Graphic Symbols for Logic Devices (Two-State Devices)

i.

International Society of Automation (ISA)


1) RP-3.2, Flange Mounted Sharp Edged Orifice Plates for Flow Measurement
2) ISA-S5.1, Instrumentation Symbols and Identification
3) ISA-S5.2, Binary Logic Diagrams for Process Operations
4) ISA-S5.3, Graphic Symbols for Distributed
Instrumentation, Logic and Computer Systems

Control/Shared

Display

5) ISA-S5.4, Instrument Loop Diagrams


6) ISA-S5.5, Graphic Symbols for Process Displays
7) ISA-S7.3, Quality Standard for Instrument Air
8) ISA-RP-12.13, Part I, Performance Requirements, Combustible Gas Detectors
9) ISA-RP-12.13, Part II, Installation, Operation, and Maintenance of Combustible
Gas Detection Instruments
10) ISA-S51.1 Process Instrumentation Terminology
11) ISA-S75.01, Flow Equations for Sizing Control Valves
12) ISA-S75.03, Face-to-Face Dimensions for Flanged Globe- Style Control Valve
Bodies (ANSI Classes 125, 150, 250, 300, and 600)
13) ISA-S75.04, Face-to-Face Dimensions for Flangeless Control Valves (ANSI
Classes 150, 300, and 600)
14) ISA-S75.05, Control Valve Terminology
15) ISA-RP-75.06, Control Valve Manifold Designs
16) ISA-S75.11, Inherent Flow Characteristics and Rangeability of Control Valves
17) ISA-S75.15, Face-to-Face Dimensions for Butt weld-End and Screwed-End Globe
Style Control Valves (ANSI Classes 150, 250, 300, 600, 900, 1500, and 2500)
18) ISA-S75.16, Face-to-Face Dimensions for Flanged Globe-Style Control Valve
Bodies (ANSI Classes 900, 1500, and 2500)
19) ISA-S75.17, Control Valve Aerodynamic Noise Prediction

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20) ISA-MC96.1, Temperature Measurement Thermocouples


j.

International Standards Organization (ISO)


1) ISO 5167, Measurement of Fluid Flow by Means of Pressure Differential Devices
Part 1: Orifice Plates, Nozzles and Venturi Tubes Inserted in Circular Cross-Section
Conduits Running Full

k.

National Electrical Manufacturers Association (NEMA)


1) NEMA-ICS6, Enclosures for Industrial Controls and Systems
2) ANSI/NEMA-WC55, Instrumentation Cables and Thermocouple Wire

l.

National Fire Protection Association (NFPA)


1) NFPA No. 70, National Electric Code

m.

Occupational Safety and Health Administration (OSHA)


1) Design Safety Standard for Electrical Systems

n.

Underwriters Laboratories, Inc. (UL)


1) UL, Listings of Approved Equipment (Intrinsic Safe Installations)
2) UL-913, Standard for Intrinsically Safe Apparatus and Associated Apparatus for
Use in Class I, II, and III, Division 1 Hazardous (Classified) Locations

o.

R. W. Miller, Flow Measurement Engineering Handbook

p.

Indian Standards (IS)


1) IS -1239 Mild steel tubes, tubulars and other wrought steel fittings
2)

IS-2147 - Degrees of protection provided by enclosures for low voltage switchgear


and controlgear.
3) IS -2148 - Electrical Apparatus for Explosive Gas Atmospheres
4)

2.2

IS 1554 PVC insulated (heavy duty) electric cables: Part 1 For working voltages
up to and including 1100 V

OTHER REGULATIONS
U.P State Pollution Control Board, norms.
Indian Boiler Regulations (IBR)
Oil Industry Safety Directorate (OISD) Norms

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LOCATION

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3.

BASIS OF DESIGN AND FABRICATION

3.1

CODES, STANDARDS AND REGULATIONS


Instruments and control systems shall meet all the applicable requirements of the codes and
standards listed in section 2.1 above. The following industry codes require particular
attention:
a.

All design and installation of instrument systems shall be in accordance with applicable
sections of API RP-551, 552, 554, 555, 556.

b.

All flanges shall conform to ANSI B16.5. Flange surface finishes shall conform to
MSS-SP6 and shall be 125 to 250 AARH unless specified on the Instrument Data
Sheets.

c.

All threaded pipe, fittings, valves and connections on instruments shall conform to
ASME B1.20.1

d.

Bolts, studs and nuts: the Seller shall certify that all bolting conforms to ASTM
Standards A193/A193M, A194/A194M and A320/A320M.

e.

Instrument piping installations shall meet the requirements of ASME B31.1, ASME
B31.3, applicable sections of API RP-551 for process plants.

f.

Instrument electrical installations shall meet the requirements of applicable national,


state and local codes and standards or recommended practices of applicable associations
or certifying agencies as well as ANSI, FM, UL, NFPA No. 70, NFPA No. 75, NFPA
No. 496, applicable sections of ISA S-12.1 and ISA RP-12.6.

g.

Regulations and requirements of the local National Environment Agency shall be


considered and followed in order to meet emission-monitoring requirements.
Where national, state and local regulatory requirements are stricter than the codes,
standards and recommended practices referred to hereafter and / or listed in Section 2.1,
instrumentation and instrument installations shall conform to all such applicable
national, state and local regulatory requirements.

3.2

MECHANICAL DESIGN
All instruments shall be specified to satisfy the design pressure and temperature conditions of
the associated piping or equipment as specified on the P&ID's, process data sheets,equipment
datasheets & Piping Specifications. MOC of wetted parts shall be as per piping specification
or superior. Instrument Enclosures/ Housing shall meet the hazardous area specifications
( where applicable.)

4.

MATERIALS

4.1

GENERAL
Materials of construction shall be suitable for the service and consistent with project piping
material specifications and/or such other documents applicable to and/or part of this

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specification. Sensing elements shall be SS 316 as a minimum. Fittings shall SS316 &
generally be of seamless construction
The Sellers shall submit welding procedures for instruments where welding is performed on
non standard or special applications. Special requirements for materials in services of -20 F
(-29 C) and below shall be defined on instrument data sheets.

4.2

MISCELLANEOUS
Materials for gaskets, studs, bolts, and nuts when supplied with instruments shall be in
accordance with piping material specifications and/or other applicable documentation.

5.

DESIGN REQUIREMENTS

5.1.1

GENERAL
a.

Process operation, supervision, monitoring, and control will be executed from New &
Stand alone Distributed Control System (DCS) & Shut Down Interlocks from existing
TMR ESD system.

b.

Separate JBs/Cables ( Independent of DCS system cabling) shall be used to wire to


existing spare marshalling terminals & system I/Os for the instruments connected to
ESD PLC system ( Triconex) configured for 2-o-o-3 Voting.

c.

ESD signals would be grouped to three ( 3) independent JBs & wired through
independent cables to three (3) separate Cards.
All instruments, controls, and associated items shall be suitable for the given application
and comply with functional requirements, process conditions, environmental conditions,
and hazardous area indicated in data sheets. All equipment shall be proven, installed
and operated, and have been in production for a minimum of 12 months.

d.

All instrumentation shall be designed to fail to a defined safe condition, under expected
normal and adverse operating conditions, in the event of loss of electrical power,
pneumatic power or remote control signal

e.

Instruments shall be protected from extremes of temperature and other adverse


conditions by protective heating, sealing, housing, insulating, purging, shading or
cooling.

f.

Field-mounted instruments shall be installed as close as possible to the take-off point


from the process piping, and mounted on a platform or grade for easy & safe
accessibility.

g.

All instrument-wetted parts shall be compatible with the fluid to which they are exposed
and inline instruments shall comply with the Project Piping Specification. The element
material of pressure transmitters shall be stainless steel as a minimum.

h.

Following Instrument tag numbering philosophy shall be adapted for this project.

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A.

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Field Instruments 10-XX-YYZZ where XX = Instrument Type


YY= Last 2 digits of PID No. for 6th Furnace & ZZ = Serial No. (as for other
Furnaces)
Typical Tag for UNIT 10 , P & ID no. 1981 10-FT-8101

B. DCS Tag Depending on the limitation of the characters in DCS tag for the
selected DCS system, either of the following philosophy will be followed.
1.
If limited to 8 characters, format shall be 1FC8101 1TI 8201
1VAH 8201 Typical (1 corresponds to UNIT 10)
2.
If not limited to 8 characters, format shall be 10FIC8101 10TI
8201 10VAH 8201 etc.
5.1.2

HAZARDOUS LOCATIONS & ENCLOSURES


The hazardous area classification shall be as per the existing plant hazardous area classification
drawings as listed below.

Area classification- Ethylene Plant drawing 6245-10-16-50-0011 Rev 1


However, shall be re-confirmed after revised Area Classification Drawing is issued for Sixth
Furnace.
a. Existing equipments will be referred for reference of the hazardous area classification
wherever required. GAIL 5th furnace design will be referred for classifying the area
related to 6th furnace project.
b.

c.

All field mounted instrumentation shall be designed suitable for location in Zone 2,
Group IIA / IIB, Temp. T3 hazardous area as a minimum.
Inside Analyzer shelter, Gr.II C area shall be considered. Gr.II C area elsewhere if any
shall be indicated during detailing on the instrument data sheet.
Hazardous location classes will conform to IEC 60079 / IS 2148
The preferred methods of protection are:
EU and International
IEC 60079
Certification ATEX or FM and Flame Proof approvals from CMRS,
DGFASLI & BIS for Indigenous
Ex e (increased Safety)/ Ex d or Combination For JBs /Local panels
depending on Signal Type
Ex ia (intrinsically safe) For all AI, AO, Thermocouples & DI
Ex d (Flameproof)
- For Solenoid Valves
Intrinsic Safety requirements shall be achieved using Isolators/Barriers in safe area.
Cable parameters shall be strictly adhered to fulfill the requirements of entity concept.
Control room, and Rack room areas are classified as safe areas.

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d. All field mounted equipment shall be weatherproof to IP 65 (IEC 60529/ IS 2147 ) as a


minimum, unless agreed with owner, and suitable for location.
5.1.3

TRANSMITTERS
a.
b.

Electronic transmitters shall be 2 wire microprocessor based programmable smart


transmitters with HART protocol. Loop power supply voltage shall be 24 VDC.
Where required, square root extraction or other linearization shall be carried out at DCS.

c.

All transmitter shall be intrinsically safe Ex-ia/ib certified for use in specified hazardous
area unless unavailable. Only in such cases Ex-d or other suitable protection technique
may be used.

d.

The rangeability shall be typically 100:1 for base model. Transmitter accuracy shall be
0.15% of calibrated span or better (including combined effect from linearity, lagging,
and repeatability). The accuracy of electronic differential pressure transmitters shall be
0.25% of full scale or better. Low pressure application The rangeability shall be 15:1

e.

All transmitters shall be provided with integral digital (LCD) display, configurable for
scale range & engineering units

f.

The design of Electronic transmitters shall be in compliance with the electromagnetic


compatibility requirements as per IEC 60801.

g.

Transmitters span and zero adjustment shall be possible without removing the cover.
The element material will normally be stainless steel as a minimum. However, corrosive
fluid, low or high temperature may require the selection of other materials. The body
material of transmitters will be as specified in the data sheet Electronic housing shall be
low copper aluminium.

h.

DP transmitters where used shall withstand differential pressures equal to the maximum
static pressure for the service. without zero or calibration changes.

i.

Temperature transmitters are not envisaged for this project.


Temperature signal: For Closed loop applications, mV signal from T/C elements shall
be wired directly to T/C to Current converters installed in Marshalling cabinet in the
Rack Room.
For Open Loops, Field MUX shall be used along with MUX Receiver in safe area
through suitable IS interface.

5.1.4

SWITCHES
Process switches where used shall be equipped with snap acting micro switches with
environmentally & hermitically sealed contacts and of adequate contact rating.

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5.2

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TRANSMISSION SYSTEM & SIGNALS


a.

All equipment shall be immune to disturbance caused by extraneous electrostatic and/or


electromagnetic interference and shall comply with the requirements of IEC
60801/SAMA PMC-33.1 and IEC 61000.

b.

Analog instrument signals will be standardized as follows:

c.

5.1.6

10059

1)

Pneumatic signals: 0.2 - 1 Kg/cm2 g

2)

Electronic analog signals: 4 20 mA DC

3)

T/C : mV signal

Digital instrument signals will be:


1)

Digital input to DCS/PLC will be 24 VDC

2)

Digital output from DCS/PLC will be 110VAC.

PNEUMATIC INSTRUMENTS
a.

Pneumatic instruments shall normally operate with a nominal 1.4 Kg/cm2g air supply
and 0.2-1.0 Kg/cm2g input and output signals.

b.

Each pneumatic instrument shall have an individual air supply complete with shutoff
valve and air set (air filter/regulator with output gauge).

c.

Pneumatic instruments shall fail safe on instrument air supply failure.

MEASUREMENT DISPLAYS, SCALES AND CHARTS


Scales for direct reading instruments shall be as shown below:
Variable
Temperature
Pressure. Near Atmos.

Engineering Units
Degrees C
mm WC

Scales
Direct Reading
Direct Reading

Differential
Pressure
Above Atmos.
Below Atmos.

mm WC (flow meter DP)

Direct Reading

kg/cm2-g
mm of Hg A

Direct Reading
Direct Reading

Absolute

kg/cm2-a

Direct Reading

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Level

Flow

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Percent of range for process;


0-100 Uniform or feet
mm of actual height for storage and inches (mm)
tanks where precise inventory is
required.

Steam
Boiler Feed
Water
Process Liquids
Water
Gas or Vapor
Air & Nitrogen
Linear Flow
Measurements

kg/hr
kg/hr

Direct Reading
Direct Reading

kg/hr
kg/hr
kg/hr
kg/hr or NM3/hr *
Units as above

Direct Reading
Direct Reading
Direct Reading
Direct Reading
Direct Reading

Analyzers
pH, % oxygen, PPM, PPB
Direct Reading
Notes:
* Standard std defined as at 60 F (15.6C) and 14.7 psia (1.03 bara)
** Direct Reading on transmitter
*** 0-100 Uniform if transmitter or receiver provides for square root extraction
**** Normal N defined as at 32 F (0C) and 14.7 psia (1.03 bara)
5.3

FIELD MOUNTED INSTRUMENTS

5.3.1

FLOW
Design, construction, and fabrication of Orifice Plates, Flow Nozzles, Flow Tubes, Venturi
Tubes shall be as per ISO 5167. Pitot Venturi Tubes, Averaging Pitot Tubes and
prefabricated meter runs shall comply with the Industry standard shown on the Instrument
Data Sheets. Differential pressure transmitters shall generally be used for Flow measurement
however, other types such as Vortex, Electro Magnetic or Coriolis flow transmitters may be
used where more suitable for the given application

5.3.1.1

ORIFICE PLATES -GENERAL


a.

5.3.1.1.1

The primary element shall generally be concentric, square edge Orifice plate mounted
between a pair of weld neck type orifice flanges & shall have flanged taps. Eccentric or
segmental orifice plates shall be used to measure the flow of liquids that contain solids
& Quadrant edge plates or segmental wedges shall be used where viscosity conditions
dictate.

CONSTRUCTION
a.

Orifice plate material shall be 316 SS, However, depending on fluid, Orifice plate with
material suitable for the service shall be provided.

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Orifice plates shall generally be in accordance with ASME-MFC-3M or ISO 5167 (for
line size greater than 50 mm & less than 1000mm & pipe Reynolds no. below 5000).
Plate thickness shall be as follows:
Line Size

Thickness

2 inch to 8 inch

1/8 inch (3.18 mm)

10 inch to 14 inch

1/4 inch (6.25 mm)

16 inch to 24 inch

3/8 inch (10 mm)

Words UPSTREAM & Orifice Bore size shall be stamped on the upstream side of the
tab, and the tag number, d/D, MOC & Rating shall be stamped on the downstream side
of the tab. Orifice Meter run lengths shall be in accordance with ASME-MFC-3M and
ISA RP-3.2 ,ISO 5167 (additional 0.5% uncertainty lengths shall be used)

5.3.1.1.2

c.

Orifice flanges shall be 300 # WN RF (125AARH ). Flange MOC, Taps ,Gaskets shall
be as indicated on data sheet

d.

The Seller shall submit his welding procedures to Purchaser for review and approval
prior to starting any fabrication.

SIZING CALCULATIONS
a.

Primary element calculations shall conform to the requirements established in ASMEMFC-3M , ISO 5167 or Flow Measurement Engineering Handbook, by R. W. Miller).
Manufacturer's proprietary formulas if used shall conform to above standards.

b.

Orifice bores shall be sized so that normal flow rate falls at approximately 70 percent of
full scale (on condition that maximum flow does not exceed 90 percent of full scale),
and minimum flow at not less than 30 percent of full scale for control and 40 percent of
full scale for higher accuracy measurements.

c.

Orifice meter differential range shall be selected for a beta ratio (d/D) of between 0.3 and
0.7 for flow control measurements and between 0.4 and 0.6 for other critical flow
measurements such as process performance guarantee or accounting. Base conditions
shall be referenced to 14.7 psia (1.03 bara) and 60 F (15.6 C). Actual orifice diameter
shall not be less than 0.25 inches (6 mm)

d. A differential range of 100 inches of water (2500 mm WC ), dry calibration, shall


normally be used for all flow meters. Other Standard range differentials for orifice taps
shall be 0-1250,0-5000 mm WC ).
e. Condensate pots may be provided for flow measurement of superheated steam and/or
high-pressure steam services.
f. Orifice plates shall be provided with vent holes for liquids or drain holes for gas/vapors in
accordance with the size determined from ISA RP-3.2

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Vortex Flow meters


a.

Vortex type flow instruments will be used for services requiring a wide range per
process operating conditions, where orifice type flow meters are impractical. In addition
to Orifice Flow meters, Vortex flow meters shall be provided for Dilution Steam flow in
order to ensure that flow measurement is always available.

b.

Meter accuracy shall be 1.0% of full scale.


Care must be taken when using Vortex meters to ensure that the minimum flow
requirement is above the minimum flow cut off. This may vary given noise in the
system. Vortex meters shall not be used where there is the possibility of condensate
droplets passing through the meter. Vortex meters are generally one size less than line
size. The use of line size meters may not achieve an operable turndown.

5.3.2

5.3.3

LEVEL
a.

D.P. transmitter with NPT or 3 flanged level transmitter (for diaphragm seal D P
instrument on vessel HP & LP) will be preferred method for level measurement.

b.

Level instrument having external float cages must be equipped with isolation valves on
both connection between vessel and cage, and must also be equipped with a drain valve.

c.

Instrument connections on vessels/columns shall be flanged.

d.

Level gauges shall be magnetic coupled type.

e.

Level gauges shall be reflex type if suitable for service with 25 NB flanged connection
to the vessel. They shall be provided with auto shut-off ball check valve.

f.

Level instruments, in general, shall be direct connected to vessels unless specifically


restricted by Project Specifications, Boiler Code, or other limitation e.g., interface
service must be direct connected. Level instruments used in shutdown service shall not
be installed on bridal.

g.

Vessel Stand Pipe connections shall be 2-inch flanged, minimum.

h.

Special Electonic Drum level gauging system working on Steam/water Conductivity


such as LevelState or Hydrastep shall be used for Boiler Drum Level measurement.

PRESSURE
All pressure sensing devices even if direct mounted must be equipped with at least one
isolating valve, permitting the instrument to be removed for servicing without depressurizing
the system being measured. Instruments having a maximum scale reading of 3 kg/cm2 or
more shall be equipped with an unobstructed blowout device. For slurries, viscous and
corrosive fluid duty, chemical seal pressure gauge shall be considered.
a.

Pressure elements shall, in general, be 316 SS except:

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1) Where the nature of the fluid is such as to require other material, the primary
element shall be suitable for the service.
2) On receiver gauges and diaphragm sealed gauges, or 2 gauges on Instrument air
service where bronze elements may be substituted.
3) On very low pressure ranges such as for draft gauges or barometrically
compensated elements for absolute pressure where alloy steel elements are not
available.
b.

Pressure gauge sockets shall be of the same material as the primary element and shall be
welded to the element using the same filler material. Brass or bronze elements may be
silver soldered.

c.

In general, pressure gauges shall have stainless steel casing.

d.

In general, pressure instruments and gauges shall be furnished with full-scale standard
pressure ranges having the lower limit of the range equal to zero gauge pressure.
Suppressed ranges may be utilized where required for measurement sensitivity. For
pressure gauges the range shall be selected so that the normal expected operating
pressure shall be between 33 percent and 67 percent of full scale, and the maximum
expected operating pressure should be less than 100 percent of full scale. Emergency
over-pressure conditions shall not exceed the over-pressure rating of the gauge.

e.

Pressure gauges shall have a 6 (150mm) dial & inch NPT bottom connection, gauge
adapter, a blowout back, and shatterproof glass. Gauges shall be in accordance with
API-551.
Solid front-type gauges shall be furnished for pressure ranges over 300 psig (20 Barg)
(Safety Pattern). Gauge size may be reviewed on specific applications.
1) Pneumatic receiver gauges shall have a 4 inch (100 mm) dial size.
2) The accuracy of the pressure gauges is 1.0 % or better.
3) The measuring element will normally be stainless steel.
4) For high-pressure applications, where the maximum operating pressure can exceed
the design pressure of the gauge, gauge savers shall be used.

f.

Pressure instruments exposed to possible vacuum shall be protected for full vacuum.

g.

Where diaphragm seals are used with pressure instruments for slurries, corrosive fluids
and very viscous liquids, they shall be the continuous duty type, shall be directly
connected to the pressure element, and furnished as a complete assembly with the
instrument mounted directly on the seal. The process connection on the seal shall
normally be 3/4 inch NPT / flanged.

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5.3.4.1

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h.

Pressure instruments on steam and other high temperature services shall be installed
with a gauge siphon or pigtail coil pipe siphon when the instrument is close coupled
and/or mounted above the pressure connection with no trap in the connecting piping.

i.

Pulsation dampeners shall be furnished for all pressure instruments and gauges on the
discharge of reciprocating pumps and on the suction and discharge of reciprocating
compressors and other pulsating services.

j.

Consideration shall be given to the use of liquid filled gauges for discharge of
reciprocating pumps, suction and discharge of reciprocating compressors, and in
corrosive atmospheres.

k.

Pressure instruments shall be located so that the head of liquid between the instrument
and the point of measurement does not exceed the manufacturers limit of impressed
static head.

TEMPERATURE
a.

Temperature point nozzles on vessels and pipes shall generally be 40 (1 1/2) mm NB


flanged. Flanged thermowells shall be fabricated out of SS 316 barstock material and
flange rating shall be as per Vessel /Pipe flange rating. Thermowells shall be procured
along with Temp.element/gauge to ensure minimum air gap.

b.

For purely local temperature indication, Bimetallic / gas filled temperature indicators
shall be used. Dial size shall be 150 mm. Accuracy of temperature gauges shall be +1.0
% of FSR or better.

c.

K type Thermocouple with characteristics as per IEC 60584 shall be used for Temp.
measurement.

CONSTRUCTION OF THERMOWELL
a.

Test thermowells shall be furnished with threaded SS plugs and chains. Where plant
ambient conditions require another material, it shall be suitable for the service.

b.

Pipe type thermowells with welded ends shall be utilized for gas temperature
measurement at fired heaters, boilers, furnaces, flues, and stacks. Wells used for
multiple element thermocouple assemblies in reactors may also be pipe type
thermowells, consideration must be given to the support of such thermowells.

c.

The thermowells shall be hydrostatically tested as per line /vessel design pressure.

d.

Thermowells shall be suitable for stresses due to stream velocity conditions. The wake
frequency (commonly referred to as Strouhal or the Von Karman Trail) shall not exceed
80 percent of the natural frequency of the thermowell in accordance with ASME PTC
19.3. In applications where large lines, high velocities, or high pressures are present,
these calculations shall be performed and submitted to client.

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e.

Thermowells shall be installed perpendicular to the straight run of pipe. For line sizes
less than 4 inch, the line shall be swaged up to 4 inches. Elbow installations for
thermowells shall generally be avoided except where required to avoid stress due to
stream velocity.

f.

Thermowells for dial thermometers and filled system instruments shall be purchased
with the instruments to assure proper fit.

THERMOCOUPLE ELEMENTS
T/C shall be furnished with terminal blocks enclosed in a corrosion resistant metallic
weatherproof head. Head cover shall be threaded & with gasket. Where the instrument is
located in a hazardous area, then the head shall be certified explosion proof/intrinsically safe.
K type Thermocouples ( 20 AWG) shall be used with sheath of 6mm OD.
Sheath material shall be SS316 as a minimum. Incolloy 800H or Kanthal material shall be
used for higher temperatures as required.
Element shall be mineral insulate and acc. To IEC 60584
Element overall lengths shall be one of 500mm,540mm,620mm,or 720mm with
NPT M process connection on Thermowell.

5.3.4.3

DIAL THERMOMETERS
Bimetallic or filled capillary, adjustable angle, dial type gauges with 6 dials shall be used
for local temperature indication. The gauges shall have NPT M bottom connection. Stem
shall be SS316 with 6 mm OD for Bimetal type & 10 mm OD for gas/vapor filled type
gauges. Insertion length shall be selected so as to ensure that tip of the thermowell is
generally at or slightly below the center line of the pipe.
Standard Insertion & overall lengths shall be as below.
Stem Insertion length 280 mm ( Over all 500 mm = 280+70+150)
Stem Insertion length 320 mm ( Over all 540 mm)
Stem Insertion length 400 mm ( Over all 620 mm)
Stem Insertion length 500 mm ( Over all 720 mm)

5.4

CONTROL VALVES
Control Valves shall be sized in accordance with ISA S75.01 (IEC 60534)

5.4.1

GENERAL
a.

Control valves shall be of the pneumatically actuated spring and diaphragm type or with
piston actuators.

b.

Control valve body type and trim shall be determined by the application and in accordance
with the applicable Piping Material Specification. Consideration shall be given to

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rangeability, noise, cavitation, flashing & fluid characteristics. Leakage class shall be in
accordance with ANSI B16.104, and any other special requirements.

5.4.2

c.

In general, globe type control valves will be used for throttling service.

d.

Eccentric rotating plug, ball, or butterfly type control valves will be used, where use of
globe type valves are impractical for the service conditions.

MECHANICAL DESIGN
a.

The material of construction shall be as per ASTM / AISI specification.

b.

Where cavitation is expected, trim with stellited SS316 material shall be used.
The stelliting of the trim implies stelliting of complete plug, seat joint, orifice unless
otherwise specified in the data sheet.

c.

Predicated noise level shall be calculated on a weighted scale & shall be measured at a
point one meter down stream of the valve and one meter from the pipe surface & shall be
limited to 85 dBA. If it exceeds 85dB, noise treatment method shall be provided to keep
the noise level below 85 dB..

d.

The permissible leakage shall be in accordance with ANSI B16.104, and as specified in
the data sheet.

e.

All accessories including expander / reducer required between the valve and the diffuser
shall be purchased with valve.
Control Valve body & flange rating shall be as per Piping Material Specifications.

f.

5.4.3

Control valves shall have inseparable flanges. Butterfly valves, rotary valves, and ball
valves may be wafer type suitable for
bolting between companion flanges if the
companion flanges have a minimum of 8 bolts and shall conform to the piping material
specifications, regardless of size.
MATERIALS
Minimum materials of construction of all wetted parts of control valve bodies and bonnets
shall be carbon steel, with alloy steel, stainless steel or other corrosion resistant alloys chosen
in accordance with piping material specifications and service requirements. Trim material
shall be 316 SS unless fluid service conditions require other materials. Materials of
construction will meet or exceed the requirements of the piping material specifications. Any
requirements for mill test certificates, heat numbers etc. are to be included with the valve
specification and requisition.
Interpretations of material specification in the data sheet as per following table.
Sl.No

Item Description

Matl. Spec. in data sh.

Interpretation

1.

Body material

Carbon Steel

A216 Gr.WCB

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2.

Body material

CS Forged

A105 Gr.WCB

3.

Body material

316 SS

A351 Gr.CF8M

4.

Trim material

Hardened SS

Plug, seat, orifice etc.


SS316 stellited. Cage /
guides of 17-4PH or other
material suited to the
process.

VALVE SELECTION
No split-body valves or separable flange styles shall be used without specific approval.
a.

Globe Valves
1) Face to face dimensions for standard globe type flanged control valves shall
conform to ISA Standards ANSI/ISA-S75.03.
2) All globe type valves shall be 1-inch minimum body size in line sizes 1 inch and
larger. In lines smaller than 1 inch, a line size control valve shall normally be
furnished. Generally, control valves not smaller than two sizes less than line size
shall be used. Where necessary, reduced trim may be used. Body sizes of nominal
diameters 1-1/4, 2-1/2 or 5 inches shall not be used.
3) Globe valves shall have the trim removable through the top of the valve body. All
valves shall have removable seat rings and solid type plugs.
4) Globe valves shall be of bolted bonnet design, with a confined bonnet gasket.

b.

Butterfly Valves
Control valves 8 inches and larger may be butterfly valves. Hand wheels shall be
provided as per data sheet. All applications for butterfly valves requiring tight shutoff
shall require these valves to be eccentric disk type valves. Butterfly valves shall be
heavy pattern type with outboard bearings. Body sizes and ratings, and end connection
types and ratings shall be the same as for globe valves, except lug body or wafer with 8
bolt flanges designed to fit between companion flanges may be used.

c.

Ball Valves
Ball valves shall be the Full-Port-Flow, Standard Reduced Ball or Characterized Ball
type with downstream seal or upstream and downstream seal. The shaft shall be firmly
affixed to the ball. The 90 degree rotation or rising stem type actuation shall be used to
rotate the ball from seat to seat. The materials of construction of the shaft and ball shall
be specified to meet service conditions without handicap to valve action. Body sizes
and ratings, and end connection types and ratings shall be the same as for globe valves.

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Eccentric Disc Plug Valves


Eccentric disc plug type valves shall have an eccentrically mounted rotating shaft with
bearings and packing. Body sizes and ratings, and end connection types shall be the
same as for globe valves, except lug body and wafer type designed to fit between
companion flanges with 8 bolts minimum may be used. Eccentric disc valves requiring
tight shutoff shall be metal-to-metal seats. Eccentric disc valves shall be heavy pattern
type with outboard bearings.

5.4.5

VALVE SIZING
a. Valves shall be sized using the selected manufacturers methods. These methods must
agree with ISA S75.01 (EU and International IEC60534). Special or proprietary design
valves shall be sized in accordance with the manufacturers procedures. Seller shall state
calculation method.

5.4.6

b.

Seller shall be fully responsible for confirming the adequacy of all valves supplied to meet
the specified operating and design requirements.

c.

All valves with linear flow characteristics shall be sized on the basis of 100 percent plant
design flow not exceeding 90 percent of valve lift.

d.

All valves with equal percentage flow characteristics shall be sized on the basis of 100
percent plant design flow not exceeding 80 percent of valve lift.

e.

Where only maximum flow is known, such flow shall not exceed 90 percent of valve travel.

f.

All butterfly valves shall be sized so that design flow rate does not require a valve disc
opening greater than 60 degrees for valves in throttling service except for characterized
vane valves, which may be sized for 90 degree opening. For valves in on/off service, 90
degrees opening is permissible for design flow rate for conventional butterfly valve

g.

All valves shall be checked by calculation for cavitation and flashing. Valve data sheets
shall note either condition.

h.

If the inlet / out let velocity, sound level or any other technical reason demand higher
body size than the same shall be provided by the purchasers specification.

VALVE MARKING
Each control valve shall have a stainless steel nameplate permanently fastened to the
superstructure. The nameplate shall be visible when the valve is installed and fully insulated.

5.4.7

INSTALLATION
a.

All tubing, wiring and installation of control valves shall be in accordance with
applicable sections of API RP-553 and ISA S7.4.

b.

Control valves shall be installed so that they are accessible from the ground, platforms,
or walkways. Clearance shall be allowed between the top of the diaphragm and the

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underside of the nearest obstruction above it for removal of the diaphragm and trim in
one piece. Special clearance shall not be provided for removal of valve trim. The
minimum clearances for hand wheel operators shall be 4 (100 mm).

5.4.8

c.

Screwed or socket weld control valves shall have flanges or unions in accordance with
the Piping Material Specifications immediately adjacent to the control valve for
purposes of removing the valve.

d.

A 3/4 inch drain valve consisting of pipe nipple and gate or globe/gate combination
valve in accordance with the Piping Material Specifications shall be provided
immediately upstream of each control valve for piping 2 inch and larger. A 1/2 inch
drain valve consisting of pipe nipple and gate valve in lines 1-1/2 inch and smaller shall
be provided upstream of each control valve. Gate valves shall have threaded plug, cap,
or blind flange.

GENERAL SERVICE
Globe style bodies with single-port, post, top, or top and bottom guided trim; double-port,
top and bottom guided trim; balanced or unbalanced cage, cage or stem guided trim; or
characterized ball or rotary disc plug type shall be used in general service.
a

Tight Shutoff (Class V OR VI)


Valves with soft seats may be used within the pressure, temperature and chemical
limitations of the seating material for positive shut-off service. (ANSI B16.104)

Cavitating, Flashing, High Noise Level, Cryogenic, Erosive Service, or Pressure Drops
in Excess of 100 psi (7 bar).
Valves shall be selected that shall be specifically designed for these services. In
particular, valves in these services shall be equipped with hard-faced (e.g..CrCo4) trim.
Valves using frictional paths, multiple port cages, vortex flow or other methods of
velocity and noise control shall be considered. Users of such valves shall consider the
possible impact of contaminants likely to cause plugging. Valve trims that are prone to
plugging should have a strainer installed upstream of the valve, i.e. cage, multiport,
torturous path, etc.

5.4.9

Hand wheels and bypasses should generally not be used with compressor anti surge,
high-pressure drop valves, or valves tripped closed as a protective function. Bypasses
may give rise to harmonics that may damage the line. Hand wheels may prevent
operation of valves when required by the remote signal.

VALVE CONSTRUCTION
a.

Valve Body
Control valves and all accessories required with the valve shall be suitable for
installation in horizontal or vertical lines. Any item not meeting this requirement must
specifically indicated by vendor tag number wise.

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Flange Face Finish


Vendor shall note that control valve face finish shall be as per ANSI / ASME B16.5
1.) Unless otherwise specified all 150# rated flange faces shall have 250 to 500 AARH
concentric or spiral serration.
2.) Unless otherwise specified all 300# rated flange faces shall have 125 to 200 AARH
concentric or spiral serration.
3.) Wherever SMF has been specified in the data sheet, it implies that flange face shall
have 125 to 200 AARH concentric or spiral serration.
4.) Wherever SERR.FIN has been specified in the data sheet, it implies that flange face
shall have 250 to 500 AARH concentric or spiral serration.

c.

Trim.
Wherever cavitation is expected, Anti cavitation trim shall be used.

d.

Packing
Packing material shall be Teflon V- ring. The graphite packing material where used shall
be self-lubricating type.

e. Actuator.
P shut-off, for the purpose of actuator sizing, shall be considered as 110% of the
specified Inlet Press. Max in the data sheet or Shut off pr., which ever is more. For the
specified service, the selection of proper size of actuator shall be vendors
responsibility. In case of any discrepancy vendor shall change or replace the same
without any price and delivery implication. For all valve with side-mounted actuators,
vendor shall offer valves with right actuators on the right hand side of the body when
looking at the body along the direction of flow.
f. Special Requirements
Radiography of Cast Valves
1. All valve castings of rating 600# and above shall undergo 100% radiographic
examination. In addition, 10% of valves of each size and rating below 600# shall
also undergo100% radiographic examination.
2. Radiography procedure and area of casting to be radiographed as per ANSI
B16.34.
Acceptance criteria shall be as per ANSI B16.34- Annexure B.Vendor shall enclose
the details of the area to be radiographer in line with ANSI B16.34.
IBR Certification
1 . All valves requiring IBR certification shall be tested in accordance with latest

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edition of Indian Boiler Regulation (IBR) and the requirement specified in this
regulation.
2 . IBR certification required has been indicated in the data sheet for each valve
requiring IBR certification. Test certificate in Form IIIC shall be furnished for
each of these valves. The certificate shall be signed by an IBR inspector or
approved representatives.
3.

Radiography of valves requiring IBR certification shall be as per IBR


requirement.

4. All valves certified, as IBR shall be painted red.


5.4.10

ACCESSORIES
Pneumatic relays, solenoid valves, pressure gauges, valve positioners, air sets, volume
boosters, and limit switches, when required, shall be mounted on the valve by Seller, with
associated air sets, filter and gauge.
a. Positioner
E/P type Smart (HART) valve positioners shall be used for this project. Input signal
range shall be 4-20 mA .
Positioner out put shall be 0.2 to 1 kg/cm2 g unless otherwise governed by standard
actuator range of the manufacturer. Positioner bypass shall be provided for all such
positioners with air supply pressure of 1.4 kg/cm2g.
b. Air Filter Regulator.
Dry, moisture free air shall be made available at 5.5 kg/cm2g.
Actuators shall be sized to work at 4 kg/cm2g. Suitable air filter regulator shall be used
for each valve.
c.

Solenoid Valves
Three-way solenoid valve, where specified, shall be as per data sheet. These shall meet
the following minimum requirements.
1. Resilient soft seats providing tight shutoff.
2. Coil voltage shall be 110 V AC & coils shall be rated for continuous duty.
3. Coil wired to a terminal block located inside the housing without any flying lead.
4. Coil suitable for + 10% and 15% variation in the power supply source.
Vendor shall provide certificate from statutory body for the solenoid including the
housing to be certified flameproof (Exd) as per IEC 79-1 and weatherproof to IP56 as
per IEC 60529.

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LOCATION

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Hand wheels and Limit Stops


Hand wheels, when specified on Data Sheets, shall be side-mounted, continuously
connected type and installed. A hand jack with lock nuts or other suitable devices shall
be provided where specified for limiting valve travel at the top or bottom portion of the
valve stroke. Hand wheels for rotary shaft valves shall be mounted on the valve shaft
and shall include a clutching and declutching arrangement. Limit stops for rotary valves
shall be separate shaft-mounted stops.

Limit Switches
Limit switches will only be fitted where specified. Limit switches and mounting brackets
shall be installed and set by the valve Seller. Proximity Switches shall be used & shall
meet the electrical area classification and shall normally be NAMUR type. SPDT micro
switch type switches may be used in non-severe services. Pneumatic type switches shall
be furnished where required by project requirements.

Tubing and Fittings


Instrument air tubing shall be OD stainless steel minimum.

5.4.11

INSPECTION AND TESTING.


a.

Unless otherwise specified, purchaser reserves the right to test and inspect all the items
at the vendors works.

b.

Vendor shall provide the following test certificate & test report for purchaser s review.
1.
2.
3.

c.

Material test certificate with detailed chemical analysis from the foundry for
each casting.
Certificate of radiography/ X ray for valve castings.
Pneumatic test certificate for all pneumatic actuators at a pressure not less than
one and half times and actuator designed pressure.

4.

IBR certificate in form IIIC for all valves covered under IBR certification.

5.

Certificate of each valves giving details of hydrostatic tests, calibration/ stroke


checks, seat leakage tests, valve characteristics, testing of accessories etc.

Hydraulic Test
Each control valve body shall be subjected to hydraulic test at one and half times the test
pressure as per ANSI rating. All control valve bodies covered under IBR shall be tested
as per IBR regulation. There should not be any visible leakage during this test.

d.

Functional Tests
Seat Leakage Test
The test shall meet the requirement as per the ANSI B16.104.

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Lift Characteristics
The test shall be carried out at no load condition and following shall be verified.
a.

Stroke check.

b. Linearity and hysteresis.


Linearity and hysteresis shall be better than 1.5% of rated lift with positioner and
5%without positioner.
Certificate from statutory bodied for explosion proof and weatherproof construction of
positioners, solenoid valve etc.
5.5

ANALYZERS & GAS CHROMATOGRAPHS

5.5.1

GENERAL
Liquid & Gas analyzers & Gas Chromatographs Analyzers shall be provided as indicated
below for the Sixth Furnace & associated equipment to ensure product purity and comply with
the environmental and safety regulations.
All Analyzers shall be supplied by a single vendor as a complete package comprising of
analyzer shelter, Gas Chromatographs, Liquid & Gas analyzers, sampling systems,
interconnecting tubing and isolating valves necessary for operation, maintenance and
calibration. Analyzers shall be installed, with provisions for start-up and initial operating
responsibility by the analyzer Seller or subcontractor. Necessary calibrating gases and/or
liquids shall be part of this purchased package.

5.5.2

ANALYZER SHELTER
Analyzer Shelter shall be of approximate size of 6 Mtr * 8 Mtrs & Designed as per OISD
norms. The Shelter shall be provided with HVAC system ( with stand by blower ) & shall be
suitable for 100 % fresh air circulation. The Shelter will be located in IEC Zone 2 Gr. IIA, IIB
hazardous area. Inside of shelter shall be classified as Zone 2, Gr. IIC area. All electrical
equipment installed inside the shelter shall be suitable for the same. Shelter shall be equipped
with LEL gas, smoke detection & chamber pressure switch to initiate local & remote alarms
& interlocked to isolate power supply to all Electrical & Electronic instruments installed in
the Shelter. The sample effluent shall be vented to the atmosphere at safe height& shall be
minimum 3 mtrs away from nearest working platform.
1 feeder of 415 V ,3 phase AC power & 1 feeder of 110 V. AC UPS ( Floating) will be
provided at the Analyzer Shelter. Further Power Distribution as required
shall be in Vendors scope. Vendor shall install Exd Junction Boxes on the outer wall of
Analyzer Shed to provide interface with field & control room cable connections. All cable &
sample tube entries shall be through MCT blocks.

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5.5.3

GAS CHROMATOGRAPHS
At present 3 nos. of Gas Chromatographs are envisaged for analysis of Hydrocarbon in
Cracked Gas, CO in Cracked Gas & CO in Decoke Gas streams. The Stream compositions &
components of interest shall be detailed in the specification during engineering.
Possibility of combining two streams in a single GC shall be explored to reduce qty of GC s to
2. Vendor shall indicate the Best Cycle time possible & the same shall not be more than 460
Secs.
Pneumatically operated & PLC controlled RAM valve shall be supplied & installed as part of
sampling system for De coke GC.
GCs shall have serial interface connectivity for MODBUS serial link connection to DCS
system. Package vendor shall supply redundant communication cable, provide necessary
assistance & support to DCS vendor to establish communication with DCS. Distance between
Analyzer Shelter & Control Room is about 550 Meters.
Other provisions shall include 4-20 mA DC electronic output signal for each measured
component, Alarm Contacts for individual components, Common alarm for GC trouble,
Alarm contacts for Gas/Fire detection, HVAC trouble etc

5.5.4

OTHER ANALYZERS
1.

On-line pH & conductivity analyzers shall be provided on continuous surface blow


down lines of VHP boiler. Operating pressure shall be

2.

Stack Gas Analyzer shall be supplied for measurement of Sox, Nox, CO & SPM in the
stack gas
Oxygen Analyzer ( Zirconia Probe type) for Excess Air & CO + CO2 (Combustibles)
analyzer on the Radiant Section of the Furnace.

3.

5.5.5

SAMPLING SYSTEM
Sample Conditioning system inclusive of sample probes, extraction pumps, all valves,
tubing, fittings, insulations etc. shall be supplied & installed by package vendor.
Supply, laying & connection of Power supply & signal cabling for all analyzers up to
analyzer shelter also shall be responsibility of the package vendor.

5.5.6

CALIBRATION
Calibration gases with cylinder holding stand, tubing & automatic calibration system shall be
provided.
Provisions shall be made for manual injection of a standard sample for calibration and
checkout purposes.

5.5.7

SPARES
All consumables required for startup, Commissioning spares & 2 years operation & maintenance
spares shall be purchased with the analyzers.

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INSTRUMENT AIR SUPPLY AND PIPING SYSTEMS


a.

b.

c.
5.6.1

10059

Existing Instrument Air system shall cater for the Instrument air requirement of the
Sixth Furnace. Instrument air shall be made available at the battery limit at supply
pressures as below.
Minimum Pr. = 5.5 Kg/cm2 g , Normal =6.5 Kg/cm2 g & Max.= 7.0 Kg/cm2 g
For safe and automatic shutdown of plant in case of an instrument air failure, the
instrument pressure shall be maintained at 80 psig (5.5Kg/ cm2-g) minimum at the
battery limits for at least 10 minutes.
In the event where the instrument air pressure drops to zero, all control valves will
automatically go to fail safe positions

AIR SUPPLY TO FIELD MOUNTED INSTRUMENTS


a.

A filter-regulator shall be used with each instrument, and shall be furnished with output
pressure gauge. A shutoff valve shall be located on the inlet side of the filter-regulator.
Piping materials for instrument air shall be in accordance with piping spec.

b.

Galvanized steel branch pipe shall be used from instrument air main header up to
Instrument air Manifold. or 3/8 OD, 316 stainless steel tubing will be used from
instrument air manifold to the instruments as per the requirement. Isolation valve shall
be used at each outlet of the manifold. Instrument air manifolds will have 20% spare
taps at design and 10% spare taps at commissioning. Air piping mounted on cylinder
valves may be 3/8 in OD 316SS tubing. The size of tubing and piping supplying large
or fast acting valves must be checked for suitability and increased if necessary.

c.
d.

Tube fittings will be 316SS.


The size of the air piping will depend on the number of air users as follows:
Number of Users

Size

15

1/2 in.

6 10

3/4 in.

e.

Each user will be equipped with an individual pressure regulator set.

f.

Instrument Air Signal Lines


Instrument air signal lines shall be a minimum of 1/4" OD 316SS tubes. 3/8 OD tubes
may be used where required.

5.7

PIPING/INSTRUMENT INTERFACE CONNECTIONS ON VESSELS AND PIPE


The following table defines the connections to be provided on vessels and pipe for
instruments. Connections on instruments are defined elsewhere in this Specification.

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This table is to be followed unless specified otherwise by Client Specifications

PING/INSTRUMENT INTERFACE CONNECTIONS (VESSELS AND PIPING)

Instrument Type
Level
Gauge Glass only (General Service)
Gauge Glass >600#
Gauge Glass and Parallel Displacer
Standpipe for Gauge Glass/Displacer
External Displacer Level Transmitters or
Controllers
Differential Pressure Level Transmitters
Differential Pressure Level Transmitters, Flange
Mounted
Capillary
Flush Diaphragm
Extended Diaphragm
Internal Ball Float
3-1/2 O.D. Ball
5 O.D. Ball
Level Switches
External Float or Displacer

Piping Instr.
Inter- Conn.
Face Size
C
C
C
C
C
A

D
D
B
D
D

3 /4
1
2
2
2
1/2
Mfr.
Std.
4
6
2

Connection
Type

Qty Notes

Flanged
Flanged
Flanged
Flanged
Flanged
Scrwd or S.W.

2
2
2
2
2
1

4
4
4
4
4
2,6, 4

Flanged
Flanged

1
1

4
4

Flanged
Flanged
Flanged
Flanged

1
1
1
2

4
4
4
4

Mfr.
Std.
1-1/2"

Dielectric Probe and Conductivity


Magnetic Gauge Glass

Orifice Piping
Flange Taps (below ANSI CL900)
Flange Taps (ANSI CL900 and above)
Pipe Taps
Pressure (and Differential Pressure)
Piping
Vessels
Thermowells (See Note 5)
All Services

A
B
B

1/2
3/4
3/4

Scrwd or S.W. 2
Scrwd or S.W. 2
Scrwd or S.W. 2

A
A

1/2
1/2

Scrwd or S.W. 1(2) 2


Scrwd or S.W. 1(2) 2,6

1-1/2"

Flanged

1
1
1,2

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PROJECT

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LOCATION

PATA, UTTAR PRADESH-DIST : AURAIYA

PING/INSTRUMENT INTERFACE CONNECTIONS (VESSELS AND PIPING)

Instrument Type

Piping Instr.
Inter- Conn.
Face Size

Connection
Type

Qty Notes

Piping Interface
A.
1/2 block valve w/ 1/2 FNPT or socket weld (S.W.) instrument connection, 2 Flange on
Vessel
B.
3/4 block valve w/ 3/4 FNPT or socket weld (S.W.) instrument connection, 2 Flange on
Vessel
C.
Flanged block valve, 2 flange on Vessel
D.
Flanged nozzle. Nozzle projection to be 4 1/2 for straight pipe and 6 for elbows.
Notes:
1. Piping clearances are an important factor and hence taps should be located 45 degrees from the
horizontal centerline, above or below as indicated by the location of the differential pressure
measuring device. Otherwise orifice taps shall preferably be located on the horizontal centerline
for liquid and steam services, and on the top vertical centerline for gas services.
2. The type of connections for pressure taps shall conform to the appropriate piping line class
specifications.
3. Materials of construction shall be in accordance with the piping line class specifications.
4. Ratings of all flanged connections shall conform to appropriate piping line class or vessel
specification.
5. If screwed or socket weld connections are not permitted, 1 inch-flanged connection shall be used.
6. Minimum vessel connection is 1 flanged.

5.8

INSTRUMENT IMPULSE PIPING SYSTEMS


a.

Tubing from orifice flanges to flow transmitter or from process isolation valve to pressure
instrument shall be 1/2 inch OD seamless 316 stainless steel tubing fully annealed.
Primary instrument tubing will be ASTM A-213 Grade TP316 seamless stainless steel
with 316 SS ferrule type double compression fittings. All fittings will be of one
manufacturer throughout the plant. Fittings shall be flareless.
For instruments connected to VHP boiler, pipes of adequate wall thickness shall
be used & shall be rated as per piping specification. All fittings shall be welded to
impulse lines. Connections at the instrument shall be flanged.

b.

Flexible tubing may be used (within its temperature and pressure ratings) for final
connections to devices subject to vibration or frequent removal.

c.

316 SS tubing shall be used unless some other material is required due to corrosion
conditions.

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LOCATION

PATA, UTTAR PRADESH-DIST : AURAIYA

Instruments shall be provided with isolation and vent manifolds. Differential pressure
transmitters shall be equipped with a five-valve manifold with instrument, test, and
equalizing valves. Pressure transmitters shall be equipped with a two-valve manifold.
The use of ANSI RF flanged manifolds for close-coupled gauges and transmitters shall
be considered.
Where necessary the instrument impulse lines shall be heat traced and/or insulated. The
heat tracing requirements are shown on the approved P&ID.

5.9

e.

When steam is used as the heat-tracing medium for instruments and pressure impulse
piping. 316SS tubing will be utilized for the tracer tubing.

f.

Pressure impulse tubing will be fabricated of 1/2 stainless steel tubing in general. Size
of analyzer sample transfer line shall be selected so that transfer time meets process
requirements.

g.

For large volume displacement instruments, e.g., bellows type, 4 inch seal pots shall be
used. No seal pots are required with negligible displacement type instruments since
tubing creates an acceptable seal.

INSTRUMENT ELECTRICAL WIRING


a.

The instrument electrical installation shall conform to the requirements of the electrical
design specification, NFPA No. 70 National Electrical Code, IEC 60079 and API RP
552.

b.

Existing UPS shall be used to cater all the power needs as per existing philosophy.
Separate 110 V AC ( Floating) UPS feeders shall be provided for Sixth Furnace. UPS
power shall be used for DCS, ESD, Analyzers ,Gas detection panel etc. DC power as
required shall be derived from within the System

c.

All the instrument electrical wiring and equipment on instrument panels shall conform to
the Specification for Instrument Panels.

d.

All junction boxes and multi-conductor cables shall be provided with a minimum 20
percent spare capacity.

e.

Analog signal junction boxes connected to IS equipment shall be increased safety e type
& weather proof to IP 65 min. Material of construction shall be sheet steel. JBs for
Digital signals shall have Flameproof (Ex d ) & Weatherproof IP65 enclosures

f.
g.

Separate JB for Analog, Digital ,Gas Detectors and SOV shall be provided.
Control and Power wiring shall be single conductor copper 2.5mm2 minimum with 1100volt insulation.
Analog Signal cables between field instrument & JB shall be 1.5 sq. mm, multi stranded
tinned copper, insulated, two wires twisted to form a pair, covered with al mylar tape &
cu drain wire shielded, PVC inner sheathed, armored , overall sheathed, 600-volt grade
type

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h.

Digital signal cables between field instrument & JB shall shall be 1.5 mm2, multi stranded
tinned copper, insulated, , two wires twisted to form a pair PVC inner sheathed, armored ,
overall sheathed, 600-volt grade type.

i.

Thermocouple Signal cables between field instrument & JB shall be 1.5 sq. mm, single
core extension wires (of same material as that of element ) two wires twisted to form a
pair, covered with al mylar tape & cu drain wire shielded, PVC inner sheathed, armored ,
overall sheathed, 600-volt grade type.

j.

Multi-pair cable shall be 1.0 sq.mm2, multi stranded copper, PVC insulated,
numbered/color coded twisted pairs, assembled with aluminum backed mylar tape& drain
wire shielded, inner sheathed, armored, and overall PVC sheathed, 600 Volt grade.
Overall shielding will not be specified for this project.

k.

Multi core cables Cable shall be 1.0 sq.mm2, multi stranded copper, PVC insulated,
numbered/color coded twisted pairs, inner sheathed, armored, and overall PVC sheathed,
600 Volt grade.

l.

Multi pair T/C extension or compensating cables shall be 1.5 sq.mm2, multi stranded,
PVC insulated, numbered/color coded twisted pairs, assembled with aluminum backed
mylar tape& drain wire shielded, inner sheathed, armored, and overall PVC sheathed.
Color coding & mv characteristic shall be as per ANSI MC 96.1
Field cable shall be installed in rigid trays and in accordance with electrical specifications.
Multi core & pair cables shall be laid on trays on sub racks & in main overhead cable duct
on the main rack.

m.

n.

As a minimum, instrument signal wiring shall be segregated by the following signal


levels:
FIELD JB / CABLE

TRAY / CONDUIT

RTD

Analog Signal

4-20mA Analog

Analog Signal (Intrinsically Safe)

4-20mA Analog

Analog Signal (Non- Intrinsically Safe)

< 50 VDC Digital (ON/OFF)


< 50 VDC Digital (ON/OFF)

< 50 V Digital Signal (Intrinsically Safe)


<50V Digital Signal (Non-Intrinsically Safe)

120 VAC/125 VDC

125 V Signal

> 120 VAC

> 120 VAC

Digital Communication (Data Highway)

Data Highway

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5.9.1

5.9.2

10059

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LOCATION

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CABLING AND WIRING


a.

Multi-core cables with 12C & 24 C and Multi Pair cables with 6 & 12 pairs will be used
between the control room and field junction boxes. Single pair, 2 Pair ( For open/close
Proximity sw) or 2 core cable shall be used between the field junction boxes and
individual instruments.

b.

The instrument cable shield of the signal cables between the control room and plant area
will be grounded on the control room side only.

c.

Minimum 20% spare conductors will be provided for multi-pair cables.

d.

Cables between the junction box and the individual instrument shall be on tray or
otherwise supported and protected.

CABLE ROUTING
Cables between the control room and junction boxes will be laid in existing cable duct / trays or
laid in trenches.
Branch trays shall be GI ladder type in sizes 40mm,60mm & 100

5.9.3

JUNCTION BOXES
Increased safety Junction boxes will be used for field termination of I.S signals ( Analog Input,
Output & Digital Input 24 V DC )) will be installed according to requirements for hazardous
areas. For Solenoid signals ( 110 V AC) , Explosion proof Junction Boxes shall be used.
Junction boxes will be located such that the length of signal branch runs will not exceed 30
Meters as a general rule. The Junction boxes will be located to facilitate safe access for
maintenance.

5.9.4

PROTECTION & HEATING BOX


Where protection from extremes of temperature is required, differential pressure transmitter,
pressure transmitter, local pressure controller, local temperature controller and receiver type
local controller may be installed in a protection or heating box, unless otherwise installed
indoors.

5.9.5

GROUNDING
Existing plant grounding system shall be used fora.

Grounding for clean earth (Signal earth) including Computer earths

b.

Safety Grounding for panel and racks in control room Plant ground.

c.

Grounding for intrinsic safety circuits (1 Ohm resistance to clean earth)

Note that local panels and racks will be grounded to the electrical grounding system. Cable
duct shall be grounded to the electrical grounding system via pipe racks and/or supports.
Signals connected to control room or equipment room shall not be earthed in the local panel or

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rack. Where this is unavoidable the signals shall be provided with galvanic or optical isolators.

5.10

ACCESSIBILITY
Instrument shall be located to facilitate maximum convenience for operating and servicing the
instruments. The following general rules shall be adhered to unless limited by other
requirements in the design of the unit:
a.

Connections shall be oriented so that instruments or piping will not obstruct aisles or
platforms.

b.

Control valves shall be accessible from the ground or platforms.. Clearance shall be
allowed between the top of the diaphragm and the underside of the nearest obstruction
above it for the removal of the diaphragm. Special clearance shall not be provided for
removal of valve trim. Clearances for hand wheel operators and valve positioners shall be
considered in accordance with the valve Seller's drawing.

c.

Local instruments operating in conjunction with control/ hand valves ( Identified on


P
& I D by notes) shall be located so that they are visible from the control valves. When not
feasible, a remote loop powered indicator shall be mounted near the valve.

d.

Connections for local pressure gauges, dial thermometers, and test wells shall be located
so that gauges will be at a visible level and test points will be readily accessible.

e.

Orifices for pedestal mounted flow meters (except in air, gas service, or underground
lines) shall be located at a minimum elevation of 7 feet (2 meters) above grade or platform
to allow the meter leads to slope down to the instruments.

f.

Orifices and line-mounted flow transmitters, as well as instruments and thermocouples,


which are located less than 22 feet (7 meters) above grade shall be accessible from
portable ladders. Above 22 feet (7 meters) they shall be accessible from walkways,
ladders, platforms, and/or portable platforms.

g.

Clearance shall be provided at orifices for valves, pots, or instruments, which may be
located at the line.

h.

Connections on vessels for gauge glasses and level instruments shall be oriented to
minimize the effect of inlet and outlet streams on the instruments.

i.

Gauge glasses and level instruments shall be adjacently located and, if possible, the gauge
glass shall be visible from any valve, which controls the level in the vessel.

j.

All instruments requiring adjustments shall be accessible for servicing from grade,
walkways, ladders, or platforms. Accessibility from the ground shall be from a portable
ladder. In addition, transmitters may also be accessible from portable platforms.